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.

Modelling of fluid flow phenomenon in laser+GMAW hybrid welding of aluminum alloy considering three phase coupling and arc plasma shear stress

NASA Astrophysics Data System (ADS)

Xu, Guoxiang; Li, Pengfei; Cao, Qingnan; Hu, Qingxian; Gu, Xiaoyan; Du, Baoshuai

2018-03-01

The present study aims to develop a unified three dimensional numerical model for fiber laser+GMAW hybrid welding, which is used to study the fluid flow phenomena in hybrid welding of aluminum alloy and the influence of laser power on weld pool dynamic behavior. This model takes into account the coupling of gas, liquid and metal phases. Laser heat input is described using a cone heat source model with changing peak power density, its height being determined based on the keyhole size. Arc heat input is modeled as a double ellipsoid heat source. The arc plasma flow and droplet transfer are simulated through the two simplified models. The temperature and velocity fields for different laser powers are calculated. The computed results are in general agreement with the experimental data. Both the peak and average values of fluid flow velocity during hybrid welding are much higher than those of GMAW. At a low level of laser power, both the arc force and droplet impingement force play a relatively large role on fluid flow in the hybrid welding. Keyhole depth always oscillates within a range. With an increase in laser power, the weld pool behavior becomes more complex. An anti-clockwise vortex is generated and the stability of keyhole depth is improved. Besides, the effects of laser power on different driving forces of fluid flow in weld pool are also discussed.

Control of Gas Tungsten Arc welding pool shape by trace element addition to the weld pool

DOEpatents

Heiple, C.R.; Burgardt, P.

1984-03-13

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

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.

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

PubMed

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

2004-11-01

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

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.

A unified 3D model for an interaction mechanism of the plasma arc, weld pool and keyhole in plasma arc welding

NASA Astrophysics Data System (ADS)

Jian, Xiaoxia; Wu, ChuanSong; Zhang, Guokai; Chen, Ji

2015-11-01

A 3D model is developed to perform numerical investigation on the coupled interaction mechanism of the plasma arc, weld pool and keyhole in plasma arc welding. By considering the traveling of the plasma arc along the welding direction, unified governing equations are solved in the whole domain including the torch, plasma arc, keyhole, weld pool and workpiece, which involves different physical mechanisms in different zones. The local thermodynamic equilibrium-diffusion approximation is used to treat the interface between the plasma arc and weld pool, and the volume-of-fluid method is used to track the evolution of the keyhole wall. The interaction effects between the plasma arc, keyhole and weld pool as well as the heat, mass and pressure transport phenomena in the whole welding domain are quantitatively simulated. It is found that when the torch is moving along the joint line, the axis of the keyhole channel tilts backward, and the envelope of molten metal surrounding the keyhole wall inside the weld pool is unsymmetrical relative to the keyhole channel. The plasma arc welding tests are conducted, and the predicted keyhole dimensions and the fusion zone shape are in agreement with the experimentally measured results.

Improving Keyhole Stability by External Magnetic Field in Full Penetration Laser Welding

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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.

Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.

1987-01-01

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

Experimental and numerical studies on three dimensional GTA weld pool convection: Non-axisymmetric effects

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

Joshi, Y.; Dutta, P.; Schupp, P.E.

1995-12-31

Observations of surface flow patterns of steel and aluminum GTAW pools have been made using a pulsed laser visualization system. The weld pool convection is found to be three dimensional, with the azimuthal circulation depending on the location of the clamp with respect to the torch. Oscillation of steel pools and undulating motion in aluminum weld pools are also observed even with steady process parameters. Current axisymmetric numerical models are unable to explain such phenomena. A three dimensional computational study is carried out in this study to explain the rotational flow in aluminum weld pools.

Modeling of the Weld Shape Development During the Autogenous Welding Process by Coupling Welding Arc with Weld Pool

NASA Astrophysics Data System (ADS)

Dong, Wenchao; Lu, Shanping; Li, Dianzhong; Li, Yiyi

2010-10-01

A numerical model of the welding arc is coupled to a model for the heat transfer and fluid flow in the weld pool of a SUS304 stainless steel during a moving GTA welding process. The described model avoids the use of the assumption of the empirical Gaussian boundary conditions, and at the same time, provides reliable boundary conditions to analyze the weld pool. Based on the two-dimensional axisymmetric numerical modeling of the argon arc, the heat flux to workpiece, the input current density, and the plasma drag stress are obtained. The arc temperature contours, the distributions of heat flux, and current density at the anode are in fair agreement with the reported experimental results. Numerical simulation and experimental studies to the weld pool development are carried out for a moving GTA welding on SUS304 stainless steel with different oxygen content from 30 to 220 ppm. The calculated result show that the oxygen can change the Marangoni convection from outward to inward direction on the liquid pool surface and make the wide shallow weld shape become narrow deep one. The calculated result for the weld shape and weld D/W ratio agrees well with the experimental one.

Application of welding science to welding engineering: A lumped parameter gas metal arc welding dynamic process model

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

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

1997-12-31

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

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

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

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

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

1988-01-01

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

Experimental measurement of stationary SS 304, SS 316L and 8630 GTA weld pool surface temperatures

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

Kraus, H.G.

1989-07-01

The optical spectral radiometric/laser reflectance experimental method, previously developed by the author, was extended to obtain high-resolution surface temperature maps of stationary GTA molten weld pools using thick-plate SS 304, SS316L, and 8630 steel. Increasing the welding current from 50 to 200 A resulted in peak pool surface temperatures from 1050{sup 0} to 2400{sup 0}C for the SS 304. At a constant welding current of 150 A, the SS 304 and various heats of SS 316L and 8630 resulted in peak weld pool temperatures from 2300{sup 0} to 2700{sup 0}C. Temperature contour plots of all the welds made are given.more » Surface temperature maps are classified into types that are believed to be indicative of the convective circulation patterns present in the weld pools.« less

A mathematical model of the chevron-like wave pattern on a weld piece

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

Dowden, J.; Kapadia, P.

1996-12-31

In welding processes in general the surface of a metallic weld displays a chevron-like pattern. Such a pattern is also clearly seen to be present if welding is carried out using a laser beam. In the welding process a laser beam is directed normally on the metal undergoing translation and usually penetrates it to form a keyhole. The keyhole is surrounded by a molten region, the weld pool. Even if a CO{sub 2} laser is used, there are numerous fluctuations and instabilities that occur, so that the keyhole imposes forcing frequencies on the molten weld pool, additional to vibrations attendantmore » on the process of translation. The weld pool in turn responds by supporting a spectrum of waves of different frequencies involving the natural frequency of the weld pool as well as various forcing frequencies. These waves are surface tension-type capillary waves and previous publications have attempted to model their behavior mathematically, although not all aspects of the problem have always been included. The wave pattern that is manifested in the chevron-like pattern seen on the weld piece is, however, not necessarily identical to the wave pattern present in the weld pool. This is because the chevron-like wave pattern forms as a result of several complicating effects that arise as the weld specimen cools on its surface immediately after the weld has been formed. This process involves the waves on the surface of the weld pool freezing to form the chevron-like wave pattern. A feature that is often ignored is the fact that the waves on the weld pool can only be regarded as irrotational if the translation speed is sufficiently low. This paper describes mathematically the formation of the chevron-like wave pattern based on suitable simplifying assumptions to model the process. The mathematical description of the way in which this chevron-like pattern forms is a step toward a more comprehensive understanding of this process.« less

Dynamic behavior of the weld pool in stationary GMAW

NASA Astrophysics Data System (ADS)

Chapuis, J.; Romero, E.; Bordreuil, C.; Soulié, F.; Fras, G.

2010-06-01

Because hump formation limits welding productivity, better understanding of the humping phenomena during the welding process is needed to access to process modifications that decrease the tendency for hump formation and then allow higher productivity welding. From a physical point of view, the mechanism identified is the Rayleigh instability initiated by strong surface tension gradient which induces a variation of kinetic flow. But the causes of the appearance of this instability are not yet well explained. Because of the phenomena complex and multi-physics, we chose in first step to conduct an analysis of the characteristic times involved in weld pool in pulsed stationary GMAW. The goal is to study the dynamic behavior of the weld pool, using our experimental multi physics approach. The experimental tool and methodology developed to understand these fast phenomena are presented first: frames acquisition with high speed digital camera and specific optical devices, numerical library. The analysis of geometric parameters of the weld pool during welding operation are presented in the last part: we observe the variations of wetting angles (or contact lines angles), the base and the height of the weld pool (macro-drop) versus weld time.

Fluid Flow Phenomena during Welding

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

Zhang, Wei

2011-01-01

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

Investigation on edge joints of Inconel 625 sheets processed with laser welding

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

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

NASA Astrophysics Data System (ADS)

Chen, Ji; Wu, Chuan-Song

2011-06-01

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

Experimental characterization of the weld pool flow in a TIG configuration

NASA Astrophysics Data System (ADS)

Stadler, M.; Masquère, M.; Freton, P.; Franceries, X.; Gonzalez, J. J.

2014-11-01

Tungsten Inert Gas (TIG) welding process relies on heat transfer between plasma and work piece leading to a metallic weld pool. Combination of different forces produces movements on the molten pool surface. One of our aims is to determine the velocity on the weld pool surface. This provides a set of data that leads to a deeper comprehension of the flow behavior and allows us to validate numerical models used to study TIG parameters. In this paper, two diagnostic methods developed with high speed imaging for the determination of velocity of an AISI 304L stainless steel molten pool are presented. Application of the two methods to a metallic weld pool under helium with a current intensity of 100 A provides velocity values around 0.70 m/s which are in good agreement with literature works.

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.

Determination and Dependencies of Melt Pool Dimensions in Laser Micro Welding

NASA Astrophysics Data System (ADS)

Patschger, Andreas; Bliedtner, Jens

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

Integrated optical sensor

DOEpatents

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

1994-01-01

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

Integrated optical sensor

DOEpatents

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

1994-01-04

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

Relationship between spatter formation and dynamic molten pool during high-power deep-penetration laser welding

NASA Astrophysics Data System (ADS)

Li, Shichun; Chen, Genyu; Katayama, Seiji; Zhang, Yi

2014-06-01

The spatter and the molten pool behavior, which were the important phenomena concerned with the welding quality, were observed and studied by using the high-speed camera and the X-ray transmission imaging system during laser welding under different welding parameters. The formation mechanism of spatter and the corresponding relationships between the spatter and molten pool behavior were investigated. The increase of laser power could cause more intense evaporation and lead to more spatter. When the focal position of laser beam was changed, different forms of spatter were generated, as well as the flow trends of molten metal on the front keyhole wall and at the rear molten pool were changed. The results revealed that the behavior of molten pool, which could be affected by the absorbed energy distribution in the keyhole, was the key factor to determine the spatter formation during laser welding. The relatively sound weld seam could be obtained during laser welding with the focal position located inside the metal.

Numerical Modeling of Fluid Flow, Heat Transfer and Arc-Melt Interaction in Tungsten Inert Gas Welding

NASA Astrophysics Data System (ADS)

Li, Linmin; Li, Baokuan; Liu, Lichao; Motoyama, Yuichi

2017-04-01

The present work develops a multi-region dynamic coupling model for fluid flow, heat transfer and arc-melt interaction in tungsten inert gas (TIG) welding using the dynamic mesh technique. The arc-weld pool unified model is developed on basis of magnetohydrodynamic (MHD) equations and the interface is tracked using the dynamic mesh method. The numerical model for arc is firstly validated by comparing the calculated temperature profiles and essential results with the former experimental data. For weld pool convection solution, the drag, Marangoni, buoyancy and electromagnetic forces are separately validated, and then taken into account. Moreover, the model considering interface deformation is adopted in a stationary TIG welding process with SUS304 stainless steel and the effect of interface deformation is investigated. The depression of weld pool center and the lifting of pool periphery are both predicted. The results show that the weld pool shape calculated with considering the interface deformation is more accurate.

Preliminary study on detection technology of the cladding weld of spent fuel storage pool

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Effect of laser welding process on the microstructure, mechanical properties and residual stresses in Ti-5Al-2.5Sn alloy

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of the detached metal drops. It was not particularly easy to generate the detachments for this experiment. This document presents the details of the theoretical modeling effort and a summary of the experimental effort to measure molten metal drop detachments from terrestrial electron beam welding in the enclosed vacuum chamber. The results of the experimental effort have shown that molten metal detachments can occur from the sample/weld plate only if a sufficiently large impact force is applied to the weld plate. A "weld pool detachment parameter" was determined to indicate whether detachment would occur. Detachment can be either full or partial (dripping), Partial detachment means that the weld pool detached from one side of the liquid-solid boundary so as to leave a hole at the puddle site but remained attached over part of the liquid-solid boundary and dripped down the plate with no fully detached material detected. Full detachment, however, does not necessarily mean that the whole pool fully detached; in some cases only a smaller portion of the pool detached, the remainder dripping down the plate. The weld pool detachment parameter according to theory and according to the empirical data allows a determination of whether full detachments might occur. Theoretical calculations indicated titanium alloy would be the most difficult from which to detach molten metal droplets followed by stainless steel and then by aluminum. The experimental results were for the most part consistent with the theoretical analysis and predictions. The above theory is applicable to other situations as desired for assessing the potential for molten metal detachments.

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.

Keyhole behavior and liquid flow in molten pool during laser-arc hybrid welding

NASA Astrophysics Data System (ADS)

Naito, Yasuaki; Katayama, Seiji; Matsunawa, Akira

2003-03-01

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

Melting Efficiency During Plasma Arc Welding

NASA Technical Reports Server (NTRS)

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

1999-01-01

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 aluminum. Arc Efficiency was measured calorimetrically and ranged between 48% and 66%. Melting efficiency depends on the weld pool shape. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Higher currents are thought to raise arc pressure and depress the liquid at the bottom of the weld pool causing a more nearly two dimensional heat flow condition.

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

PubMed

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

2017-11-01

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

An Assessment of Molten Metal Detachment Hazards for Electron Beam Welding in the Space Environment: Analysis and Test Results

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Russell, C.; Bhat, B.; Fragomeni, J. M.

1998-01-01

Conditions under which molten metal detachments might occur in a space welding environment are analyzed. A weld pool detachment parameter specifying conditions for pool detachment by impact is derived and corroborated by experimental evidence. Impact detachment for the pool is unlikely. Impact detachment for a drop of metal on the end of the weld wire may be possible under extreme conditions. Other potential causes of molten metal detachment considered, vaporization pressure forces and wire flickout from the pool, did not appear to present significant detachment threats.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of the detached metal drops. It was not particularly easy to generate the detachments fo

Influence of Joint Configuration on the Strength of Laser Welded Presshardened Steel

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

Shenghai, Zhang; Yifu, Shen; Huijuan, Qiu

2013-06-01

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

Phase-field simulation of weld solidification microstructure in an Al Cu alloy

NASA Astrophysics Data System (ADS)

Farzadi, A.; Do-Quang, M.; Serajzadeh, S.; Kokabi, A. H.; Amberg, G.

2008-09-01

Since the mechanical properties and the integrity of the weld metal depend on the solidification behaviour and the resulting microstructural characteristics, understanding weld pool solidification is of importance to engineers and scientists. Thermal and fluid flow conditions affect the weld pool geometry and solidification parameters. During solidification of the weld pool, a columnar grain structure develops in the weld metal. Prediction of the formation of the microstructure during welding may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the molten zone for specific temperature conditions. In this study, the solidification microstructures of the weld pool at different locations along the fusion boundary are simulated during gas tungsten arc welding of Al-3wt%Cu alloy using the phase-field model for the directional solidification of dilute binary alloys. A macroscopic heat transfer and fluid flow model was developed to assess the solidification parameters, notably the temperature gradient and solidification growth rate. The effect of the welding speed is investigated. Computer simulations of the solidification conditions and the formation of a cellular morphology during the directional solidification in gas tungsten arc welding are described. Moreover, the simulation results are compared with existing theoretical models and experimental findings.

Weld pool development during GTA and laser beam welding of Type 304 stainless steel; Part I - theoretical analysis

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

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

1989-12-01

A computational and experimental study was carried out to quantitatively understand the influence of the heat flow and the fluid flow in the transient development of the weld pool during gas tungsten arc (GTA) and laser beam welding of Type 304 stainless steel. Stationary gas tungsten arc and laser beam welds were made on two heats of Type 304 austenitic stainless steels containing 90 ppm sulfur and 240 ppm sulfur. A transient heat transfer model was utilized to simulate the heat flow and fluid flow in the weld pool. In this paper, the results of the heat flow and fluidmore » flow analysis are presented.« less

Simulation and Technology of Hybrid Welding of Thick Steel Parts with High Power Fiber Laser

NASA Astrophysics Data System (ADS)

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

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

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.

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.

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

NASA Astrophysics Data System (ADS)

Wang, Lei; Wei, Yanhong

2018-02-01

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

Numerical analysis of fume formation mechanism in arc welding

NASA Astrophysics Data System (ADS)

Tashiro, Shinichi; Zeniya, Tasuku; Yamamoto, Kentaro; Tanaka, Manabu; Nakata, Kazuhiro; Murphy, Anthony B.; Yamamoto, Eri; Yamazaki, Kei; Suzuki, Keiichi

2010-11-01

In order to clarify the fume formation mechanism in arc welding, a quantitative investigation based on the knowledge of interaction among the electrode, arc and weld pool is indispensable. A fume formation model consisting of a heterogeneous condensation model, a homogeneous nucleation model and a coagulation model has been developed and coupled with the GTA or GMA welding model. A series of processes from evaporation of metal vapour to fume formation from the metal vapour was totally investigated by employing this simulation model. The aim of this paper is to visualize the fume formation process and clarify the fume formation mechanism theoretically through a numerical analysis. Furthermore, the reliability of the simulation model was also evaluated through a comparison of the simulation result with the experimental result. As a result, it was found that the size of the secondary particles consisting of small particles with a size of several tens of nanometres reached 300 nm at maximum and the secondary particle was in a U-shaped chain form in helium GTA welding. Furthermore, it was also clarified that most part of the fume was produced in the downstream region of the arc originating from the metal vapour evaporated mainly from the droplet in argon GMA welding. The fume was constituted by particles with a size of several tens of nanometres and had similar characteristics to that of GTA welding. On the other hand, if the metal transfer becomes unstable and the metal vapour near the droplet diffuses directly towards the surroundings of the arc not getting into the plasma flow, the size of the particles reaches several hundred nanometres.

Investigation of molten pool oscillation during GMAW-P process based on a 3D model

NASA Astrophysics Data System (ADS)

Wang, L. L.; Lu, F. G.; Cui, H. C.; Tang, X. H.

2014-11-01

In order to better reveal the oscillation mechanism of the pulsed gas metal arc welding (GMAW-P) process due to an alternately varied welding current, arc plasma and molten pool oscillation were simulated through a self-consistent three-dimensional model. Based on an experimental analysis of the dynamic variation of the arc plasma and molten pool captured by a high-speed camera, the model was validated by comparison of the measured and predicted results. The calculated results showed that arc pressure was the key factor causing the molten pool to oscillate. The variation in arc size and temperature from peak time to base time resulted in a great difference in the heat input and arc pressure acting on the molten pool. The surface deformation of the molten pool due to the varying degrees of arc pressure induced alternate displacement and backflow in the molten metal. The periodic iteration of deeper and shallower surface deformation, drain and backflow of molten metal caused the molten pool to oscillate at a certain frequency. In this condition, the arc pressure at the peak time is more than six times higher than that at the base time, and the maximum surface depression is 1.4 mm and 0.6 mm, respectively, for peak time and base time.

Modeling macro-and microstructures of Gas-Metal-Arc Welded HSLA-100 steel

NASA Astrophysics Data System (ADS)

Yang, Z.; Debroy, T.

1999-06-01

Fluid flow and heat transfer during gas-metal-arc welding (GMAW) of HSLA-100 steel were studied using a transient, three-dimensional, turbulent heat transfer and fluid flow model. The temperature and velocity fields, cooling rates, and shape and size of the fusion and heat-affected zones (HAZs) were calculated. A continuous-cooling-transformation (CCT) diagram was computed to aid in the understanding of the observed weld metal microstructure. The computed results demonstrate that the dissipation of heat and momentum in the weld pool is significantly aided by turbulence, thus suggesting that previous modeling results based on laminar flow need to be re-examined. A comparison of the calculated fusion and HAZ geometries with their corresponding measured values showed good agreement. Furthermore, “finger” penetration, a unique geometric characteristic of gas-metal-arc weld pools, could be satisfactorily predicted from the model. The ability to predict these geometric variables and the agreement between the calculated and the measured cooling rates indicate the appropriateness of using a turbulence model for accurate calculations. The microstructure of the weld metal consisted mainly of acicular ferrite with small amounts of bainite. At high heat inputs, small amounts of allotriomorphic and Widmanstätten ferrite were also observed. The observed microstructures are consistent with those expected from the computed CCT diagram and the cooling rates. The results presented here demonstrate significant promise for understanding both macro-and microstructures of steel welds from the combination of the fundamental principles from both transport phenomena and phase transformation theory.

Nd:YAG laser welding of coated sheet steel

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

Graham, M.P.; Kerr, H.W.; Weckman, D.C.

1994-12-31

Coated sheet steels are used extensively in the automotive industry for the fabrication of automobile body components; however, their reduced weldability by the traditional welding processes has led to numerous studies into the use of alternate process such as laser welding. In this paper, we present a modified joint geometry which allows high quality lap welds of coated sheet steels to be made by laser welding processes. Hot-dipped galvanized sheet (16 gauge), with a 60 g/m zinc coating was used in this study. A groove was created in the top sheet of a specimen pair by pressing piano wires ofmore » various diameters into the sheet. The specimens were clamped together in a lag-joint configuration such that they were in contacted only along the grove projection. A parametric study was conducted using the variables of welding speed, laser mean power (685 W, 1000 W and 1350 W), and grove size. Weld quality and weld pool dimensions were assessed using metallurgical cross-sections and image analysis techniques. Acceptable quality seam welds were produced in the galvanized sheet steel with both grove sizes when using 1000 W and 1350 W laser mean powers and a range of welding speeds. Results of the shear-tensile tests showed that high loads to failure, with failure occurring in the parent material, were predominately found in welds produced at speeds over 1.2 m/min and when using the high mean laser powers: 1000 W and 1350 W. A modified lap joint geometry, in which a groove is pre-placed in the top sheet of the lap-joint configuration, has been developed which permits laser welding of coated sheet steels. Good quality seam welds have been produced in 16 gauge galvanized sheet steels at speeds up to 2.7 m/min using a 2 kW CW Nd:YAG laser operating at 1350 W laser mean power. Weld quality was not affected by changes in groove size.« less

Investigation of Microstructural Features Determining the Toughness of 980 MPa Bainitic Weld Metal

NASA Astrophysics Data System (ADS)

Cao, R.; Zhang, X. B.; Wang, Z.; Peng, Y.; Du, W. S.; Tian, Z. L.; Chen, J. H.

2014-02-01

The microstructural features that control the impact toughness of weld metals of a 980 MPa 8 pct Ni high-strength steel are investigated using instrumented Charpy V tester, optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM), electron back-scattered diffraction (EBSD), and finite-element method (FEM) calculation. The results show that the critical event for cleavage fracture in this high-strength steel and weld metals is the propagation of a bainite packet-sized crack across the packet boundary into contiguous packets, and the bainitic packet sizes control the impact toughness. The high-angle misorientation boundaries detected in a bainite packet by EBSD form fine tear ridges on fracture surfaces. However, they are not the decisive factors controlling the cleavage fracture. The effects of Ni content are essential factors for improving the toughness. The extra large cleavage facets seriously deteriorate the toughness, which are formed on the interfaces of large columnar crystals growing in welding pools with high heat input.

Investigation of the Microstructure of Laser-Arc Hybrid Welded Boron Steel

NASA Astrophysics Data System (ADS)

Son, Seungwoo; Lee, Young Ho; Choi, Dong-Won; Cho, Kuk-Rae; Shin, Seung Man; Lee, Youngseog; Kang, Seong-Hoon; Lee, Zonghoon

2018-05-01

The microstructure of boron steel for automotive driving shaft manufacturing after laser-arc hybrid welding was investigated. Laser-arc hybrid welding technology was applied to 3-mm-thick plates of boron steel, ST35MnB. The temperature distribution of the welding pool was analyzed using the finite element method, and the microstructure of the welded boron steel was characterized using optical microscopy and scanning and transmission electron microscopies. The microstructure of the weld joint was classified into the fusion zone, the heat-affected zone (HAZ), and the base material. At the fusion zone, the bainite grains exist in the martensite matrix and show directionality because of heat input from the welding. The HAZ is composed of smaller grains, and the hardness of the HAZ is greater than that of the fusion zone. We discuss that the measured grain size and the hardness of the HAZ originate from undissolved precipitates that retard the grain growth of austenite.

Optical penetration sensor for pulsed laser welding

DOEpatents

Essien, Marcelino; Keicher, David M.; Schlienger, M. Eric; Jellison, James L.

2000-01-01

An apparatus and method for determining the penetration of the weld pool created from pulsed laser welding and more particularly to an apparatus and method of utilizing an optical technique to monitor the weld vaporization plume velocity to determine the depth of penetration. A light source directs a beam through a vaporization plume above a weld pool, wherein the plume changes the intensity of the beam, allowing determination of the velocity of the plume. From the velocity of the plume, the depth of the weld is determined.

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

NASA Astrophysics Data System (ADS)

Tolvanen, Sakari; Pederson, Robert; Klement, Uta

2018-03-01

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

Welding deviation detection algorithm based on extremum of molten pool image contour

NASA Astrophysics Data System (ADS)

Zou, Yong; Jiang, Lipei; Li, Yunhua; Xue, Long; Huang, Junfen; Huang, Jiqiang

2016-01-01

The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding(GMAW) molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels(0.16 mm), and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.

An integrated optical sensor for GMAW feedback control

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

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

1992-08-01

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

An integrated optical sensor for GMAW feedback control

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

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

1992-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Contribution to study of heat transfer and fluid flow during GTA welding

NASA Astrophysics Data System (ADS)

Koudadje, Koffi; Delalondre, Clarisse; Médale, Marc; Carpreau, Jean-Michel

2014-06-01

In this paper, the effect of surface-active elements especially sulfur on weld pool shape has been reported. In our contribution, we analyze the influence of the weld pool chemical composition (Mn, Si, …), welding energy, sulphur gradient and electromagnetic effect. The computed results are in good agreement with the corresponding experimental results, indicating the validity of the modeling approach.

Modeling macro-and microstructures of gas-metal-arc welded HSLA-100 steel

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

Yang, Z.; Debroy, T.

1999-06-01

Fluid flow and heat transfer during gas-metal-arc welding (GMAW) of HSLA-100 steel were studied using a transient, three-dimensional, turbulent heat transfer and fluid flow model. The temperature and velocity fields, cooling rates, and shape and size of the fusion and heat-affected zones (HAZs) were calculated. A continuous-cooling-transformation (CCT) diagram was computed to aid in the understanding of the observed weld metal microstructure. The computed results demonstrate that the dissipation of heat and momentum in the weld pool is significantly aided by turbulence,m thus suggesting that previous modeling results based on laminar flow need to be re-examined. A comparison of themore » calculated fusion and HAZ geometries with their corresponding measured values showed good agreement. Furthermore, finger penetration, a unique geometric characteristic of gas-metal-arc weld pools, could be satisfactorily predicted from the model. The ability to predict these geometric variables and the agreement between the calculated and the measured cooling rates indicate the appropriateness of using a turbulence model for accurate calculations. The microstructure of the weld metal consisted mainly of acicular ferrite with small amounts of bainite. At high heat inputs, small amounts of allotriomorphic and Widmanstaetten ferrite were also observed. The observed microstructures are consistent with those expected from the computed CCT diagram and the cooling rates. The results presented here demonstrate significant promise for understanding both macro-and microstructures of steel welds from the combination of the fundamental principles from both transport phenomena and phase transformation theory.« less

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.

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.

Numerical simulation of heat transfer and fluid flow during double-sided laser beam welding of T-joints for aluminum aircraft fuselage panels

NASA Astrophysics Data System (ADS)

Yang, Zhibin; Tao, Wang; Li, Liqun; Chen, Yanbin; Shi, Chunyuan

2017-06-01

In comparison with conventional laser beam welding, double-sided laser beam welding has two laser heat sources simultaneously and symmetrically loaded from both sides makes it to be a more complicated coupled heat transport and fluid flow process. In this work, in order to understand the heat transfer and fluid flow, a three-dimensional model was developed and validated with the experimental results. The temperature field, fluid flow field, and keyhole characteristic were calculated using the developed model by FLUENT software. Calculated results indicated that the temperature and fluid flow fields were bilateral symmetry along the stringer center, and the molten pool maximum length was located near the keyhole intersection position. The skin side had higher temperature and faster cooling speed. Several characteristic flow patterns in the weld pool cross section, including the vortexes flows near the keyhole opening position, the convection flows above the keyhole intersection location, the regularity downward flows at the molten pool bottom. And in the lengthwise section, a distinct vortex flow below the keyhole, and the liquid metal behind the keyhole first flowed to near the molten pool maximum length location and then to the molten pool surface. Perpendicular to and along welding direction the keyhole liquid metal flowed to the weld molten pool surface and around the keyhole, respectively. The special temperature fields and fluid flow patterns were closely related to the effects of the double sides' laser energy coupling and enhancement. The calculated weld pool geometry basically in good agreement with the experimental results indicated that the developed model was validity and reasonable.

Effects of SO/sub 2/ torch gas additions on GTA weld shape

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

Heiple, C.R.; Burgardt, P.

1984-01-01

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

Molten Pool Behavior and Mechanical Properties of Pulsed Current Double-Sided Synchronization GTA Welded Fe-18Cr-17Mn-Ni-N

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

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

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

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

2015-04-15

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

ARC and Melting Efficiency of Plasma ARC Welds

NASA Technical Reports Server (NTRS)

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

1999-01-01

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

A Quantitative Model of Keyhole Instability Induced Porosity in Laser Welding of Titanium Alloy

NASA Astrophysics Data System (ADS)

Pang, Shengyong; Chen, Weidong; Wang, Wen

2014-06-01

Quantitative prediction of the porosity defects in deep penetration laser welding has generally been considered as a very challenging task. In this study, a quantitative model of porosity defects induced by keyhole instability in partial penetration CO2 laser welding of a titanium alloy is proposed. The three-dimensional keyhole instability, weld pool dynamics, and pore formation are determined by direct numerical simulation, and the results are compared to prior experimental results. It is shown that the simulated keyhole depth fluctuations could represent the variation trends in the number and average size of pores for the studied process conditions. Moreover, it is found that it is possible to use the predicted keyhole depth fluctuations as a quantitative measure of the average size of porosity. The results also suggest that due to the shadowing effect of keyhole wall humps, the rapid cooling of the surface of the keyhole tip before keyhole collapse could lead to a substantial decrease in vapor pressure inside the keyhole tip, which is suggested to be the mechanism by which shielding gas enters into the porosity.

Three-dimensional modeling of the plasma arc in arc welding

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

Xu, G.; Tsai, H. L.; Hu, J.

2008-11-15

Most previous three-dimensional modeling on gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) focuses on the weld pool dynamics and assumes the two-dimensional axisymmetric Gaussian distributions for plasma arc pressure and heat flux. In this article, a three-dimensional plasma arc model is developed, and the distributions of velocity, pressure, temperature, current density, and magnetic field of the plasma arc are calculated by solving the conservation equations of mass, momentum, and energy, as well as part of the Maxwell's equations. This three-dimensional model can be used to study the nonaxisymmetric plasma arc caused by external perturbations such asmore » an external magnetic field. It also provides more accurate boundary conditions when modeling the weld pool dynamics. The present work lays a foundation for true three-dimensional comprehensive modeling of GTAW and GMAW including the plasma arc, weld pool, and/or electrode.« less

Laser Beam Oscillation Strategies for Fillet Welds in Lap Joints

NASA Astrophysics Data System (ADS)

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

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

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

[Impact of introduction of O2 on the welding arc of gas pool coupled activating TIG].

PubMed

Huang, Yong; Wang, Yan-Lei; Zhang, Zhi-Guo

2014-05-01

In the present paper, Boltzmann plot method was applied to analyze the temperature distributions of the are plasma when the gas pool coupled activating TIG welding was at different coupling degrees with the outer gas being O2. Based on this study of temperature distributions, the changing regularities of are voltage and are appearance were studied. The result shows that compared with traditional TIG welding, the introduction of O2 makes the welding arc constricted slightly, the temperature of the are center build up, and the are voltage increase. When argon being the inner gas, oxygen serving as the outer gas instead of argon makes the are constricted more obviously. When the coupling degree increases from 0 to 2, the temperature of the are center and the are voltage both increase slightly. In the gas pool coupled activating TIG welding the are is constricted not obviously, and the reason why the weld penetration is improved dramatically in the welding of stainless steel is not are constriction.

Effect of Inverter Power Source Characteristics on Welding Stability and Heat Affected Zone Dimensions

NASA Astrophysics Data System (ADS)

Il'yaschenko, D. P.; Chinakhov, D. A.; Mamadaliev, R. A.

2018-01-01

The paper presents results the research in the effect of power sources dynamic characteristics on stability of melting and electrode metal transfer to the weld pool shielded metal arc welding. It is proved that when applying inverter-type welding power sources, heat and mass transfer characteristics change, arc gap short-circuit time and drop generation time are reduced. This leads to reduction of weld pool heat content and contraction of the heat-affected zone by 36% in comparison the same parameters obtained using a diode rectifier.

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.

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Stability of Full Penetration, Flat Position Weld Pools

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.; Coan, Al. B.

1999-01-01

The dynamics of the dropthrough distance of a full penetration, flat position weld pool is described. Close to incipient root side penetration the dropthrough is metastable, so that a small drop in power can cause a loss of penetration if not followed soon enough by a compensating rise in power. The SPA (Soft Plasma Arc) process with higher pressure on top of the weld pool loses penetration more quickly than the GTA (Gas Tungsten Arc) process. 2195 aluminum-lithium alloy with a lower surface tension loses penetration more quickly than 2219 aluminum alloy. An instance of loss of penetration of a SPA weld in 2195 aluminum-lithium alloy is discussed in the light of the model.

Mechanical properties and microstructures of a magnesium alloy gas tungsten arc welded with a cadmium chloride flux

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

Zhang, Z.D.; Liu, L.M.; Shen, Y.

2008-01-15

Gas tungsten arc (GTA) welds were prepared on 5-mm thick plates of wrought magnesium AZ31B alloy, using an activated flux. The microstructural characteristics of the weld joint were investigated using optical and scanning microscopy, and the fusion zone microstructure was compared with that of the base metal. The elemental distribution was also investigated by electron probe microanalysis (EPMA). Mechanical properties were determined by standard tensile tests on small-scale specimens. The as-welded fusion zone prepared using a CdCl{sub 2} flux exhibited a larger grain size than that prepared without flux; the microstructure consisted of matrix {alpha}-Mg, eutectic {alpha}-Mg and {beta}-Al{sub 12}Mg{submore » 17}. The HAZ was observed to be slightly wider for the weld prepared with a CdCl{sub 2} flux compared to that prepared without flux; thus the tensile strength was lower for the flux-prepared weld. The fact that neither Cd nor Cl was detected in the weld seam by EPMA indicates that the CdCl{sub 2} flux has a small effect on convection in the weld pool.« less

Welding wire pressure sensor assembly

NASA Technical Reports Server (NTRS)

Morris, Timothy B. (Inventor); Milly, Peter F., Sr. (Inventor); White, J. Kevin (Inventor)

1994-01-01

The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

Investigation on the Mechanism and Failure Mode of Laser Transmission Spot Welding Using PMMA Material for the Automotive Industry

PubMed Central

Wang, Xiao; Liu, Baoguang; Liu, Wei; Zhong, Xuejiao; Jiang, Yingjie; Liu, Huixia

2017-01-01

To satisfy the need of polymer connection in lightweight automobiles, a study on laser transmission spot welding using polymethyl methacrylate (PMMA) is conducted by using an Nd:YAG pulse laser. The influence of three variables, namely peak voltages, defocusing distances and the welding type (type I (pulse frequency and the duration is 25 Hz, 0.6 s) and type II (pulse frequency and the duration is 5 Hz, 3 s)) to the welding quality was investigated. The result showed that, in the case of the same peak voltages and defocusing distances, the number of bubbles for type I was obviously more than type II. The failure mode of type I was the base plate fracture along the solder joint, and the connection strength of type I was greater than type II. The weld pool diameter:depth ratio for type I was significantly greater than type II. It could be seen that there was a certain relationship between the weld pool diameter:depth ratio and the welding strength. By the finite element simulation, the weld pool for type I was more slender than type II, which was approximately the same as the experimental results. PMID:28772383

Shielding gas selection for increased weld penetration and productivity in GTA welding

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

Leinonen, J.I.

1996-12-31

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

Investigation on the Mechanism and Failure Mode of Laser Transmission Spot Welding Using PMMA Material for the Automotive Industry.

PubMed

Wang, Xiao; Liu, Baoguang; Liu, Wei; Zhong, Xuejiao; Jiang, Yingjie; Liu, Huixia

2017-01-01

To satisfy the need of polymer connection in lightweight automobiles, a study on laser transmission spot welding using polymethyl methacrylate (PMMA) is conducted by using an Nd:YAG pulse laser. The influence of three variables, namely peak voltages, defocusing distances and the welding type (type I (pulse frequency and the duration is 25 Hz, 0.6 s) and type II (pulse frequency and the duration is 5 Hz, 3 s)) to the welding quality was investigated. The result showed that, in the case of the same peak voltages and defocusing distances, the number of bubbles for type I was obviously more than type II. The failure mode of type I was the base plate fracture along the solder joint, and the connection strength of type I was greater than type II. The weld pool diameter:depth ratio for type I was significantly greater than type II. It could be seen that there was a certain relationship between the weld pool diameter:depth ratio and the welding strength. By the finite element simulation, the weld pool for type I was more slender than type II, which was approximately the same as the experimental results.

The influence of arc plasma parameters on the form of a welding pool

NASA Astrophysics Data System (ADS)

Frolov, V. Ya.; Toropchin, A. I.

2015-07-01

The influence of the Marangoni force on the form of a welding pool has been considered. Results of computer simulation of the processes of welding arc generation with a non-consumable tungsten electrode in inert gas are shown. The experimental results are reported and comparatively analyzed. The calculations were carried out in a package of applied programs at various currents.

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

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

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

1983-03-01

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

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.

Probing Reliability of Transport Phenomena Based Heat Transfer and Fluid Flow Analysis in Autogeneous Fusion Welding Process

NASA Astrophysics Data System (ADS)

Bag, S.; de, A.

2010-09-01

The transport phenomena based heat transfer and fluid flow calculations in weld pool require a number of input parameters. Arc efficiency, effective thermal conductivity, and viscosity in weld pool are some of these parameters, values of which are rarely known and difficult to assign a priori based on the scientific principles alone. The present work reports a bi-directional three-dimensional (3-D) heat transfer and fluid flow model, which is integrated with a real number based genetic algorithm. The bi-directional feature of the integrated model allows the identification of the values of a required set of uncertain model input parameters and, next, the design of process parameters to achieve a target weld pool dimension. The computed values are validated with measured results in linear gas-tungsten-arc (GTA) weld samples. Furthermore, a novel methodology to estimate the overall reliability of the computed solutions is also presented.

Effects of shielding gas composition on arc profile and molten pool dynamics in gas metal arc welding of steels

NASA Astrophysics Data System (ADS)

Wang, L. L.; Lu, F. G.; Wang, H. P.; Murphy, A. B.; Tang, X. H.

2014-11-01

In gas metal arc welding, gases of different compositions are used to produce an arc plasma, which heats and melts the workpiece. They also protect the workpiece from the influence of the air during the welding process. This paper models gas metal arc welding (GMAW) processes using an in-house simulation code. It investigates the effects of the gas composition on the temperature distribution in the arc and on the molten pool dynamics in gas metal arc welding of steels. Pure argon, pure CO2 and different mixtures of argon and CO2 are considered in the study. The model is validated by comparing the calculated weld profiles with physical weld measurements. The numerical calculations reveal that gas composition greatly affects the arc temperature profile, heat transfer to the workpiece, and consequently the weld dimension. As the CO2 content in the shielding gas increases, a more constricted arc plasma with higher energy density is generated as a result of the increased current density in the arc centre and increased Lorentz force. The calculation also shows that the heat transferred from the arc to the workpiece increases with increasing CO2 content, resulting in a wider and deeper weld pool and decreased reinforcement height.

Interaction of trace elements and welding parameters on GTA weld shape. [Variation with penetration and tip angle

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

Burgardt, P.; Heiple, C.R.

1985-01-01

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

On the hot cracking susceptibility of a semisolid aluminium 6061 weld: Application of a coupled solidification- thermomechanical model

NASA Astrophysics Data System (ADS)

Zareie Rajani, H. R.; Phillion, A. B.

2015-06-01

A coupled solidification-thermomechanical model is presented that investigates the hot tearing susceptibility of an aluminium 6061 semisolid weld. Two key phenomena are considered: excessive deformation of the semisolid weld, initiating a hot tear, and the ability of the semisolid weld to heal the hot tear by circulation of the molten metal. The model consists of two major modules: weld solidification and thermomechanical analysis. 1) By means of a multi-scale model of solidification, the microstructural evolution of the semisolid weld is simulated in 3D. The semisolid structure, which varies as a function of welding parameters, is composed of solidifying grains and a network of micro liquid channels. The weld solidification module is utilized to obtain the solidification shrinkage. The size of the micro liquid channels is used as an indicator to assess the healing ability of the semisolid weld. 2) Using the finite element method, the mechanical interaction between the weld pool and the base metal is simulated to capture the transient force field deforming the semisolid weld. Thermomechanical stresses and shrinkage stresses are both considered in the analysis; the solidification contractions are extracted from the weld solidification module and applied to the deformation simulation as boundary conditions. Such an analysis enables characterization of the potential for excessive deformation of the weld. The outputs of the model are used to study the effect of welding parameters including welding current and speed, and also welding constraint on the hot cracking susceptibility of an aluminium alloy 6061 semisolid weld.

Influence of Oxides on Microstructures and Mechanical Properties of High-Strength Steel Weld Joint

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

Analysis of Welding Zinc Coated Steel Sheets in Zero Gap Configuration by 3D Simulations and High Speed Imaging

NASA Astrophysics Data System (ADS)

Koch, Holger; Kägeler, Christian; Otto, Andreas; Schmidt, Michael

Welding of zinc coated sheets in zero gap configuration is of eminent interest for the automotive industry. This Laser welding process would enable the automotive industry to build auto bodies with a high durability in a plain manufacturing process. Today good welding results can only be achieved by expensive constructive procedures such as clamping devices to ensure a defined gad. The welding in zero gap configuration is a big challenge because of the vaporised zinc expelled from the interface between the two sheets. To find appropriate welding parameters for influencing the keyhole and melt pool dynamics, a three dimensional simulation and a high speed imaging system for laser keyhole welding have been developed. The obtained results help to understand the process of the melt pool perturbation caused by vaporised zinc.

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.

Self-Aligning Sensor-Mounting Fixture

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.; Mills, Rhonda J.

1991-01-01

Optical welding sensors replaced without realignment. Mounting fixture for optical weld-penetration sensor enables accurate and repeatable alignment. Simple and easy to use. Assembled on welding torch, it holds sensor securely and keeps it pointed toward weld pool. Designed for use on gas/tungsten arc-welding torch, fixture replaces multipiece bracket.

Research on the welding process of aluminum alloy based on high power fiber laser

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

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

NASA Astrophysics Data System (ADS)

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

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

Acoustic-Emission Weld-Penetration Monitor

NASA Technical Reports Server (NTRS)

Maram, J.; Collins, J.

1986-01-01

Weld penetration monitored by detection of high-frequency acoustic emissions produced by advancing weld pool as it melts and solidifies in workpiece. Acoustic emission from TIG butt weld measured with 300-kHz resonant transducer. Rise in emission level coincides with cessation of weld penetration due to sudden reduction in welding current. Such monitoring applied to control of automated and robotic welders.

Experimental research on the dynamic behaviors of the keyhole and molten pool in laser deep-penetration welding

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

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

NASA Astrophysics Data System (ADS)

Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

2014-05-01

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

Fluid Flow Characteristics and Porosity Behavior in Full Penetration Laser Welding of a Titanium Alloy

NASA Astrophysics Data System (ADS)

Chang, Baohua; Allen, Chris; Blackburn, Jon; Hilton, Paul; Du, Dong

2015-04-01

In this paper, a computational fluid mechanics model is developed for full penetration laser welding of titanium alloy Ti6Al4V. This has been used to analyze possible porosity formation mechanisms, based on predictions of keyhole behavior and fluid flow characteristics in the weld pool. Numerical results show that when laser welding 3 mm thickness titanium alloy sheets with given laser beam focusing optics, keyhole depth oscillates before a full penetration keyhole is formed, but thereafter keyhole collapses are not predicted numerically. For lower power, lower speed welding, the fluid flow behind the keyhole is turbulent and unstable, and vortices are formed. Molten metal is predicted to flow away from the center plane of the weld pool, and leave a gap or void within the weld pool behind the keyhole. For higher power, higher speed welding, fluid flow is less turbulent, and such vortices are not formed. Corresponding experimental results show that porosity was absent in the melt runs made at higher power and higher welding speed. In contrast, large pores were present in melt runs made at lower power and lower welding speed. Based on the combination of experimental results and numerical predictions, it is proposed that porosity formation when keyhole laser welding may result from turbulent fluid flow behind the keyhole, with the larger the value of associated Reynolds number, the higher the possibility of porosity formation. For such fluid flow controlled porosities, measures to decrease Reynolds number of the fluid flow close to the keyhole could prove effective in reducing or avoiding porosity.

Virtual welding equipment for simulation of GMAW processes with integration of power source regulation

NASA Astrophysics Data System (ADS)

Reisgen, Uwe; Schleser, Markus; Mokrov, Oleg; Zabirov, Alexander

2011-06-01

A two dimensional transient numerical analysis and computational module for simulation of electrical and thermal characteristics during electrode melting and metal transfer involved in Gas-Metal-Arc-Welding (GMAW) processes is presented. Solution of non-linear transient heat transfer equation is carried out using a control volume finite difference technique. The computational module also includes controlling and regulation algorithms of industrial welding power sources. The simulation results are the current and voltage waveforms, mean voltage drops at different parts of circuit, total electric power, cathode, anode and arc powers and arc length. We describe application of the model for normal process (constant voltage) and for pulsed processes with U/I and I/I-modulation modes. The comparisons with experimental waveforms of current and voltage show that the model predicts current, voltage and electric power with a high accuracy. The model is used in simulation package SimWeld for calculation of heat flux into the work-piece and the weld seam formation. From the calculated heat flux and weld pool sizes, an equivalent volumetric heat source according to Goldak model, can be generated. The method was implemented and investigated with the simulation software SimWeld developed by the ISF at RWTH Aachen University.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

Experimental study of hot cracking at circular welding joints of 42CrMo steel

NASA Astrophysics Data System (ADS)

Zhang, Yan; Chen, Genyu; Chen, Binghua; Wang, Jinhai; Zhou, Cong

2017-12-01

The hot cracking at circular welding joints of quenched and tempered 42CrMo steel were studied. The flow of the molten pool and the solidification process of weld were observed with a high-speed video camera. The information on the variations in the weld temperature was collected using an infrared (IR) thermal imaging system. The metallurgical factors of hot cracking were analyzed via metallographic microscope and scanning electron microscope (SEM). The result shows that leading laser laser-metal active gas (MAG) hybrid welding process has a smaller solid-liquid boundary movement rate (VSL) and a smaller solid-liquid boundary temperature gradient (GSL) compared with leading arc laser-MAG hybrid welding process and laser welding process. Additionally, the metal in the molten pool has superior permeability while flowing toward the dendritic roots and can compensate for the inner-dendritic pressure balance. Therefore, leading laser laser-MAG hybrid welding process has the lowest hot cracking susceptibility.

Numerical modeling of keyhole dynamics in laser welding

NASA Astrophysics Data System (ADS)

Zhang, Wen-Hai; Zhou, Jun; Tsai, Hai-Lung

2003-03-01

Mathematical models and the associated numerical techniques have been developed to study the following cases: (1) the formation and collapse of a keyhole, (2) the formation of porosity and its control strategies, (3) laser welding with filler metals, and (4) the escape of zinc vapor in laser welding of galvanized steel. The simulation results show that the formation of porosity in the weld is caused by two competing mechanisms: one is the solidification rate of the molten metal and the other is the speed that molten metal backfills the keyhole after laser energy is terminated. The models have demonstrated that porosity can be reduced or eliminated by adding filler metals, controlling laser tailing power, or applying an electromagnetic force during keyhole collapse process. It is found that a uniform composition of weld pool is difficult to achieve by filler metals due to very rapid solidification of the weld pool in laser welding, as compared to that in gas metal arc welding.

Numerical Simulations on the Laser Spot Welding of Zirconium Alloy Endplate for Nuclear Fuel Bundle Assembly

NASA Astrophysics Data System (ADS)

Satyanarayana, G.; Narayana, K. L.; Boggarapu, Nageswara Rao

2018-03-01

In the nuclear industry, a critical welding process is joining of an end plate to a fuel rod to form a fuel bundle. Literature on zirconium welding in such a critical operation is limited. A CFD model is developed and performed for the three-dimensional non-linear thermo-fluid analysis incorporating buoyancy and Marnangoni stress and specifying temperature dependent properties to predict weld geometry and temperature field in and around the melt pool of laser spot during welding of a zirconium alloy E110 endplate with a fuel rod. Using this method, it is possible to estimate the weld pool dimensions for the specified laser power and laser-on-time. The temperature profiles will estimate the HAZ and microstructure. The adequacy of generic nature of the model is validated with existing experimental data.

Welding Penetration Control of Fixed Pipe in TIG Welding Using Fuzzy Inference System

NASA Astrophysics Data System (ADS)

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

This paper presents a study on welding penetration control of fixed pipe in Tungsten Inert Gas (TIG) welding using fuzzy inference system. The welding penetration control is essential to the production quality welds with a specified geometry. For pipe welding using constant arc current and welding speed, the bead width becomes wider as the circumferential welding of small diameter pipes progresses. Having welded pipe in fixed position, obviously, the excessive arc current yields burn through of metals; in contrary, insufficient arc current produces imperfect welding. In order to avoid these errors and to obtain the uniform weld bead over the entire circumference of the pipe, the welding conditions should be controlled as the welding proceeds. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position using the AC welding machine. The monitoring system used a charge-coupled device (CCD) camera to monitor backside image of molten pool. The captured image was processed to recognize the edge of molten pool by image processing algorithm. Simulation of welding control using fuzzy inference system was constructed to simulate the welding control process. The simulation result shows that fuzzy controller was suitable for controlling the welding speed and appropriate to be implemented into the welding system. A series of experiments was conducted to evaluate the performance of the fuzzy controller. The experimental results show the effectiveness of the control system that is confirmed by sound welds.

Variable-Polarity Plasma Arc Welding Of Alloy 2219

NASA Technical Reports Server (NTRS)

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

1989-01-01

Report presents results of study of variable-polarity plasma arc (VPPA) welding of aluminum alloy 2219. Consists of two parts: Examination of effects of microsegregation and transient weld stress on macrosegregation in weld pool and, electrical characterization of straight- and reverse-polarity portions of arc cycle.

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.

Field comparison of three inhalable samplers (IOM, PGP-GSP 3.5 and Button) for welding fumes.

PubMed

Zugasti, Agurtzane; Montes, Natividad; Rojo, José M; Quintana, M José

2012-02-01

Inhalable sampler efficiency depends on the aerodynamic size of the airborne particles to be sampled and the wind speed. The aim of this study was to compare the behaviour of three personal inhalable samplers for welding fumes generated by Manual Metal Arc (MMA) and Metal Active Gas (MAG) processes. The selected samplers were the ones available in Spain when the study began: IOM, PGP-GSP 3.5 (GSP) and Button. Sampling was carried out in a welding training center that provided a homogeneous workplace environment. The static sampling assembly used allowed the placement of 12 samplers and 2 cascade impactors simultaneously. 183 samples were collected throughout 2009 and 2010. The range of welding fumes' mass concentrations was from 2 mg m(-3) to 5 mg m(-3). The pooled variation coefficients for the three inhalable samplers were less than or equal to 3.0%. Welding particle size distribution was characterized by a bimodal log-normal distribution, with MMADs of 0.7 μm and 8.2 μm. For these welding aerosols, the Button and the GSP samplers showed a similar performance (P = 0.598). The mean mass concentration ratio was 1.00 ± 0.01. The IOM sampler showed a different performance (P < 0.001). The mean mass concentration ratios were 0.90 ± 0.01 for Button/IOM and 0.92 ± 0.02 for GSP/IOM. This information is useful to consider the measurements accomplished by the IOM, GSP or Button samplers together, in order to assess the exposure at workplaces over time or to study exposure levels in a specific industrial activity, as welding operations.

Keyhole and weld shapes for plasma arc welding under normal and zero gravity

NASA Technical Reports Server (NTRS)

Keanini, R. G.; Rubinsky, B.

1990-01-01

A first order study of the interfacial (keyhole) shape between a penetrating argon plasma arc jet and a stationary liquid metal weld pool is presented. The interface is determined using the Young-Laplace equation by assuming that the plasma jet behaves as a one-dimensional ideal gas flow and by neglecting flow within the weld pool. The solution for the keyhole shape allows an approximate determination of the liquid-solid metal phase boundary location based on the assumption that the liquid melt is a stagnant thermal boundary layer. Parametric studies examine the effect of plasma mass flow rate, initial plasma enthalpy, liquid metal surface tension, and jet shear on weldment shape under both normal and zero gravity. Among the more important findings of this study is that keyhole and weld geometries are minimally affected by gravity, suggesting that data gathered under gravity can be used in planning in-space welding.

Effect of carbon black on temperature field and weld profile during laser transmission welding of polymers: A FEM study

NASA Astrophysics Data System (ADS)

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

2012-04-01

The influence of the carbon black on temperature distribution and weld profile, during laser transmission welding of polymers, is investigated in the present research work. A transient numerical model, based on conduction mode heat transfer, is developed to analyze the process. The heat input to the model is considered to be the volumetric Gaussian heat source. The computation of temperature field during welding is carried out for polycarbonates having different proportion of carbon black in polymer matrix. The temperature dependent material properties of polycarbonate are taken into account for modeling. The finite element code ANSYS ® is employed to obtain the numerical results. The numerically computed results of weld pool dimensions are compared with the experimental results. The comparison shows a fair agreement between them, which gives confidence to use the developed model for intended investigation with acceptable accuracy. The results obtained have revealed that the carbon black has considerable influence on the temperature field distribution and the formation of the weld pool geometry.

Laser Beam Welding of Nitride Steel Components

NASA Astrophysics Data System (ADS)

Gu, Hongping; Yin, Guobin; Shulkin, Boris

Laser beam welding is a joining technique that has many advantages over conventional GMAW welding, such as low heat input, short cycle time as well as good cosmetic welds. Laser beam welding has been widely used for welding powertrain components in automotive industry. When welding nitride steel components, however, laser beam welding faces a great challenge. The difficulty lies in the fact that the nitride layer in the joint releases the nitrogen into the weld pool, resulting in a porous weld. This research presents an industrial ready solution to prevent the nitrogen from forming gas bubbles in the weld.

Surface preparation effects on GTA (gas tungsten arc) weld penetration in JBK-75 stainless steel

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

Campbell, R.D.; Heiple, C.R.; Sturgill, P.L.

1989-01-01

The results of a study are reported here on the effects of surface preparation on the shape of GTA welds on JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface (weld groove) preparation produced substantial changes in the penetration characteristics and welding behavior of this alloy. Increased and more consistent weld penetration (higher d/w ratios) along with improved arc stability and less arc wander result from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any improvement in penetration. Abrasive treatments roughen the surface, increase the surface area, andmore » increase the surface oxide thickness. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension driven fluid flow pattern in the weld pool. Similar results were observed with changes in filler wire surface oxide thickness, caused by changes in wire production conditions. 15 refs., 14 figs., 4 tabs.« less

Study on laser welding of austenitic stainless steel by varying incident angle of pulsed laser beam

NASA Astrophysics Data System (ADS)

Kumar, Nikhil; Mukherjee, Manidipto; Bandyopadhyay, Asish

2017-09-01

In the present work, AISI 304 stainless steel sheets are laser welded in butt joint configuration using a robotic control 600 W pulsed Nd:YAG laser system. The objective of the work is of twofold. Firstly, the study aims to find out the effect of incident angle on the weld pool geometry, microstructure and tensile property of the welded joints. Secondly, a set of experiments are conducted, according to response surface design, to investigate the effects of process parameters, namely, incident angle of laser beam, laser power and welding speed, on ultimate tensile strength by developing a second order polynomial equation. Study with three different incident angle of laser beam 89.7 deg, 85.5 deg and 83 deg has been presented in this work. It is observed that the weld pool geometry has been significantly altered with the deviation in incident angle. The weld pool shape at the top surface has been altered from semispherical or nearly spherical shape to tear drop shape with decrease in incident angle. Simultaneously, planer, fine columnar dendritic and coarse columnar dendritic structures have been observed at 89.7 deg, 85.5 deg and 83 deg incident angle respectively. Weld metals with 85.5 deg incident angle has higher fraction of carbide and δ-ferrite precipitation in the austenitic matrix compared to other weld conditions. Hence, weld metal of 85.5 deg incident angle achieved higher micro-hardness of ∼280 HV and tensile strength of 579.26 MPa followed by 89.7 deg and 83 deg incident angle welds. Furthermore, the predicted maximum value of ultimate tensile strength of 580.50 MPa has been achieved for 85.95 deg incident angle using the developed equation where other two optimum parameter settings have been obtained as laser power of 455.52 W and welding speed of 4.95 mm/s. This observation has been satisfactorily validated by three confirmatory tests.

Effects of beam configurations on wire melting and transfer behaviors in dual beam laser welding with filler wire

NASA Astrophysics Data System (ADS)

Ma, Guolong; Li, Liqun; Chen, Yanbin

2017-06-01

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

A Lossless hybrid wavelet-fractal compression for welding radiographic images.

PubMed

Mekhalfa, Faiza; Avanaki, Mohammad R N; Berkani, Daoud

2016-01-01

In this work a lossless wavelet-fractal image coder is proposed. The process starts by compressing and decompressing the original image using wavelet transformation and fractal coding algorithm. The decompressed image is removed from the original one to obtain a residual image which is coded by using Huffman algorithm. Simulation results show that with the proposed scheme, we achieve an infinite peak signal to noise ratio (PSNR) with higher compression ratio compared to typical lossless method. Moreover, the use of wavelet transform speeds up the fractal compression algorithm by reducing the size of the domain pool. The compression results of several welding radiographic images using the proposed scheme are evaluated quantitatively and compared with the results of Huffman coding algorithm.

The effect of the welding direction on the plasma and metal transfer behavior of CO2 laser+GMAW-P hybrid welding processes

NASA Astrophysics Data System (ADS)

Zhang, Wang; Hua, Xueming; Liao, Wei; Li, Fang; Wang, Min

2014-07-01

During laser-arc hybrid welding, the welding direction exerts direct effects on the plasma properties, the transient behavior of the droplet, the weld pool behavior, and the temperature field. Ultimately, it will affect the welding process and the weld quality. However, the behavior of the CO2 laser+GMAW-P hybrid welding process has not been systematically studied. In this paper, the current-voltage characteristics of different welding processes were analyzed and compared. The dynamics of the droplet transfer, the plasma behavior, and the weld pool behavior were observed by using two high-speed camera systems. Moreover, an optical emission spectroscopy was applied to analyze the plasma temperature and the electron number density. The results indicated that the electrical resistance of the arc plasma reduced in the laser leading mode. For the same pulse duration, the metal transfer mode was the spray type with the laser leading arrangement. The temperature and electron density distribution showed bimodal behavior in the case of arc leading mode, while this phenomenon does not exist in the caser of laser leading mode. The double elliptic-planar distribution which conventional simulation process used was not applicable in the laser leading mode.

Surface preparation effects on GTA weld shape in JBK-75 stainless steel

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

Campbell, R.D.; Robertson, A.M.; Heiple, C.R.

1993-02-01

The results of a study are reported here on the effects of surface preparation on the shape of autogenous gas tungsten arc (GTA) welds in JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface preparation produced substantial changes in the fusion zone shape and welding behavior of this alloy. Increased and more consistent depth of fusion (higher d/w ratios) along with improved arc stability and less arc wander resulted from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any increase in depth of fusion. Abrasive treatments roughen themore » surface, increase the surface area, increase the surface oxide thickness, and entrap oxide. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension-driven fluid flow pattern in the weld pool. Increased depth of fusion in wire-fed U-groove weld joints also resulted when welding wire with a greater surface oxide thickness was used. Increasing the amount of wire brushing produced even deeper welds. However, a maximum in depth of fusion was observed with further wire brushing, beyond which weld fusion depth decreased.« less

Wire Arc Additive Manufacturing of AZ31 Magnesium Alloy: Grain Refinement by Adjusting Pulse Frequency.

PubMed

Guo, Jing; Zhou, Yong; Liu, Changmeng; Wu, Qianru; Chen, Xianping; Lu, Jiping

2016-10-09

Wire arc additive manufacturing (WAAM) offers a potential approach to fabricate large-scale magnesium alloy components with low cost and high efficiency, although this topic is yet to be reported in literature. In this study, WAAM is preliminarily applied to fabricate AZ31 magnesium. Fully dense AZ31 magnesium alloy components are successfully obtained. Meanwhile, to refine grains and obtain good mechanical properties, the effects of pulse frequency (1, 2, 5, 10, 100, and 500 Hz) on the macrostructure, microstructure and tensile properties are investigated. The results indicate that pulse frequency can result in the change of weld pool oscillations and cooling rate. This further leads to the change of the grain size, grain shape, as well as the tensile properties. Meanwhile, due to the resonance of the weld pool at 5 Hz and 10 Hz, the samples have poor geometry accuracy but contain finer equiaxed grains (21 μm) and exhibit higher ultimate tensile strength (260 MPa) and yield strength (102 MPa), which are similar to those of the forged AZ31 alloy. Moreover, the elongation of all samples is above 23%.

Surface temperature distribution of GTA weld pools on thin-plate 304 stainless steel

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

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

1995-11-01

A transient multidimensional computational model was utilized to study gas tungsten arc (GTA) welding of thin-plate 304 stainless steel (SS). The model eliminates several of the earlier restrictive assumptions including temperature-independent thermal-physical properties. Consequently, all important thermal-physical properties were considered as temperature dependent throughout the range of temperatures experienced by the weld metal. The computational model was used to predict surface temperature distribution of the GTA weld pools in 1.5-mm-thick AISI 304 SS. The welding parameters were chosen so as to correspond with an earlier experimental study that produced high-resolution surface temperature maps. One of the motivations of the presentmore » study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate excellent agreement, thereby verifying the model.« less

Numerical Simulation of Stationary AC Tungsten Inert Gas Welding of Aluminum Plate in Consideration of Oxide Layer Cleaning

NASA Astrophysics Data System (ADS)

Tashiro, Shinichi; Tanaka, Manabu

An unified numerical simulation model of AC TIG welding of the aluminum plate considering energy balance among the electrode, the arc and the base metal and employing an analytical model for calculating cleaning rate of the oxide layer has been developed for investigating heat transport properties and weld pool formation process in AC TIG welding of aluminum plate. As a result of this simulation, it was shown that although the heat flux from the arc onto the base metal increases in EN (Electrode Negative) phase due to the electron condensation, that in EP (Electrode Positive) phase conversely decreases because mainly of cooling caused by the electron emission. Furthermore, the validity of the simulation model was confirmed by comparing to experimental results such as the arc voltage, the area of cleaning zone and the shape of weld pool.

Laser Spot Welding of Copper-aluminum Joints Using a Pulsed Dual Wavelength Laser at 532 and 1064 nm

NASA Astrophysics Data System (ADS)

Stritt, Peter; Hagenlocher, Christian; Kizler, Christine; Weber, Rudolf; Rüttimann, Christoph; Graf, Thomas

A modulated pulsed laser source emitting green and infrared laser light is used to join the dissimilar metals copper and aluminum. The resultant dynamic welding process is analyzed using the back reflected laser light and high speed video observations of the interaction zone. Different pulse shapes are applied to influence the melt pool dynamics and thereby the forming grain structure and intermetallic phases. The results of high-speed images and back-reflections prove that a modulation of the pulse shape is transferred to oscillations of the melt pool at the applied frequency. The outcome of the melt pool oscillation is shown by the metallurgically prepared cross-section, which indicates different solidification lines and grain shapes. An energy-dispersivex-ray analysis shows the mixture and the resultant distribution of the two metals, copper and aluminum, within the spot weld. It can be seen that the mixture is homogenized the observed melt pool oscillations.

A hot-cracking mitigation technique for welding high-strength aluminum alloy

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

Yang, Y.P.; Dong, P.; Zhang, J.

2000-01-01

A hot-cracking mitigation technique for gas tungsten arc welding (GTAW) of high-strength aluminum alloy 2024 is presented. The proposed welding technique incorporates a trailing heat sink (an intense cooling source) with respect to the welding torch. The development of the mitigation technique was based on both detailed welding process simulation using advanced finite element techniques and systematic laboratory experiments. The finite element methods were used to investigate the detailed thermomechanical behavior of the weld metal that undergoes the brittle temperature range (BTR) during welding. As expected, a tensile deformation zone within the material BTR region was identified behind the weldmore » pool under conventional GTA welding process conventional GTA welding process conditions for the aluminum alloy studied. To mitigate hot cracking, the tensile zone behind the weld pool must be eliminated or reduce to a satisfactory level if the weld metal hot ductility cannot be further improved. With detailed computational modeling, it was found that by the introduction of a trailing heat sink at some distance behind the welding arc, the tensile strain rate with respect to temperature in the zone encompassing the BTR region can be significantly reduced. A series of parametric studies were also conducted to derive optimal process parameters for the trailing heat sink. The experimental results confirmed the effectiveness of the trailing heat sink technique. With a proper implementation of the trailing heat sink method, hot cracking can be completely eliminated in welding aluminum alloy 2024 (AA 2024).« less

Metal transfer and V-I transients in GMAW of aluminium

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

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

1996-12-31

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

Real-time monitoring of the laser hot-wire welding process

NASA Astrophysics Data System (ADS)

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

2014-04-01

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

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

NASA Astrophysics Data System (ADS)

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

2002-12-01

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

Laser welding in space

NASA Technical Reports Server (NTRS)

Kaukler, W. F.; Workman, G. L.

1991-01-01

Autogenous welds in 304 stainless steel were performed by Nd-YAG laser heating in a simulated space environment. Simulation consists of welding on the NASA KC-135 aircraft to produce the microgravity and by containing the specimen in a vacuum chamber. Experimental results show that the microgravity welds are stronger, harder in the fusion zone, have deeper penetration and have a rougher surface rippling of the weld pool than one-g welds. To perform laser welding in space, a solar-pumped laser concept that significantly increases the laser conversion efficiency and makes welding viable despite the limited power availability of spacecraft is proposed.

Numerical simulation of heat transfer and fluid flow in laser drilling of metals

NASA Astrophysics Data System (ADS)

Zhang, Tingzhong; Ni, Chenyin; Zhou, Jie; Zhang, Hongchao; Shen, Zhonghua; Ni, Xiaowu; Lu, Jian

2015-05-01

Laser processing as laser drilling, laser welding and laser cutting, etc. is rather important in modern manufacture, and the interaction of laser and matter is a complex phenomenon which should be detailed studied in order to increase the manufacture efficiency and quality. In this paper, a two-dimensional transient numerical model was developed to study the temperature field and molten pool size during pulsed laser keyhole drilling. The volume-of-fluid method was employed to track free surfaces, and melting and evaporation enthalpy, recoil pressure, surface tension, and energy loss due to evaporating materials were considered in this model. Besides, the enthalpy-porosity technique was also applied to account for the latent heat during melting and solidification. Temperature fields and melt pool size were numerically simulated via finite element method. Moreover, the effectiveness of the developed computational procedure had been confirmed by experiments.

Research on the Effect of Welding Speed on the Quality of Welding Seam Based on the Local Dry Underwater Welding

NASA Astrophysics Data System (ADS)

Liu, Lei; Chen, Wu; Wang, Huagang; Ba, Jinyu; Li, Bing

2017-12-01

The repair of nuclear spent fuel pool has a high requirement for the quality of welding, the welding speed directly affects the quality of the weld when local dry automatic underwater welding is used to repair the damaged surface. Under the condition of the same condition, the local dry automatic underwater welding test was carried out under the condition of the same welding condition. Taking the 20cm as the experimental condition, after massive experiments show that when the welding speed is approximately 48cm/min the weld quality is high, meeting the design requirements, based on the double layer shrinkage nozzle chamber of local dry underwater automatic welding.

Annual report, FY 1979 Spent fuel and fuel pool component integrity.

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

Johnson, A.B. Jr.; Bailey, W.J.; Schreiber, R.E.

International meetings under the BEFAST program and under INFCE Working Group No. 6 during 1978 and 1979 continue to indicate that no cases of fuel cladding degradation have developed on pool-stored fuel from water reactors. A section from a spent fuel rack stand, exposed for 1.5 y in the Yankee Rowe (PWR) pool had 0.001- to 0.003-in.-deep (25- to 75-..mu..m) intergranular corrosion in weld heat-affected zones but no evidence of stress corrosion cracking. A section of a 304 stainless steel spent fuel storage rack exposed 6.67 y in the Point Beach reactor (PWR) spent fuel pool showed no significant corrosion.more » A section of 304 stainless steel 8-in.-dia pipe from the Three Mile Island No. 1 (PWR) spent fuel pool heat exchanger plumbing developed a through-wall crack. The crack was intergranular, initiating from the inside surface in a weld heat-affected zone. The zone where the crack occurred was severely sensitized during field welding. The Kraftwerk Union (Erlangen, GFR) disassembled a stainless-steel fuel-handling machine that operated for 12 y in a PWR (boric acid) spent fuel pool. There was no evidence of deterioration, and the fuel-handling machine was reassembled for further use. A spent fuel pool at a Swedish PWR was decontaminated. The procedure is outlined in this report.« less

Effect of Electromagnetic Stirring on Weld Pools.

DTIC Science & Technology

1983-10-01

R136 71S EFFECT OF ELECTROMAGNET1C STIRRING ON WELD POOL5(U) i/lD DAVID W TAYLOR NAVAL SH-IP RE5ERRCH AND DEVELOPMENT CENTER ANN. R DENRLE ET RL...COMMANDER TECHNICAL DIRECTOR 01 OFFICER-IN-CHARGE OFFICER-IN-CHARGE CARDEROCK ANNAPOLIS 06 04 SYSTEMS DEVELOPMENT DEPARTMENT 11 SHIP PERFORMANCE AVIATION AND...SHIP ACOUSTICS PROPULSION AND DEPARTMENT AUXILIARY SYSTEMS DEPARTMENT 19 27 SHIP MATERIALS CENTRAL ENGINEERING INSTRUMENTATION DEPARTMENT DEPARTMENT28

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

NASA Astrophysics Data System (ADS)

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

2012-10-01

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

Effects of Cr2O3 Activating Flux on the Plasma Plume in Pulsed Laser Welding

NASA Astrophysics Data System (ADS)

Yi, Luo; Yunfei, Du; Xiaojian, Xie; Rui, Wan; Liang, Zhu; Jingtao, Han

2016-11-01

The effects of Cr2O3 activating flux on pulsed YAG laser welding of stainless steel and, particularly, on the behavior of the plasma plume in the welding process were investigated. According to the acoustic emission (AE) signals detected in the welding process, the possible mechanism for the improvement in penetration depth was discussed. The results indicated that the AE signals detected in the welding process reflected the behavior of the plasma plume as pulsed laser energy affecting the molten pool. The root-mean-square (RMS) waveform, AE count, and power spectrum of AE signals were three effective means to characterize the behavior of the plasma plume, which indicated the characteristics of energy released by the plasma plume. The activating flux affected by the laser beam helped to increase the duration and intensity of energy released by the plasma plume, which improved the recoil force and thermal effect transferred from the plasma plume to the molten pool. These results were the main mechanism for Cr2O3 activating flux addition improving the penetration depth in pulsed YAG laser welding.

Effects of current on droplet generation and arc plasma in gas metal arc welding

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

Hu, J.; Tsai, H. L.

2006-09-01

In gas metal arc welding (GMAW), a technology using pulsed currents has been employed to achieve the one-droplet-per-pulse (ODPP) metal transfer mode with the advantages of low average currents, a stable and controllable droplet generation, and reduced spatter. In this paper, a comprehensive model was developed to study the effects of different current profiles on the droplet formation, plasma generation, metal transfer, and weld pool dynamics in GMAW. Five types of welding currents were studied, including two constant currents and three wave form currents. In each type, the transient temperature and velocity distributions of the arc plasma and the moltenmore » metal, and the shapes of the droplet and the weld pool were calculated. The results showed that a higher current generates smaller droplets, higher droplet frequency, and higher electromagnetic force that becomes the dominant factor detaching the droplet from the electrode tip. The model has demonstrated that a stable ODPP metal transfer mode can be achieved by choosing a current with proper wave form for given welding conditions.« less

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

NASA Astrophysics Data System (ADS)

Zhang, Wei

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

Effect of Forced Convection Heat Transfer on Weld Pools.

DTIC Science & Technology

1986-01-01

Cooling Curves for GTAW Welds Superimposed on CCT Diagram ............. 26 11 - Photomacrographs Showing Weld Macrostructure (TS Plane...decomposition kinetics. Superposition of the weld metal cooling rates measured in this study on the CCT diagram shows that the time for nucleation and growth...m - TABLE 2 - TRANSFORMATION AND COOLING TIMES FROM CCT DIAGRAM *II I I. I I I Cooling Rate I Transformation I Time to Cool tL-I- I Heat Input I

Associations of welding and manganese exposure with Parkinson disease

PubMed Central

Borenstein, Amy R.; Nelson, Lorene M.

2012-01-01

Objective: To examine associations of welding and manganese exposure with Parkinson disease (PD) using meta-analyses of data from cohort, case-control, and mortality studies. Methods: Epidemiologic studies related to welding or manganese exposure and PD were identified in a PubMed search, article references, published reviews, and abstracts. Inclusion criteria were 1) cohort, case-control, or mortality study with relative risk (RR), odds ratio (OR), or mortality OR (MOR) and 95 confidence intervals (95% CI); 2) RR, OR, and MOR matched or adjusted for age and sex; 3) valid study design and analysis. When participants of a study were a subgroup of those in a larger study, only results of the larger study were included to assure independence of datasets. Pooled RR/OR estimates and 95% CIs were obtained using random effects models; heterogeneity of study effects were evaluated using the Q statistic and I2 index in fixed effect models. Results: Thirteen studies met inclusion criteria for the welding meta-analysis and 3 studies for the manganese exposure meta-analysis. The pooled RR for the association between welding and PD for all study designs was 0.86 (95% CI 0.80–0.92), with absence of between-study heterogeneity (I2 = 0.0). Effect measures for cohort, case-control, and mortality studies were similar (0.91, 0.82, 0.87). For the association between manganese exposure and PD, the pooled OR was 0.76 (95% CI 0.41–1.42). Conclusions: Welding and manganese exposure are not associated with increased PD risk. Possible explanations for the inverse association between welding and PD include confounding by smoking, healthy worker effect, and hormesis. PMID:22965675

Wire Arc Additive Manufacturing of AZ31 Magnesium Alloy: Grain Refinement by Adjusting Pulse Frequency

PubMed Central

Guo, Jing; Zhou, Yong; Liu, Changmeng; Wu, Qianru; Chen, Xianping; Lu, Jiping

2016-01-01

Wire arc additive manufacturing (WAAM) offers a potential approach to fabricate large-scale magnesium alloy components with low cost and high efficiency, although this topic is yet to be reported in literature. In this study, WAAM is preliminarily applied to fabricate AZ31 magnesium. Fully dense AZ31 magnesium alloy components are successfully obtained. Meanwhile, to refine grains and obtain good mechanical properties, the effects of pulse frequency (1, 2, 5, 10, 100, and 500 Hz) on the macrostructure, microstructure and tensile properties are investigated. The results indicate that pulse frequency can result in the change of weld pool oscillations and cooling rate. This further leads to the change of the grain size, grain shape, as well as the tensile properties. Meanwhile, due to the resonance of the weld pool at 5 Hz and 10 Hz, the samples have poor geometry accuracy but contain finer equiaxed grains (21 μm) and exhibit higher ultimate tensile strength (260 MPa) and yield strength (102 MPa), which are similar to those of the forged AZ31 alloy. Moreover, the elongation of all samples is above 23%. PMID:28773944

Laser-TIG Welding of Titanium Alloys

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulsky, I.; Somonov, V.; Kuznetsov, M.; Akhmetov, A.

2016-08-01

The article presents the results of investigation the technological opportunity of laser-TIG welding of titanium alloys. The experimental stand for implementation of process with the capability to feed a filler wire was made. The research of the nature of transfer the filler wire into the welding pool has been demonstrated. The influence of distance between the electrode and the surface of the welded plates on the stability of the arc was shown. The relationship between welding velocity, the position of focal plane of the laser beam and the stability of penetration of plates was determined.

Problems of Pore Formation in Welded Joints of Titanium Alloys

NASA Astrophysics Data System (ADS)

Murav'ev, V. I.

2005-07-01

Special features of formation of the connection zone in front of the front of molten pool and changes in the macro- and microstructure of the weld metal are considered for conditions of fusion welding of titanium alloys on an example of pseudo-α-titanium alloy VT20.Ways for forming macrotexture on the surface of joined preforms are determined with the aim of obtaining weld metal with structure and properties close to those of the base metal.

Study on the special vision sensor for detecting position error in robot precise TIG welding of some key part of rocket engine

NASA Astrophysics Data System (ADS)

Zhang, Wenzeng; Chen, Nian; Wang, Bin; Cao, Yipeng

2005-01-01

Rocket engine is a hard-core part of aerospace transportation and thrusting system, whose research and development is very important in national defense, aviation and aerospace. A novel vision sensor is developed, which can be used for error detecting in arc length control and seam tracking in precise pulse TIG welding of the extending part of the rocket engine jet tube. The vision sensor has many advantages, such as imaging with high quality, compactness and multiple functions. The optics design, mechanism design and circuit design of the vision sensor have been described in detail. Utilizing the mirror imaging of Tungsten electrode in the weld pool, a novel method is proposed to detect the arc length and seam tracking error of Tungsten electrode to the center line of joint seam from a single weld image. A calculating model of the method is proposed according to the relation of the Tungsten electrode, weld pool, the mirror of Tungsten electrode in weld pool and joint seam. The new methodologies are given to detect the arc length and seam tracking error. Through analyzing the results of the experiments, a system error modifying method based on a linear function is developed to improve the detecting precise of arc length and seam tracking error. Experimental results show that the final precision of the system reaches 0.1 mm in detecting the arc length and the seam tracking error of Tungsten electrode to the center line of joint seam.

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Contribution For Arc Temperature Affected By Current Increment Ratio At Peak Current In Pulsed Arc

NASA Astrophysics Data System (ADS)

Kano, Ryota; Mitubori, Hironori; Iwao, Toru

2015-11-01

Tungsten Inert Gas (TIG) Welding is one of the high quality welding. However, parameters of the pulsed arc welding are many and complicated. if the welding parameters are not appropriate, the welding pool shape becomes wide and shallow.the convection of driving force contributes to the welding pool shape. However, in the case of changing current waveform as the pulse high frequency TIG welding, the arc temperature does not follow the change of the current. Other result of the calculation, in particular, the arc temperature at the reaching time of peak current is based on these considerations. Thus, the accurate measurement of the temperature at the time is required. Therefore, the objective of this research is the elucidation of contribution for arc temperature affected by current increment ratio at peak current in pulsed arc. It should obtain a detail knowledge of the welding model in pulsed arc. The temperature in the case of increment of the peak current from the base current is measured by using spectroscopy. As a result, when the arc current increases from 100 A to 150 A at 120 ms, the transient response of the temperature didn't occur during increasing current. Thus, during the current rise, it has been verified by measuring. Therefore, the contribution for arc temperature affected by current increment ratio at peak current in pulsed arc was elucidated in order to obtain more knowledge of welding model of pulsed arc.

Plasma effect on weld pool surface reconstruction by shape-from-polarization analysis

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

Coniglio, N.; Mathieu, A., E-mail: alexandre.mathieu@u-bourgogne.fr; Aubreton, O.

2014-03-31

The polarimetric state of the thermal radiations emitted by the weld metal contains geometric information about the emitting surface. Even though the analysed thermal radiation has a wavelength corresponding to a blind spectral window of the arc plasma, the physical presence of the arc plasma itself interferes with the rays radiated by the weld pool surface before attaining the polarimeter, thus modifying the geometric information transported by the ray. In the present work, the effect of the arc plasma-surrounding zone on the polarimetric state and propagation direction of the radiated ray is analyzed. The interaction with the arc plasma zonemore » induces a drop in ray intensity and a refraction of ray optical path.« less

Initial Parameter Estimation for Inverse Thermal Analysis of Ti-6Al-4V Deep Penetration Welds

DTIC Science & Technology

2014-05-16

theory, for the case of deep-penetration welding, is simulation of the coupling of keyhole formation, melting, fluid flow in the weld melt pool and...isothermal boundaires, e.g., TTB and TM. A specific procedure for interpolation, however, has not been considered. For the present study, the close ...Clarendon Press, Oxford, 2nd ed, 374, 1959. 19. R. Rai, J.W. Elmer, T.A. Palmer, T. DebRoy, Heat Transfer and Fluid Flow During Keyhole Mode Laser Welding

Study on Surface Depression of Ti-6Al-4V with Ultrahigh-Frequency Pulsed Gas Tungsten Arc Welding

NASA Astrophysics Data System (ADS)

Mingxuan, Yang; Zhou, Yang; Bojin, Qi

2015-08-01

Molten pool surface depression was observed with the arc welding process that was caused by arc pressure. It was supposed to have a significant effect on fluid in the molten pool that was important for the microstructure and joint properties. The impact of arc force was recognized as the reason for the surface depression during arc welding. The mathematical distribution of arc force was produced with the exponent and parabola models. Different models showed different concentrations and attenuations. The comparison between them was discussed with the simulation results. The volume of fluid method was picked up with the arc force distribution model. The surface depression was caused by the arc force. The geometry of the surface depression was discussed with liquid metal properties. The welding process was carried out with different pulsed frequencies. The results indicated the forced depression exists in molten pool and the geometry of depression was hugely due to the arc force distribution. The previous work calculated the depression in the center with force balance at one point. The other area of gas shielding was resistant by the reverse gravity from the feedback of liquid metal that was squeezed out. The article discusses the pressure effect with free deformation that allowed resistance of liquid and was easy to compare with different distributions. The curve profiles were studied with the arc force distributions, and exponent model was supposed to be more accurate to the as-weld condition.

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.

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

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.

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

Number size distribution of fine and ultrafine fume particles from various welding processes.

PubMed

Brand, Peter; Lenz, Klaus; Reisgen, Uwe; Kraus, Thomas

2013-04-01

Studies in the field of environmental epidemiology indicate that for the adverse effect of inhaled particles not only particle mass is crucial but also particle size is. Ultrafine particles with diameters below 100 nm are of special interest since these particles have high surface area to mass ratio and have properties which differ from those of larger particles. In this paper, particle size distributions of various welding and joining techniques were measured close to the welding process using a fast mobility particle sizer (FMPS). It turned out that welding processes with high mass emission rates (manual metal arc welding, metal active gas welding, metal inert gas welding, metal inert gas soldering, and laser welding) show mainly agglomerated particles with diameters above 100 nm and only few particles in the size range below 50 nm (10 to 15%). Welding processes with low mass emission rates (tungsten inert gas welding and resistance spot welding) emit predominantly ultrafine particles with diameters well below 100 nm. This finding can be explained by considerably faster agglomeration processes in welding processes with high mass emission rates. Although mass emission is low for tungsten inert gas welding and resistance spot welding, due to the low particle size of the fume, these processes cannot be labeled as toxicologically irrelevant and should be further investigated.

Numerical and Experimental Investigations of Humping Phenomena in Laser Micro Welding

NASA Astrophysics Data System (ADS)

Otto, Andreas; Patschger, Andreas; Seiler, Michael

The Humping effect is a phenomenon which is observed approximately since 50 years in various welding procedures and is characterized by droplets due to a pile-up of the melt pool. It occurs within a broad range of process parameters. Particularly during micro welding, humping effect is critical due to typically high feed rates. In the past, essentially two approaches (fluid-dynamic approach of streaming melt within the molten pool and the Plateau-Rayleigh instability of a liquid jet) were discussed in order to explain the occurrence of the humping effect. But none of both can fully explain all observed effects. For this reason, experimental studies in micro welding of thin metal foils were performed in order to determine the influence of process parameters on the occurrence of humping effects. The experimental observations were compared with results from numerical multi-physical simulations (incorporating beam propagation, incoupling, heat transfer, fluid dynamics etc.) to provide a deeper understanding of the causes for hump formation.

Solidification microstructures in single-crystal stainless steel melt pools

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

Sipf, J.B.; Boatner, L.A.; David, S.A.

1994-03-01

Development of microstructure of stationary melt pools of oriented stainless steel single crystals (70%Fe-15%Ni-15%Cr was analyzed. Stationary melt pools were formed by electron-beam and gas-tungsten-arc heating on (001), (011), and (111) oriented planes of the austenitic, fcc-alloy crystals. Characterization and analysis of resulting microstructure was carried out for each crystallographic plane and welding method. Results showed that crystallography which favors ``easy growth`` along the <100> family of directions is a controlling factor in the microstructural formation along with the melt-pool shape. The microstructure was found to depend on the melting method, since each method forms a unique melt-pool shape. Thesemore » results are used in making a three-dimensional reconstruction of the microstructure for each plane and melting method employed. This investigation also suggests avenues for future research into the microstructural properties of electron-beam welds as well as providing an experimental basis for mathematical models for the prediction of solidification microstructures.« less

The effect of welding parameters on penetration in GTA welds

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

Shirali, A.A.; Mills, K.C.

1993-07-01

The effect of various welding parameters on the penetration of GTA welds has been investigated. Increases in welding speed were found to reduce penetration; however, increases in welding current were observed to increase the penetration in high sulfur (HS) casts and decrease penetration in low sulfur (LS) steels. Plots of penetration as a function of increasing linear energy (the heat supplied per unit length of weld) revealed a similar trend with increased penetration in HS casts, but the penetration in LS casts was unaffected by increases in linear energy. These results support the Burgardt-Heiple proposition that changes in welding parametersmore » on penetration can be explained in terms of their effect, sequentially, on the temperature gradient and the Marangoni forces operating in the weld pool. Increases in arc length were found to decrease weld penetration regardless of the sulfur concentration of the steel, and the effects of electrode geometry and welding position on weld penetration were also investigated.« less

The keyhole region in VPPA welds

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.

1988-01-01

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. The effects of microsegregation and transient weld stress on macrosegregation in the weld tool are examined. In addition the electrical character of straight and reverse polarity portions of the arc cycle were characterized. The results of the former study indicate that alloy 2219 is weldable because large liquid volumes are available during latter stages of weld solidification. Strains in the pool region, acting in conjunction with weld microsegregation can produce macrosegregation great enough to produce radiographic contrast effects in welds. Mechanisms of surface copper enrichment were identified. The latter study has demonstrated that increased heat is delivered to workpieces if the reverse polarity proportion of the weld cycle is increased. Current in the straight polarity portion of the welding cycle increased as the reverse cycle proportion increased. Voltage during reverse polarity segments is large.

Autocorrelation Function for Monitoring the Gap between The Steel Plates During Laser Welding

NASA Astrophysics Data System (ADS)

Mrna, Libor; Hornik, Petr

Proper alignment of the plates prior to laser welding represents an important factor that determines the quality of the resulting weld. A gap between the plates in a butt or overlap joint affects the oscillations of the keyhole and the surrounding weld pool. We present an experimental study of the butt and overlap welds with the artificial gap of the different thickness of the plates. The welds were made on a 2 kW fiber laser machine for the steel plates and the various welding parameters settings. The eigenfrequency of the keyhole oscillations and its changes were determined from the light emissions of the plasma plume using an autocorrelation function. As a result, we describe the relations between the autocorrelation characteristics, the thickness of the gap between plates and the weld geometry.

Modeling of plasma and thermo-fluid transport in hybrid welding

NASA Astrophysics Data System (ADS)

Ribic, Brandon D.

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

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.

Optimization of hybrid laser - TIG welding of 316LN steel using response surface methodology (RSM)

NASA Astrophysics Data System (ADS)

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

2017-07-01

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

Physicochemical and toxicological characteristics of welding fume derived particles generated from real time welding processes.

PubMed

Chang, Cali; Demokritou, Philip; Shafer, Martin; Christiani, David

2013-01-01

Welding fume particles have been well studied in the past; however, most studies have examined welding fumes generated from machine models rather than actual exposures. Furthermore, the link between physicochemical and toxicological properties of welding fume particles has not been well understood. This study aims to investigate the physicochemical properties of particles derived during real time welding processes generated during actual welding processes and to assess the particle size specific toxicological properties. A compact cascade impactor (Harvard CCI) was stationed within the welding booth to sample particles by size. Size fractionated particles were extracted and used for both off-line physicochemical analysis and in vitro cellular toxicological characterization. Each size fraction was analyzed for ions, elemental compositions, and mass concentration. Furthermore, real time optical particle monitors (DustTrak™, TSI Inc., Shoreview, Minn.) were used in the same welding booth to collect real time PM2.5 particle number concentration data. The sampled particles were extracted from the polyurethane foam (PUF) impaction substrates using a previously developed and validated protocol, and used in a cellular assay to assess oxidative stress. By mass, welding aerosols were found to be in coarse (PM 2.5–10), and fine (PM 0.1–2.5) size ranges. Most of the water soluble (WS) metals presented higher concentrations in the coarse size range with some exceptions such as sodium, which presented elevated concentration in the PM 0.1 size range. In vitro data showed size specific dependency, with the fine and ultrafine size ranges having the highest reactive oxygen species (ROS) activity. Additionally, this study suggests a possible correlation between welders' experience, the welding procedure and equipment used and particles generated from welding fumes. Mass concentrations and total metal and water soluble metal concentrations of welding fume particles may be greatly influenced by these factors. Furthermore, the results also confirmed the hypothesis that smaller particles generate more ROS activity and should be evaluated carefully for risk assessment.

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.

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

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Novel low-cost vision-sensing technology with controllable of exposal time for welding

NASA Astrophysics Data System (ADS)

Zhang, Wenzeng; Wang, Bin; Chen, Nian; Cao, Yipeng

2005-02-01

In the process of robot Welding, position of welding seam and welding pool shape is detected by CCD camera for quality control and seam tracking in real-time. It is difficult to always get a clear welding image in some welding methods, such as TIG welding. A novel idea that the exposal time of CCD camera is automatically controlled by arc voltage or arc luminance is proposed to get clear welding image. A set of special device and circuits are added to a common industrial CCD camera in order to flexibly control the CCD to start or close exposal by control of the internal clearing signal of the accumulated charge. Two special vision sensors according to the idea are developed. Their exposal grabbing can be triggered respectively by the arc voltage and the variety of the arc luminance. Two prototypes have been designed and manufactured. Experiments show that they can stably grab clear welding images at appointed moment, which is a basic for the feedback control of automatic welding.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Investigation of Weld Pool Structure and Property Control in Pulsed Arc Welding.

DTIC Science & Technology

1981-03-04

noted, elsewhere, freezing rate in the trailing and transverse directions show similarly contrasting behavior (6 𔄁 ). The movement of the solidus and...rise to low freezing eutectics and, hence, should be kept to the lowest possible level.1 3 󈧒 Solidification Cracking in Stainless Steel Welds It has...been observed 1 5 that hot cracking in austenitic stainless steel weldments is reduced or prevented when a small amount of delta ferrite is present

Understanding heat and fluid flow in linear GTA welds

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

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

1992-01-01

A transient heat flow and fluid flow model was used to predict the development of gas tungsten arc (GTA) weld pools in 1.5 mm thick AISI 304 SS. The welding parameters were chosen so as to correspond to an earlier experimental study which produced high-resolution surface temperature maps. The motivation of the present study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate good agreement.

Understanding heat and fluid flow in linear GTA welds

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

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

1992-12-31

A transient heat flow and fluid flow model was used to predict the development of gas tungsten arc (GTA) weld pools in 1.5 mm thick AISI 304 SS. The welding parameters were chosen so as to correspond to an earlier experimental study which produced high-resolution surface temperature maps. The motivation of the present study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate good agreement.

Simulation on the Effects of Surfactants and Observed Thermocapillary Motion for Laser Melting Physics

NASA Astrophysics Data System (ADS)

Nourgaliev, Robert; Barney, Rebecca; Weston, Brian; Delplanque, Jean-Pierre; McCallen, Rose

2017-11-01

A newly developed, robust, high-order in space and time, Newton-Krylov based reconstructed discontinuous Galerkin (rDG) method is used to model and analyze thermocapillary convection in melt pools. The application of interest is selective laser melting (SLM) which is an Additive Manufacturing (AM, 3D metal laser printing) process. These surface tension driven flows are influenced by temperature gradients and surfactants (impurities), and are known as the Marangoni flow. They have been experimentally observed in melt pools for welding applications, and are thought to influence the microstructure of the re-solidified material. We study the effects of the laser source configuration (power, beam size and scanning speed), as well as surfactant concentrations. Results indicate that the surfactant concentration influences the critical temperature, which governs the direction of the surface thermocapillary traction. When the surface tension traction changes sign, very complex flow patterns emerge, inducing hydrodynamic instability under certain conditions. These in turn would affect the melt pool size (depth) and shape, influencing the resulting microstructure, properties, and performance of a finished product part produced using 3D metal laser printing technologies. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. Information management release number LLNL-ABS-735908.

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.

Laser Overlap Welding of Zinc-coated Steel on Aluminum Alloy

NASA Astrophysics Data System (ADS)

Kashani, Hamed Tasalloti; Kah, Paul; Martikainen, Jukka

Local reinforcement of aluminum with laser welded patches of zinc-coated steel can effectively contribute to crashworthiness, durability and weight reduction of car body. However, the weld between Zn-coated steel and aluminum is commonly susceptible to defects such as spatter, cavity and crack. The vaporization of Zn is commonly known as the main source of instability in the weld pool and cavity formation, especially in a lap joint configuration. Cracks are mainly due to the brittle intermetallic compounds growing at the weld interface of aluminum and steel. This study provides a review on the main metallurgical and mechanical concerns regarding laser overlap welding of Zn-coated steel on Al-alloy and the methods used by researchers to avoid the weld defects related to the vaporization of Zn and the poor metallurgical compatibility between steel and aluminum.

Low-Temperature Friction-Stir Welding of 2024 Aluminum

NASA Technical Reports Server (NTRS)

Benavides, S.; Li, Y.; Murr, L. E.; Brown, D.; McClure, J. C.

1998-01-01

Solid state friction-stir welding (FSW) has been demonstrated to involve dynamic recrystallization producing ultra-fine, equiaxed grain structures to facilitate superplastic deformation as the welding or joining mechanism. However, the average residual, equiaxed, grain size in the weld zone has ranged from roughly 0.5 micron to slightly more than 10 micron, and the larger weld zone grain sizes have been characterized as residual or static grain growth as a consequence of the temperatures in the weld zone (where center-line temperatures in the FSW of 6061 Al have been shown to be as high as 480C or -0.8 T(sub M) where T(sub M) is the absolute melting temperature)). In addition, the average residual weld zone grain size has been observed to increase near the top of the weld, and to decrease with distance on either side of the weld-zone centerline, an d this corresponds roughly to temperature variations within the weld zone. The residual grain size also generally decreases with decreasing FSW tool rotation speed. These observations are consistent with the general rules for recrystallization where the recrystallized grain size decreases with increasing strain (or deformation) at constant strain rate, or with increasing strain-rate, or with increasing strain rate at constant strain; especially at lower ambient temperatures, (or annealing temperatures). Since the recrystallization temperature also decreases with increasing strain rate, the FSW process is somewhat complicated because the ambient temperature, the frictional heating fraction, and the adiabatic heating fraction )proportional to the product of strain and strain-rate) will all influence both the recrystallization and growth within the FSW zone. Significantly reducing the ambient temperature of the base metal or work pieces to be welded would be expected to reduce the residual weld-zone grain size. The practical consequences of this temperature reduction would be the achievement of low temperature welding. This study compares the residual grain sizes and microstructures in 2024 Al friction-stir welded at room temperature (about 30C and low temperature (-30C).

Analysis of ripple formation in single crystal spot welds

NASA Technical Reports Server (NTRS)

Rappaz, M.; Corrigan, D.; Boatner, L. A.

1997-01-01

Stationary spot welds have been made at the (001) surface of Fe-l5%Ni-15%Cr single crystals using a Gas Tungsten Arc (GTA). On the top surface of the spot welds, very regular and concentric ripples were observed after solidification by differential interference color microscopy. Their height (typically 1--5 micrometers and spacing, typically approximately 60 micrometers) decreased with the radius of the pool. These ripples were successfully accounted for in terms of capillary-wave theory using the fundamental mode frequency f(sub 0) given by the first zero of the zero-order Bessel function. The spacing d between the ripples was then equated to v(sub s)/f(sub 0), where v(sub s) is the solidification rate. From the measured ripple spacing, the velocity of the pool was deduced as a function of the radius, and this velocity was in good agreement with the results of a heat-flow simulation.

Experimental and theoretical characterization of deep penetration welding threshold induced by 1-μm laser

NASA Astrophysics Data System (ADS)

Zou, J. L.; He, Y.; Wu, S. K.; Huang, T.; Xiao, R. S.

2015-12-01

The deep penetration-welding threshold (DPWT) is the critical value that describes the welding mode transition from the thermal conduction to the deep penetration. The objective of this research is to clarify the DPWT induced by the lasers with wavelength of 1 μm (1-μm laser), based on experimental observation and theoretical analysis. The experimental results indicated that the DPWT was the ratio between laser power and laser spot diameter (P/d) rather than laser power density (P/S). The evaporation threshold was smaller than the DPWT, while the jump threshold of the evaporated mass flux in the molten pool surface was consistent with the DPWT. Based on the force balance between the evaporation recoil pressure and the surface tension pressure at the gas-liquid interface of the molten pool as well as the temperature field, we developed a self-focusing model, which further confirmed the experimental results.

Nano- and Microparticles in Welding Aerosol: Granulometric Analysis

NASA Astrophysics Data System (ADS)

Kirichenko, K. Yu.; Drozd, V. A.; Chaika, V. V.; Gridasov, A. V.; Kholodov, A. S.; Golokhvast, K. S.

The paper presents the first results of the study of the size of particles appearing in the welding process by means of laser granulometry. It is shown that welding aerosol is the source of nano-and micro-sized particles extremely dangerous for human and animal health. Particle size distribution in the microrange was from 1 to 10 μm and up to 100%. It is shown that in 9 cases out of 28 with the use of various welding modes, welding rods and components the emission of aerosol with nano-sized particles (from 45.5% to 99.4%) is observed.

Gravitational effects on the development of weld-pool and solidification microstructures

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

Boatner, L.A.; David, S.A.; Workman, G.

1994-09-01

This research effort has as its objective the development of a quantitative understanding of the effects of both low- and high-g environments on the solidification microstructures and morphologies that are produced in alloy single crystals during a variety of melting and solidification processes. The overall goal of the effort is to delineate the nature of the roles played by natural convection, surface-tension-driven convection, and mass transport effects due to interactions associated with various heating methods that are used to form melt pools in practical, commercially important alloy systems. The experimental and theoretical investigations comprising this effort encompass the study ofmore » configurations in which stationary heat sources are employed as well as melt pools formed by moving heat sources like those frequently used in fusion-welding processes.« less

A study of narrow gap laser welding for thick plates using the multi-layer and multi-pass method

NASA Astrophysics Data System (ADS)

Li, Ruoyang; Wang, Tianjiao; Wang, Chunming; Yan, Fei; Shao, Xinyu; Hu, Xiyuan; Li, Jianmin

2014-12-01

This paper details a new method that combines laser autogenous welding, laser wire filling welding and hybrid laser-GMAW welding to weld 30 mm thick plate using a multi-layer, multi-pass process. A “Y” shaped groove was used to create the joint. Research was also performed to optimize the groove size and the processing parameters. Laser autogenous welding is first used to create the backing weld. The lower, narrowest part of the groove is then welded using laser wire filling welding. Finally, the upper part of the groove is welded using laser-GMAW hybrid welding. Additionally, the wire feeding and droplet transfer behaviors are observed by high speed photography. The two main conclusions from this work are: the wire is often biased towards the side walls, resulting in a lack of fusion at the joint and the creation of other defects for larger groove sizes. Additionally, this results in the droplet transfer behavior becoming unstable, leading to a poor weld appearance for smaller groove sizes.

Hybrid laser arc welding: State-of-art review

NASA Astrophysics Data System (ADS)

Acherjee, Bappa

2018-02-01

Hybrid laser arc welding simultaneously utilizes the arc welding and the laser welding, in a common interaction zone. The synergic effects of laser beam and eclectic arc in the same weld pool results in an increase of welding speed and penetration depth along with the enhancement of gap bridging capability and process stability. This paper presents the current status of this hybrid technique in terms of research, developments and applications. Effort is made to present a comprehensive technical know-how about this process through a systematic review of research articles, industrial catalogues, technical notes, etc. In the introductory part of the review, an overview of the hybrid laser arc welding is presented, including operation principle, process requirements, historical developments, benefits and drawbacks of the process. This is followed by a detailed discussion on control parameters those govern the performance of hybrid laser arc welding process. Thereafter, a report of improvements of performance and weld qualities achieved by using hybrid welding process is presented based on review of several research papers. The succeeding sections furnish the examples of industrial applications and the concluding remarks.

Welding of 316L Austenitic Stainless Steel with Activated Tungsten Inert Gas Process

NASA Astrophysics Data System (ADS)

Ahmadi, E.; Ebrahimi, A. R.

2015-02-01

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

Coupling of Laser with Plasma Arc to Facilitate Hybrid Welding of Metallic Materials: A Review

NASA Astrophysics Data System (ADS)

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

2013-02-01

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

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.

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.)

Optimization of hybrid laser arc welding of 42CrMo steel to suppress pore formation

NASA Astrophysics Data System (ADS)

Zhang, Yan; Chen, Genyu; Mao, Shuai; Zhou, Cong; Chen, Fei

2017-06-01

The hybrid laser arc welding (HLAW) of 42CrMo quenched and tempered steel was conducted. The effect of the processing parameters, such as the relative positions of the laser and the arc, the shielding gas flow rate, the defocusing distance, the laser power, the wire feed rate and the welding speed, on the pore formation was analyzed, the morphological characteristics of the pores were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the majority of the pores were invasive. The pores formed at the leading a laser (LA) welding process were fewer than those at the leading a arc (AL) welding process. Increasing the shielding gas flow rate could also facilitate the reduction of pores. The laser power and the welding speed were two key process parameters to reduce the pores. The flow of the molten pool, the weld cooling rate and the pore escaping rate as a result of different parameters could all affect pore formation. An ideal pore-free weld was obtained for the optimal welding process parameters.

The porosity formation mechanism in the laser-MIG hybrid welded joint of Invar alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Gao, Qiyu; Gu, Cheng; Sun, Weihua; Chen, Jicheng; Wei, Yanhong

2017-10-01

The porosity formation mechanism in the laser-metal inter gas (MIG) multi-layer hybrid welded (HW) joint of 19.05 mm thick Invar alloy is investigated. The microstructure characteristics and energy dispersive spectroscopy (EDS) are analyzed. The phase identification was conducted by the X-ray diffractometer (XRD). Experimental results show that the generation of porosity is caused by the relatively low laser power in the root pass and low current in the cover pass. It is also indicated that the microstructures of the welded joints are mainly observed to be columnar crystal and equiaxial crystal, which are closely related to the porosity formation. The EDS results show that oxygen content is significantly high in the inner wall of the porosity. The XRD results indicate that the BM and the WB of laser-MIG HW all are composed of Fe0.64Ni0.36 and γ-(Fe,Ni). When the weld pool is cooled quickly, [NiO] [FeO] and [MnO] are formed that react on C to generate CO/CO2 gases. The porosity of laser-MIG HW for Invar alloy is oxygen pore. The root source of metallurgy porosity formation is that the dissolved gases are hard to escape sufficiently and thus exist in the weld pool. Furthermore, 99.99% pure Argon is recommended as protective gas in the laser-MIG HW of Invar alloy.

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

PubMed

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

2011-12-01

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

Grain Refinement of AZ31 Magnesium Alloy Weldments by AC Pulsing Technique

NASA Astrophysics Data System (ADS)

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

2012-11-01

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

Analysis of ripple formation in single crystal spot welds

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

Rappaz, M.; Corrigan, D.; Boatner, L.A.

1997-10-01

Stationary spot welds have been made at the (001) surface of Fe-l5%Ni-15%Cr single crystals using a Gas Tungsten Arc (GTA). On the top surface of the spot welds, very regular and concentric ripples were observed after solidification by differential interference color microscopy. Their height (typically 1--5 {micro}m) and spacing (typically {approximately} 60 {micro}m) decreased with the radius of the pool. These ripples were successfully accounted for in terms of capillary-wave theory using the fundamental mode frequency f{sub 0} given by the first zero of the zero-order Bessel function. The spacing d between the ripples was then equated to v{sub s}/f{submore » 0}, where v{sub s} is the solidification rate. From the measured ripple spacing, the velocity of the pool was deduced as a function of the radius, and this velocity was in good agreement with the results of a heat-flow simulation.« less

Hot-wire Laser Welding of Deep and Wide Gaps

NASA Astrophysics Data System (ADS)

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

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

Impact of friction stir welding on the microstructure of ODS steel

NASA Astrophysics Data System (ADS)

Dawson, H.; Serrano, M.; Cater, S.; Iqbal, N.; Almásy, L.; Tian, Q.; Jimenez-Melero, E.

2017-04-01

We have assessed the impact of the welding parameters on the nano-sized oxide dispersion and the grain size in the matrix of an ODS steel after friction stir welding. Our results, based on combined small angle neutron scattering and electron microscopy, reveal a decrease in the volume fraction of the particles smaller than 80 nm in the welds, mainly due to particle agglomeration. The increase in tool rotation speed or decrease in transverse speed leads to a higher reduction in nano-sized particle fraction, and additionally to the occurrence of particle melting. The dependence of the average grain size in the matrix on the particle volume fraction follows a Zener pinning-type relationship. This result points to the principal role that the particles have in pinning grain boundary movement, and consequently in controlling the grain size during welding.

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.

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.

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

NASA Astrophysics Data System (ADS)

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

2018-06-01

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

Influence of Aluminum Content on Grain Refinement and Strength of AZ31 Magnesium GTA Weld Metal

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

Babu, N. Kishore; Cross, Carl E.

2012-06-28

The goal is to characterize the effect of Al content on AZ31 weld metal, the grain size and strength, and examine role of Al on grain refinement. The approach is to systematically vary the aluminum content of AZ31 weld metal, Measure average grain size in weld metal, and Measure cross-weld tensile properties and hardness. Conclusions are that: (1) increased Al content in AZ31 weld metal results in grain refinement Reason: higher undercooling during solidification; (2) weld metal grain refinement resulted in increased strength & hardness Reason: grain boundary strengthening; and (3) weld metal strength can be raised to wrought basemore » metal levels.« less

Investigation on size tolerance of pore defect of girth weld pipe.

PubMed

Li, Yan; Shuai, Jian; Xu, Kui

2018-01-01

Welding quality control is an important parameter for safe operation of oil and gas pipes, especially for high-strength steel pipes. Size control of welding defect is a bottleneck problem for current pipe construction. As a key part of construction procedure for butt-welding of pipes, pore defects in girth weld is difficult to ignore. A three-dimensional non-linear finite element numerical model is established to study applicability of size control indices based on groove shape and softening phenomenon of material in heat-affected zone of practical pipe girth weld. Taking design criteria of pipe as the basis, basic tensile, extremely tensile and extremely compressive loading conditions are determined for pipe stress analysis, and failure criteria based on flow stress is employed to perform stress analysis for pipe girth weld with pore defect. Results show that pipe girth welding stresses of pores at various radial locations are similar. Whereas, stress for pores of different sharpness varied significantly. Besides, tolerance capability of API 5L X90 grade pipe to pore defect of girth weld is lower than that of API 5L X80 grade pipe, and size control index of 3 mm related to pore defect in current standards is applicable to API 5L X80 and X90 grade girth welded pipes with radially non-sharp pore defects.

Size-separated particle fractions of stainless steel welding fume particles - A multi-analytical characterization focusing on surface oxide speciation and release of hexavalent chromium.

PubMed

Mei, N; Belleville, L; Cha, Y; Olofsson, U; Odnevall Wallinder, I; Persson, K-A; Hedberg, Y S

2018-01-15

Welding fume of stainless steels is potentially health hazardous. The aim of this study was to investigate the manganese (Mn) and chromium (Cr) speciation of welding fume particles and their extent of metal release relevant for an inhalation scenario, as a function of particle size, welding method (manual metal arc welding, metal arc welding using an active shielding gas), different electrodes (solid wires and flux-cored wires) and shielding gases, and base alloy (austenitic AISI 304L and duplex stainless steel LDX2101). Metal release investigations were performed in phosphate buffered saline (PBS), pH 7.3, 37°, 24h. The particles were characterized by means of microscopic, spectroscopic, and electroanalytical methods. Cr was predominantly released from particles of the welding fume when exposed in PBS [3-96% of the total amount of Cr, of which up to 70% as Cr(VI)], followed by Mn, nickel, and iron. Duplex stainless steel welded with a flux-cored wire generated a welding fume that released most Cr(VI). Nano-sized particles released a significantly higher amount of nickel compared with micron-sized particle fractions. The welding fume did not contain any solitary known chromate compounds, but multi-elemental highly oxidized oxide(s) (iron, Cr, and Mn, possibly bismuth and silicon). Copyright © 2017 The Authors. Published by Elsevier B.V. All rights reserved.

Real-time ultrasonic weld evaluation system

NASA Astrophysics Data System (ADS)

Katragadda, Gopichand; Nair, Satish; Liu, Harry; Brown, Lawrence M.

1996-11-01

Ultrasonic testing techniques are currently used as an alternative to radiography for detecting, classifying,and sizing weld defects, and for evaluating weld quality. Typically, ultrasonic weld inspections are performed manually, which require significant operator expertise and time. Thus, in recent years, the emphasis is to develop automated methods to aid or replace operators in critical weld inspections where inspection time, reliability, and operator safety are major issues. During this period, significant advances wee made in the areas of weld defect classification and sizing. Very few of these methods, however have found their way into the market, largely due to the lack of an integrated approach enabling real-time implementation. Also, not much research effort was directed in improving weld acceptance criteria. This paper presents an integrated system utilizing state-of-the-art techniques for a complete automation of the weld inspection procedure. The modules discussed include transducer tracking, classification, sizing, and weld acceptance criteria. Transducer tracking was studied by experimentally evaluating sonic and optical position tracking techniques. Details for this evaluation are presented. Classification is obtained using a multi-layer perceptron. Results from different feature extraction schemes, including a new method based on a combination of time and frequency-domain signal representations are given. Algorithms developed to automate defect registration and sizing are discussed. A fuzzy-logic acceptance criteria for weld acceptance is presented describing how this scheme provides improved robustness compared to the traditional flow-diagram standards.

Investigation on size tolerance of pore defect of girth weld pipe

PubMed Central

Shuai, Jian; Xu, Kui

2018-01-01

Welding quality control is an important parameter for safe operation of oil and gas pipes, especially for high-strength steel pipes. Size control of welding defect is a bottleneck problem for current pipe construction. As a key part of construction procedure for butt-welding of pipes, pore defects in girth weld is difficult to ignore. A three-dimensional non-linear finite element numerical model is established to study applicability of size control indices based on groove shape and softening phenomenon of material in heat-affected zone of practical pipe girth weld. Taking design criteria of pipe as the basis, basic tensile, extremely tensile and extremely compressive loading conditions are determined for pipe stress analysis, and failure criteria based on flow stress is employed to perform stress analysis for pipe girth weld with pore defect. Results show that pipe girth welding stresses of pores at various radial locations are similar. Whereas, stress for pores of different sharpness varied significantly. Besides, tolerance capability of API 5L X90 grade pipe to pore defect of girth weld is lower than that of API 5L X80 grade pipe, and size control index of 3 mm related to pore defect in current standards is applicable to API 5L X80 and X90 grade girth welded pipes with radially non-sharp pore defects. PMID:29364986

Tungsten Carbide Grain Size Computation for WC-Co Dissimilar Welds

NASA Astrophysics Data System (ADS)

Zhou, Dongran; Cui, Haichao; Xu, Peiquan; Lu, Fenggui

2016-06-01

A "two-step" image processing method based on electron backscatter diffraction in scanning electron microscopy was used to compute the tungsten carbide (WC) grain size distribution for tungsten inert gas (TIG) welds and laser welds. Twenty-four images were collected on randomly set fields per sample located at the top, middle, and bottom of a cross-sectional micrograph. Each field contained 500 to 1500 WC grains. The images were recognized through clustering-based image segmentation and WC grain growth recognition. According to the WC grain size computation and experiments, a simple WC-WC interaction model was developed to explain the WC dissolution, grain growth, and aggregation in welded joints. The WC-WC interaction and blunt corners were characterized using scanning and transmission electron microscopy. The WC grain size distribution and the effects of heat input E on grain size distribution for the laser samples were discussed. The results indicate that (1) the grain size distribution follows a Gaussian distribution. Grain sizes at the top of the weld were larger than those near the middle and weld root because of power attenuation. (2) Significant WC grain growth occurred during welding as observed in the as-welded micrographs. The average grain size was 11.47 μm in the TIG samples, which was much larger than that in base metal 1 (BM1 2.13 μm). The grain size distribution curves for the TIG samples revealed a broad particle size distribution without fine grains. The average grain size (1.59 μm) in laser samples was larger than that in base metal 2 (BM2 1.01 μm). (3) WC-WC interaction exhibited complex plane, edge, and blunt corner characteristics during grain growth. A WC ( { 1 {bar{{1}}}00} ) to WC ( {0 1 1 {bar{{0}}}} ) edge disappeared and became a blunt plane WC ( { 10 1 {bar{{0}}}} ) , several grains with two- or three-sided planes and edges disappeared into a multi-edge, and a WC-WC merged.

The effect of weld metal matching on girth weld performance: Volume III - an ECA analysis. Final report

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

Denys, R.M.; Martin, J.T.

1995-02-01

Modern pipeline standards contain alternative methodologies for determining the acceptable defect size in pipeline welds. Through the use of fracture mechanics and plastic collapse assessments, the mechanical and toughness properties of the defective region relate to the applied stress at the defect and defect geometry. The assumptions made in these methodologies are not always representative of the situation accurring in pipeline girth welds. To determine the effect of the various input parameters on acceptable defect size, The Welding Supervisory Committee of the American Gas Association commenced in 1990, in collaboration with the Laboratorium Soete of the University Gent, Belgium, amore » series of small scale (Charpy V impact and CTOD) and large scale (fatigue pre-cracked wide plate) tests. All the experimental investigations were intended to evaluate the effects of weld metal mis-match, temperature, defect size, defect type, defect interaction, pipe wall thickness and yield to tensile ratio on girth weld fracture behaviour. The aim of this report was to determine how weld metal yield strength overmatching or undermatching influences girth weld defect size prediction. A further analysis was conducted using the newly revised PD6493:1991 to provide a critical analysis with the objective of explaining the behaviour of the wide plate tests.« less

Method for welding an article and terminating the weldment within the perimeter of the article

NASA Technical Reports Server (NTRS)

Snyder, John H. (Inventor); Smashey, Russell W. (Inventor); Boerger, Eric J. (Inventor); Borne, Bruce L. (Inventor)

2000-01-01

An article is welded, as in weld repair of a defect, by positioning a weld lift-off block at a location on the surface of the article adjacent to the intended location of the end of the weldment on the surface of the article. The weld lift-off block has a wedge shape including a base contacting the surface of the article, and an upper face angled upwardly from the base from a base leading edge. A weld pool is formed on the surface of the article by directly heating the surface of the article using a heat source. The heat source is moved relative to the surface of the article and onto the upper surface of the weld lift-off block by crossing the leading edge of the wedge, without discontinuing the direct heating of the article by the heat source. The heating of the article with the heat source is discontinued only after the heat source is directly heating the upper face of the weld lift-off block, and not the article.

Manufacturing of New Welding Fluxes Using Silicomanganese Slag

NASA Astrophysics Data System (ADS)

Kryukov, Roman E.; Kozyrev, Nikolay A.; Kozyreva, Olga A.; Usoltsev, Aleksander A.

2017-10-01

There were developed the composition and manufacturing technology of new welding flux using industrial products such as slag of silicomanganese production. The effect of fractional composition on welding and fabrication characteristics was studied. It was found that using of small-sized fracture of welding flux at a rate of 30-40% decreases the oxide non-metallic impurity rating of the weld and herewith doesn’t affect its constituents. To increase technical-and-economic indexes it was suggested to mix small-sized fracture and water glass. The use of ceramic flux made by mixing the dust fraction of silicomanganese slug with fraction size less than 0.45 mm and water glass provides the decrease of non-metallic impurity rating of the weld. Herewith the increase of its content from 15 to 40% doesn’t have a significant influence on the non-metallic impurity rating of the weld and its constituents.

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.

Temperature and emissivity determination of liquid steel S235

NASA Astrophysics Data System (ADS)

Schöpp, H.; Sperl, A.; Kozakov, R.; Gött, G.; Uhrlandt, D.; Wilhelm, G.

2012-06-01

Temperature determination of liquid metals is difficult but a necessary tool for improving materials and processes such as arc welding in the metal-working industry. A method to determine the surface temperature of the weld pool is described. A TIG welding process and absolute calibrated optical emission spectroscopy are used. This method is combined with high-speed photography. 2D temperature profiles are obtained. The emissivity of the radiating surface has an important influence on the temperature determination. A temperature dependent emissivity for liquid steel is given for the spectral region between 650 and 850 nm.

An investigation on capability of hybrid Nd:YAG laser-TIG welding technology for AA2198 Al-Li alloy

NASA Astrophysics Data System (ADS)

Faraji, Amir Hosein; Moradi, Mahmoud; Goodarzi, Massoud; Colucci, Pietro; Maletta, Carmine

2017-09-01

This paper surveys the capability of the hybrid laser-arc welding in comparison with lone laser welding for AA2198 aluminum alloy experimentally. In the present research, a continuous Nd:YAG laser with a maximum power of 2000 W and a 350 A electric arc were used as two combined welding heat sources. In addition to the lone laser welding experiments, two strategies were examined for hybrid welding; the first one was low laser power (100 W) accompanied by high arc energy, and the second one was high laser power (2000 W) with low arc energy. Welding speed and arc current varied in the experiments. The influence of heat input on weld pool geometry was surveyed. The macrosection, microhardness profile and microstructure of the welded joints were studied and compared. The results indicated that in lone laser welding, conduction mode occurred and keyhole was not formed even in low welding speeds and thus the penetration depth was so low. It was also found that the second approach (high laser power accompanied with low arc energy) is superior to the first one (low laser power accompanied with high arc energy) in hybrid laser-arc welding of Al2198, since lower heat input was needed for full penetration weld and as a result a smaller HAZ was created.

46 CFR 154.528 - Piping joints: Flange type.

Code of Federal Regulations, 2014 CFR

2014-10-01

... following types: (1) Welding neck. (2) Slip-on. (3) Socket weld. (b) If the piping is designed for a... nominal pipe size is 100 mm (4 in.) or less; (2) Socket weld, if the nominal pipe size is 50 mm (2 in.) or...

46 CFR 154.528 - Piping joints: Flange type.

Code of Federal Regulations, 2011 CFR

2011-10-01

... following types: (1) Welding neck. (2) Slip-on. (3) Socket weld. (b) If the piping is designed for a... nominal pipe size is 100 mm (4 in.) or less; (2) Socket weld, if the nominal pipe size is 50 mm (2 in.) or...

46 CFR 154.528 - Piping joints: Flange type.

Code of Federal Regulations, 2012 CFR

2012-10-01

... following types: (1) Welding neck. (2) Slip-on. (3) Socket weld. (b) If the piping is designed for a... nominal pipe size is 100 mm (4 in.) or less; (2) Socket weld, if the nominal pipe size is 50 mm (2 in.) or...

46 CFR 154.528 - Piping joints: Flange type.

Code of Federal Regulations, 2013 CFR

2013-10-01

... following types: (1) Welding neck. (2) Slip-on. (3) Socket weld. (b) If the piping is designed for a... nominal pipe size is 100 mm (4 in.) or less; (2) Socket weld, if the nominal pipe size is 50 mm (2 in.) or...

Nano-Sized Grain Refinement Using Friction Stir Processing

DTIC Science & Technology

2013-03-01

friction stir weld is a very fine grain microstructure produced as a result of dynamic recrystallization. The friction stir ... Friction Stir Processing, Magnesium, Nano-size grains Abstract A key characteristic of a friction stir weld is a very fine grain microstructure...state process developed on the basis of the friction stir welding (FSW) technique invented by The Welding Institute (TWI) in 1991 [2]. During

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

NASA Astrophysics Data System (ADS)

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

2015-07-01

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

Physics-based process model approach for detecting discontinuity during friction stir welding

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

Shrivastava, Amber; Pfefferkorn, Frank E.; Duffie, Neil A.

2015-02-12

The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities weremore » generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create "cold" welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.« less

Studying of welding aerosol using laser granulometry

NASA Astrophysics Data System (ADS)

Kirichenko, K. Y.; Gridasov, A. V.; Drozd, V. A.; Golokhvast, K. S.

2016-11-01

The paper presents results of a study of the size of the particles that arise during the welding process using laser granulometry method. It is shown that the welding aerosol - extremely dangerous for human and animal health and the source of nano- and micro-sized particles.

Estimation and control of droplet size and frequency in projected spray mode of a gas metal arc welding (GMAW) process.

PubMed

Anzehaee, Mohammad Mousavi; Haeri, Mohammad

2011-07-01

New estimators are designed based on the modified force balance model to estimate the detaching droplet size, detached droplet size, and mean value of droplet detachment frequency in a gas metal arc welding process. The proper droplet size for the process to be in the projected spray transfer mode is determined based on the modified force balance model and the designed estimators. Finally, the droplet size and the melting rate are controlled using two proportional-integral (PI) controllers to achieve high weld quality by retaining the transfer mode and generating appropriate signals as inputs of the weld geometry control loop. Copyright © 2011 ISA. Published by Elsevier Ltd. All rights reserved.

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.

A FRAMEWORK TO DEVELOP FLAW ACCEPTANCE CRITERIA FOR STRUCTURAL INTEGRITY ASSESSMENT OF MULTIPURPOSE CANISTERS FOR EXTENDED STORAGE OF USED NUCLEAR FUEL

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

Lam, P.; Sindelar, R.; Duncan, A.

2014-04-07

A multipurpose canister (MPC) made of austenitic stainless steel is loaded with used nuclear fuel assemblies and is part of the transfer cask system to move the fuel from the spent fuel pool to prepare for storage, and is part of the storage cask system for on-site dry storage. This weld-sealed canister is also expected to be part of the transportation package following storage. The canister may be subject to service-induced degradation especially if exposed to aggressive environments during possible very long-term storage period if the permanent repository is yet to be identified and readied. Stress corrosion cracking may bemore » initiated on the canister surface in the welds or in the heat affected zone because the construction of MPC does not require heat treatment for stress relief. An acceptance criteria methodology is being developed for flaw disposition should the crack-like defects be detected by periodic Inservice Inspection. The external loading cases include thermal accident scenarios and cask drop conditions with the contribution from the welding residual stresses. The determination of acceptable flaw size is based on the procedure to evaluate flaw stability provided by American Petroleum Institute (API) 579 Fitness-for-Service (Second Edition). The material mechanical and fracture properties for base and weld metals and the stress analysis results are obtained from the open literature such as NUREG-1864. Subcritical crack growth from stress corrosion cracking (SCC), and its impact on inspection intervals and acceptance criteria, is not addressed.« less

Thermomechanically coupled conduction mode laser welding simulations using smoothed particle hydrodynamics

NASA Astrophysics Data System (ADS)

Hu, Haoyue; Eberhard, Peter

2017-10-01

Process simulations of conduction mode laser welding are performed using the meshless Lagrangian smoothed particle hydrodynamics (SPH) method. The solid phase is modeled based on the governing equations in thermoelasticity. For the liquid phase, surface tension effects are taken into account to simulate the melt flow in the weld pool, including the Marangoni force caused by a temperature-dependent surface tension gradient. A non-isothermal solid-liquid phase transition with the release or absorption of additional energy known as the latent heat of fusion is considered. The major heat transfer through conduction is modeled, whereas heat convection and radiation are neglected. The energy input from the laser beam is modeled as a Gaussian heat source acting on the initial material surface. The developed model is implemented in Pasimodo. Numerical results obtained with the model are presented for laser spot welding and seam welding of aluminum and iron. The change of process parameters like welding speed and laser power, and their effects on weld dimensions are investigated. Furthermore, simulations may be useful to obtain the threshold for deep penetration welding and to assess the overall welding quality. A scalability and performance analysis of the implemented SPH algorithm in Pasimodo is run in a shared memory environment. The analysis reveals the potential of large welding simulations on multi-core machines.

Effects of SO/sub 2/ shielding gas additions on GTA weld shape

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

Heiple, C.R.; Burgardt, P.

1985-06-01

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

Numerical simulation and experimental investigation of laser dissimilar welding of carbon steel and austenitic stainless steel

NASA Astrophysics Data System (ADS)

Nekouie Esfahani, M. R.; Coupland, J.; Marimuthu, S.

2015-07-01

This study reports an experimental and numerical investigation on controlling the microstructure and brittle phase formation during laser dissimilar welding of carbon steel to austenitic stainless steel. The significance of alloying composition and cooling rate were experimentally investigated. The investigation revealed that above a certain specific point energy the material within the melt pool is well mixed and the laser beam position can be used to control the mechanical properties of the joint. The heat-affected zone within the high-carbon steel has significantly higher hardness than the weld area, which severely undermines the weld quality. A sequentially coupled thermo-metallurgical model was developed to investigate various heat-treatment methodology and subsequently control the microstructure of the HAZ. Strategies to control the composition leading to dramatic changes in hardness, microstructure and service performance of the dissimilar laser welded fusion zone are discussed.

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

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

Force measurement-based discontinuity detection during friction stir welding

DOE PAGES

Shrivastava, Amber; Zinn, Michael; Duffie, Neil A.; ...

2017-02-23

Here, the objective of this work is to develop a method for detecting the creation of discontinuities ( i.e., voids, volume defects) during friction stir welding. Friction stir welding is inherently cost effective, however, the need for significant weld inspection can make the process cost prohibitive. A new approach to weld inspection is required in which an in situ characterization of weld quality can be obtained, reducing the need for postprocess inspection. To this end, friction stir welds with subsurface voids and without voids were created. The subsurface voids were generated by reducing the friction stir tool rotation frequency andmore » increasing the tool traverse speed in order to create “colder” welds. Process forces were measured during welding, and the void sizes were measured postprocess by computerized tomography ( i.e., 3D X-ray imaging). Two parameters, based on frequency domain content and time-domain average of the force signals, were found to be correlated with void size. Criteria for subsurface void detection and size prediction were developed and shown to be in good agreement with experimental observations. Furthermore, with the proper choice of data acquisition system and frequency analyzer the occurrence of subsurface voids can be detected in real time.« less

Force measurement-based discontinuity detection during friction stir welding

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

Shrivastava, Amber; Zinn, Michael; Duffie, Neil A.

Here, the objective of this work is to develop a method for detecting the creation of discontinuities ( i.e., voids, volume defects) during friction stir welding. Friction stir welding is inherently cost effective, however, the need for significant weld inspection can make the process cost prohibitive. A new approach to weld inspection is required in which an in situ characterization of weld quality can be obtained, reducing the need for postprocess inspection. To this end, friction stir welds with subsurface voids and without voids were created. The subsurface voids were generated by reducing the friction stir tool rotation frequency andmore » increasing the tool traverse speed in order to create “colder” welds. Process forces were measured during welding, and the void sizes were measured postprocess by computerized tomography ( i.e., 3D X-ray imaging). Two parameters, based on frequency domain content and time-domain average of the force signals, were found to be correlated with void size. Criteria for subsurface void detection and size prediction were developed and shown to be in good agreement with experimental observations. Furthermore, with the proper choice of data acquisition system and frequency analyzer the occurrence of subsurface voids can be detected in real time.« less

Damage Tolerance Assessment of Friction Pull Plug Welds

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

Development of 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

Welding Residual Stress Analysis and Fatigue Strength Assessment at Elevated Temperature for Multi-pass Dissimilar Material Weld Between Alloy 617 and P92 Steel

NASA Astrophysics Data System (ADS)

Lee, Juhwa; Hwang, Jeongho; Bae, Dongho

2018-03-01

In this paper, welding residual stress analysis and fatigue strength assessment were performed at elevated temperature for multi-pass dissimilar material weld between Alloy 617 and P92 steel, which are used in thermal power plant. Multi-pass welding between Alloy 617 and P92 steel was performed under optimized welding condition determined from repeated pre-test welding. In particular, for improving dissimilar material weld-ability, the buttering welding technique was applied on the P92 steel side before multi-pass welding. Welding residual stress distribution at the dissimilar material weld joint was numerically analyzed by using the finite element method, and compared with experimental results which were obtained by the hole-drilling method. Additionally, fatigue strength of dissimilar material weld joint was assessed at the room temperature (R.T), 300, 500, and 700 °C. In finite element analysis results, numerical peak values; longitudinal (410 MPa), transverse (345 MPa) were higher than those of experiments; longitudinal (298 MPa), transverse (245 MPa). There are quantitatively big differences between numerical and experimental results, due to some assumption about the thermal conductivity, specific heat, effects of enforced convection of the molten pool, dilution, and volume change during phase transformation caused by actual shield gas. The low fatigue limit at R.T, 300 °C, 500 °C and 700 °C was assessed to be 368, 276, 173 and 137 MPa respectively.

Welding Residual Stress Analysis and Fatigue Strength Assessment at Elevated Temperature for Multi-pass Dissimilar Material Weld Between Alloy 617 and P92 Steel

NASA Astrophysics Data System (ADS)

Lee, Juhwa; Hwang, Jeongho; Bae, Dongho

2018-07-01

In this paper, welding residual stress analysis and fatigue strength assessment were performed at elevated temperature for multi-pass dissimilar material weld between Alloy 617 and P92 steel, which are used in thermal power plant. Multi-pass welding between Alloy 617 and P92 steel was performed under optimized welding condition determined from repeated pre-test welding. In particular, for improving dissimilar material weld-ability, the buttering welding technique was applied on the P92 steel side before multi-pass welding. Welding residual stress distribution at the dissimilar material weld joint was numerically analyzed by using the finite element method, and compared with experimental results which were obtained by the hole-drilling method. Additionally, fatigue strength of dissimilar material weld joint was assessed at the room temperature (R.T), 300, 500, and 700 °C. In finite element analysis results, numerical peak values; longitudinal (410 MPa), transverse (345 MPa) were higher than those of experiments; longitudinal (298 MPa), transverse (245 MPa). There are quantitatively big differences between numerical and experimental results, due to some assumption about the thermal conductivity, specific heat, effects of enforced convection of the molten pool, dilution, and volume change during phase transformation caused by actual shield gas. The low fatigue limit at R.T, 300 °C, 500 °C and 700 °C was assessed to be 368, 276, 173 and 137 MPa respectively.

Distribution of Argon Arc Contaminated with Nitrogen as Function of Frequency in Pulsed TIG Welding

NASA Astrophysics Data System (ADS)

Takahashi, Hiroki; Tanaka, Tatsuro; Yamamoto, Shinji; Iwao, Toru

2016-09-01

TIG arc welding is the high-quality and much applicable material joining technology. However, the current has to be small because the cathode melting should be prevented. In this case, the heat input to the welding pool becomes low, then, the welding defect sometimes occurs. The pulsed TIG arc welding is used to improve this disadvantage This welding can be controlled by some current parameters such as frequency However, few report has reported the distribution of argon arc contaminated with nitrogen It is important to prevent the contamination of nitrogen because the melting depth increases in order to prevent the welding defects. In this paper, the distribution of argon arc contaminated as function of frequency with nitrogen in pulsed TIG welding is elucidated. The nitrogen concentration, the radial flow velocity, the arc temperature were calculated using the EMTF simulation when the time reached at the base current. As a result, the nitrogen concentration into the arc became low with increasing the frequency The diffusion coefficient decreased because of the decrement of temperature over 4000 K. In this case, the nitrogen concentration became low near the anode. Therefore, the nitrogen concentration became low because the frequency is high.

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.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Probabilistic Estimation of Critical Flaw Sizes in the Primary Structure Welds of the Ares I-X Launch Vehicle

NASA Technical Reports Server (NTRS)

Pai, Shantaram S.; Hoge, Peter A.; Patel, B. M.; Nagpal, Vinod K.

2009-01-01

The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.

Dynamic modeling of GMA fillet welding using cross-correlation

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

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

1996-12-31

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

Grain Refinement of Freeform Fabricated Ti-6Al-4V Alloy Using Beam/Arc Modulation

NASA Technical Reports Server (NTRS)

Mitzner, Scott; Liu, Stephen; Domack, Marcia S.; Hafley, Robert A.

2012-01-01

Grain refinement can significantly improve the mechanical properties of freeform-fabricated Ti-6Al-4V alloy, promoting increased strength and enhanced isotropy compared with coarser grained material. Large beta-grains can lead to a segregated microstructure, in regard to both alpha-phase morphology and alpha-lath orientation. Beam modulation, which has been used in conventional fusion welding to promote grain refinement, is explored in this study for use in additive manufacturing processes including electron beam freeform fabrication (EBF(sup 3)) and gas-tungsten arc (GTA) deposition to alter solidification behavior and produce a refined microstructure. The dynamic molten pool size induced by beam modulation causes rapid heat flow variance and results in a more competitive grain growth environment, reducing grain size. Consequently, improved isotropy and strength can be achieved with relatively small adjustments to deposition parameters.

Characterization of ambient particles size in workplace of manufacturing physical fitness equipments

PubMed Central

LIN, Chih-Chung; CHEN, Mei-Ru; CHANG, Sheng-Lang; LIAO, Wei-Heng; CHEN, Hsiu-Ling

2014-01-01

The manufacturing of fitness equipment involves several processes, including the cutting and punching of iron tubes followed by welding. Welding operations produce hazardous gases and particulate matter, which can enter the alveolar, resulting in adverse health effects. This study sought to verify the particle size distribution and exposure concentrations of atmospheric air samples in various work areas of a fitness equipment manufacturing industry. Observed particle concentrations are presented by area and in terms of relative magnitude: painting (15.58 mg/m3) > automatic welding (0.66 mg/m3) > manual welding (0.53 mg/m3) > punching (0.18 mg/m3) > cutting (0.16 mg/m3). The concentrations in each of the five work areas were Cinh>Cthor>Cresp. In all areas except the painting area, extra-fine particles produced by welding at high temperatures, and further those coagulated to form larger particles. This study observed bimodal distribution in the size of welding fume in the ranges of 0.7–1 µm and 15–21 µm. Meanwhile, the mass concentrations of particles with different sizes were not consistent across work areas. In the painting area, the mass concentration was higher in Chead>Cth>Calv, but in welding areas, it was found that Calv>Chead>Cth. Particles smaller than 1µm were primarily produced by welding. PMID:25327301

LPT. EBOR (TAN646) interior, installing reactor in STF pool ("vault"). ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

LPT. EBOR (TAN-646) interior, installing reactor in STF pool ("vault"). Pressure vessel shows core barrel and outlet nozzle (next to man below) to inner duct weld, which is prepared and in position for stress relieving. Camera facing southeast. Photographer: Comiskey. Date: January 20, 1965. INEEL negative no. 65-239 - Idaho National Engineering Laboratory, Test Area North, Scoville, Butte County, ID

Effect of A-TIG Welding Process on the Weld Attributes of Type 304LN and 316LN Stainless Steels

NASA Astrophysics Data System (ADS)

Vasudevan, M.

2017-03-01

The specific activated flux has been developed for enhancing the penetration performance of TIG welding process for autogenous welding of type 304LN and 316LN stainless steels through systematic study. Initially single-component fluxes were used to study their effect on depth of penetration and tensile properties. Then multi-component activated flux was developed which was found to produce a significant increase in penetration of 10-12 mm in single-pass TIG welding of type 304LN and 316LN stainless steels. The significant improvement in penetration achieved using the activated flux developed in the present work has been attributed to the constriction of the arc and as well as reversal of Marangoni flow in the molten weld pool. The use of activated flux has been found to overcome the variable weld penetration observed in 316LN stainless steel with <50 ppm of sulfur. There was no degradation in the microstructure and mechanical properties of the A-TIG welds compared to that of the welds produced by conventional TIG welding on the contrary the transverse strength properties of the 304LN and 316LN stainless steel welds produced by A-TIG welding exceeded the minimum specified strength values of the base metals. Improvement in toughness values were observed in 316LN stainless steel produced by A-TIG welding due to refinement in the weld microstructure in the region close to the weld center. Thus, activated flux developed in the present work has greater potential for use during the TIG welding of structural components made of type 304LN and 316LN stainless steels.

Processing, Microstructure, and Material Property Relationships Following Friction Stir Welding of Oxide Dispersion Strengthened Steels

DTIC Science & Technology

2013-09-01

2.75), (b) 400 RPM/100 MMPM (HI= 4 ), (c) 300 RPM/50 MMPM (HI= 6 ), and (d) 500 RPM/25 MMPM (HI=10) showing increase in grain size as HI is increased...Heat Index Weld Quality Weld Penetration 200 50 4 Lack of Consolidation Incomplete 300 50 6 Defect-free Full 300 100 3 Lack of Consolidation...Specifically, the grain size for HI= 6 (300 RPM/50 MMPM) is less than the grain size for HI= 4 (400 RPM/100 MMPM); however, grain size did

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

NASA Astrophysics Data System (ADS)

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

2008-02-01

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

The Influence of Welding Parameters on the Nugget Formation of Resistance Spot Welding of Inconel 625 Sheets

NASA Astrophysics Data System (ADS)

Rezaei Ashtiani, Hamid Reza; Zarandooz, Roozbeh

2015-09-01

A 2D axisymmetric electro-thermo-mechanical finite element (FE) model is developed to investigate the effect of current intensity, welding time, and electrode tip diameter on temperature distributions and nugget size in resistance spot welding (RSW) process of Inconel 625 superalloy sheets using ABAQUS commercial software package. The coupled electro-thermal analysis and uncoupled thermal-mechanical analysis are used for modeling process. In order to improve accuracy of simulation, material properties including physical, thermal, and mechanical properties have been considered to be temperature dependent. The thickness and diameter of computed weld nuggets are compared with experimental results and good agreement is observed. So, FE model developed in this paper provides prediction of quality and shape of the weld nuggets and temperature distributions with variation of each process parameter, suitably. Utilizing this FE model assists in adjusting RSW parameters, so that expensive experimental process can be avoided. The results show that increasing welding time and current intensity lead to an increase in the nugget size and electrode indentation, whereas increasing electrode tip diameter decreases nugget size and electrode indentation.

Study made to establish parameters and limitations of explosive welding

NASA Technical Reports Server (NTRS)

Polhemus, F. C.

1967-01-01

It is theorized that metal jetting must be present for welding to occur, therefore an explosive weld interface may indicate the relation between the metal jet velocity and shock wave velocity in welding. Parameters for effecting explosive welding in patches of 3 or 4 inches in diameter were established, and found applicable to explosive welding of patches of various sizes.

Mathematical Model Of Variable-Polarity Plasma Arc Welding

NASA Technical Reports Server (NTRS)

Hung, R. J.

1996-01-01

Mathematical model of variable-polarity plasma arc (VPPA) welding process developed for use in predicting characteristics of welds and thus serves as guide for selection of process parameters. Parameters include welding electric currents in, and durations of, straight and reverse polarities; rates of flow of plasma and shielding gases; and sizes and relative positions of welding electrode, welding orifice, and workpiece.

Mass-size distribution and concentration of metals from personal exposure to arc welding fume in pipeline construction: a case report.

PubMed

Yang, Show-Yi; Lin, Jia-Ming; Young, Li-Hao; Chang, Ching-Wen

2018-04-07

We investigate exposure to welding fume metals in pipeline construction, which are responsible for severe respiratory problems. We analyzed air samples obtained using size-fractioning cascade impactors that were attached to the welders performing shielded metal and gas tungsten arc welding outdoors. Iron, aluminum, zinc, chromium, manganese, copper, nickel, and lead concentrations in the water-soluble (WS) and water-insoluble (WI) portions were determined separately, using inductively coupled plasma mass spectrometry. The mass-size distribution of welding fume matches a log-normal distribution with two modes. The metal concentrations in the welding fume were ranked as follows: Fe > Al > Zn > Cr > Mn > Ni > Cu > Pb. In the WS portion, the capacities of metals dissolving in water are correlated with the metal species but particle sizes. Particularly, Zn, Mn, and Pb exhibit relatively higher capacities than Cu, Cr, Al, Fe, and Ni. Exposure of the gas-exchange region of the lungs to WS metals were in the range of 4.9% to 34.6% of the corresponding metals in air by considering the particle-size selection in lungs, metal composition by particle size, and the capacities of each metal dissolving in water.

Real-time GMAW quality classification using an artificial neural network with airborne acoustic signals as inputs

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

Matteson, A.; Morris, R.; Tate, R.

1993-12-31

The acoustic signal produced by the gas metal arc welding (GMAW) arc contains information about the behavior of the arc column, the molten pool and droplet transfer. It is possible to detect some defect producing conditions from the acoustic signal from the GMAW arc. An intelligent sensor, called the Weld Acoustic Monitor (WAM) has been developed to take advantage of this acoustic information in order to provide real-time quality assessment information for process control. The WAM makes use of an Artificial Neural Network (ANN) to classify the characteristic arc acoustic signals of acceptable and unacceptable welds. The ANN used inmore » the Weld Acoustic Monitor developed its own set of rules for this classification problem by learning a data base of known GMAW acoustic signals.« less

Influence of Solute Content and Solidification Parameters on Grain Refinement of Aluminum Weld Metal

NASA Astrophysics Data System (ADS)

Schempp, Philipp; Cross, Carl Edward; Pittner, Andreas; Rethmeier, Michael

2013-07-01

Grain refinement provides an important possibility to enhance the mechanical properties ( e.g., strength and ductility) and the weldability (susceptibility to solidification cracking) of aluminum weld metal. In the current study, a filler metal consisting of aluminum base metal and different amounts of commercial grain refiner Al Ti5B1 was produced. The filler metal was then deposited in the base metal and fused in a GTA welding process. Additions of titanium and boron reduced the weld metal mean grain size considerably and resulted in a transition from columnar to equiaxed grain shape ( CET). In commercial pure aluminum (Alloy 1050A), the grain-refining efficiency was higher than that in the Al alloys 6082 and 5083. Different welding and solidification parameters influenced the grain size response only slightly. Furthermore, the observed grain-size reduction was analyzed by means of the undercooling parameter P and the growth restriction parameter Q, which revealed the influence of solute elements and nucleant particles on grain size.

Effect of temporal pulse shaping on the reduction of laser weld defects in a Pd-Ag-Sn dental alloy.

PubMed

Bertrand, C; Poulon-Quintin, A

2011-03-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Thermal regulation in multiple-source arc welding involving material transformations

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

Doumanidis, C.C.

1995-06-01

This article addresses regulation of the thermal field generated during arc welding, as the cause of solidification, heat-affected zone and cooling rate related metallurgical transformations affecting the final microstructure and mechanical properties of various welded materials. This temperature field is described by a dynamic real-time process model, consisting of an analytical composite conduction expression for the solid region, and a lumped-state, double-stream circulation model in the weld pool, integrated with a Gaussian heat input and calibrated experimentally through butt joint GMAW tests on plain steel plates. This model serves as the basis of an in-process thermal control system employing feedbackmore » of part surface temperatures measured by infrared pyrometry; and real-time identification of the model parameters with a multivariable adaptive control strategy. Multiple heat inputs and continuous power distributions are implemented by a single time-multiplexed torch, scanning the weld surface to ensure independent, decoupled control of several thermal characteristics. Their regulation is experimentally obtained in longitudinal GTAW of stainless steel pipes, despite the presence of several geometrical, thermal and process condition disturbances of arc welding.« less

Welding-fume-induced transmission loss in tapered optical fibers

NASA Astrophysics Data System (ADS)

Yi, Ji-Haeng

2015-09-01

This paper presents a method for sensing welding fumes in real time. This method is based on the results of nanoparticle-induced optical-fiber loss experiments that show that the losses are determined by the nanoparticle density and the taper waist. The tapered fiber is obtained by applying heat radiated from hot quartz, and monitoring is done in real time. First, the durability of the tapered fiber during the welding process is proven. Then, the loss is categorized by using the sizes of welding fume particles. The sensitivity to welding fumes increases with increasing size of the particles; consequently, the dimension of the taper waist decreases.

Weldability of a high entropy CrMnFeCoNi alloy

DOE PAGES

Wu, Zhenggang; David, Stan A.; Feng, Zhili; ...

2016-07-19

We present the high-entropy alloys are unique alloys in which five or more elements are all in high concentrations. In order to determine its potential as a structural alloy, a model face-centered-cubic CrMnFeCoNi alloy was selected to investigate its weldability. Welds produced by electron beam welding show no cracking. The grain structures within the fusion zone (FZ) are controlled by the solidification behavior of the weld pool. The weldment possesses mechanical properties comparable to those of the base metal (BM) at both room and cryogenic temperatures. Finally, compared with the BM, deformation twinning was more pronounced in the FZ ofmore » the tested alloy.« less

Fast, Nonspattering Inert-Gas Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.

1991-01-01

Proposed welding technique combines best features of metal (other than tungsten)/inert-gas welding, plasma arc welding, and tungsten/inert-gas welding. Advantages include: wire fed to weld joint preheated, therefore fed at high speed without spattering; high-frequency energy does not have to be supplied to workpiece to initiate welding; size of arc gap not critical, power-supply control circuit adjusts voltage across gap to compensate for changes; only low gas-flow rate needed; welding electrode replaced easily as prefabricated assembly; external wire-feeding manipulator not needed; and welding process relatively forgiving of operator error.

A model for heat and mass input control in GMAW

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

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

1993-05-01

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

Energetic additive manufacturing process with feed wire

DOEpatents

Harwell, Lane D.; Griffith, Michelle L.; Greene, Donald L.; Pressly, Gary A.

2000-11-07

A process for additive manufacture by energetic wire deposition is described. A source wire is fed into a energy beam generated melt-pool on a growth surface as the melt-pool moves over the growth surface. This process enables the rapid prototyping and manufacture of fully dense, near-net shape components, as well as cladding and welding processes. Alloys, graded materials, and other inhomogeneous materials can be grown using this process.

Fatigue crack propagation behavior of stainless steel welds

NASA Astrophysics Data System (ADS)

Kusko, Chad S.

The fatigue crack propagation behavior of austenitic and duplex stainless steel base and weld metals has been investigated using various fatigue crack growth test procedures, ferrite measurement techniques, light optical microscopy, stereomicroscopy, scanning electron microscopy, and optical profilometry. The compliance offset method has been incorporated to measure crack closure during testing in order to determine a stress ratio at which such closure is overcome. Based on this method, an empirically determined stress ratio of 0.60 has been shown to be very successful in overcoming crack closure for all da/dN for gas metal arc and laser welds. This empirically-determined stress ratio of 0.60 has been applied to testing of stainless steel base metal and weld metal to understand the influence of microstructure. Regarding the base metal investigation, for 316L and AL6XN base metals, grain size and grain plus twin size have been shown to influence resulting crack growth behavior. The cyclic plastic zone size model has been applied to accurately model crack growth behavior for austenitic stainless steels when the average grain plus twin size is considered. Additionally, the effect of the tortuous crack paths observed for the larger grain size base metals can be explained by a literature model for crack deflection. Constant Delta K testing has been used to characterize the crack growth behavior across various regions of the gas metal arc and laser welds at the empirically determined stress ratio of 0.60. Despite an extensive range of stainless steel weld metal FN and delta-ferrite morphologies, neither delta-ferrite morphology significantly influence the room temperature crack growth behavior. However, variations in weld metal da/dN can be explained by local surface roughness resulting from large columnar grains and tortuous crack paths in the weld metal.

Cooling Rate Determination in Additively Manufactured Aluminum Alloy 2219

NASA Astrophysics Data System (ADS)

Brice, Craig A.; Dennis, Noah

2015-05-01

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

Control of the electrode metal transfer by means of the welding current pulse generator

NASA Astrophysics Data System (ADS)

Knyaz'kov, A.; Pustovykh, O.; Verevkin, A.; Terekhin, V.; Shachek, A.; Knyaz'kov, S.; Tyasto, A.

2016-04-01

The paper presents a generator of welding current pulses to transfer an electrode metal into the molten pool. A homogeneous artificial line is used to produce near rectangular pulses. The homogeneous artificial line provides the minimum heat input with in the pulse to transfer the electrode metal, and it significantly decreases the impact of disturbances affecting this transfer. The pulse frequency does not exceed 300 Hz, and the duration is 0.6 ÷ 0.9 ms.

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

NASA Astrophysics Data System (ADS)

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

2017-11-01

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

Cellular Automaton Study of Hydrogen Porosity Evolution Coupled with Dendrite Growth During Solidification in the Molten Pool of Al-Cu Alloys

NASA Astrophysics Data System (ADS)

Gu, Cheng; Wei, Yanhong; Yu, Fengyi; Liu, Xiangbo; She, Lvbo

2017-09-01

Welding porosity defects significantly reduce the mechanical properties of welded joints. In this paper, the hydrogen porosity evolution coupled with dendrite growth during solidification in the molten pool of Al-4.0 wt pct Cu alloy was modeled and simulated. Three phases, including a liquid phase, a solid phase, and a gas phase, were considered in this model. The growth of dendrites and hydrogen gas pores was reproduced using a cellular automaton (CA) approach. The diffusion of solute and hydrogen was calculated using the finite difference method (FDM). Columnar and equiaxed dendrite growth with porosity evolution were simulated. Competitive growth between different dendrites and porosities was observed. Dendrite morphology was influenced by porosity formation near dendrites. After solidification, when the porosities were surrounded by dendrites, they could not escape from the liquid, and they made pores that existed in the welded joints. With the increase in the cooling rate, the average diameter of porosities decreased, and the average number of porosities increased. The average diameter of porosities and the number of porosities in the simulation results had the same trend as the experimental results.

The Strength and Characteristics of VPPA Welded 2219-T87 Aluminum Alloy

NASA Technical Reports Server (NTRS)

Jemian, W. A.

1985-01-01

A study of the variable polarity plasma arc (VPPA) welding process and those factors that control the structure and properties of VPPA welded aluminum alloy 2219-T87 was conducted. The importance of joint preparation, alignment of parts and welding process variables are already established. Internal weld defects have been eliminated. However, a variation of properties was found to be due to the size variation of interdendritic particles in the fusion zone. These particles contribute to the void formation process, which controls the ultimate tensile strength of the welded alloy. A variation of 150 microns in particle size correlated with a 10 ksi variation of ultimate tensile strength. It was found that all fracture surfaces were of the dimple rupture type, with fracture initiating within the fusion zone.

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.

Dual-beam laser welding of AZ31B magnesium alloy in zero-gap lap joint configuration

NASA Astrophysics Data System (ADS)

Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

2014-03-01

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

Eddy current inspection of weld defects in tubing

NASA Technical Reports Server (NTRS)

Katragadda, G.; Lord, W.

1992-01-01

An approach using differential probes for the inspection of weld defects in tubing is studied. Finite element analysis is used to model the weld regions and defects. Impedance plane signals are predicted for different weld defect types and compared wherever possible with signals from actual welds in tubing. Results show that detection and sizing of defects in tubing is possible using differential eddy current techniques. The phase angle of the impedance plane trajectory gives a good indication of the sizing of the crack. Data on the type of defect can be obtained from the shape of the impedance plane trajectory and the phase. Depending on the skin depth, detection of outer wall, inner wall, and subsurface defects is possible.

Fatigue properties of dissimilar metal laser welded lap joints

NASA Astrophysics Data System (ADS)

Dinsley, Christopher Paul

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

Critical Initial Flaw Size Analysis

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Raju, Ivatury S.; Cheston, Derrick J.

2008-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The USS consists of several "tuna can" segments that are approximately 216 inches in diameter, 115 inches tall, and 0.5 inches thick. A 6 inch wide by 1 inch thick flange is welded to the skin and is used to fasten adjacent tuna cans. A schematic of a "tuna can" and the location of the flange-to-skin weld are shown in Figure 1. Gussets (shown in yellow in Figure 1) are welded to the skin and flange every 10 degrees around the circumference of the "tuna can". The flange-to-skin weld is a flux core butt weld with a fillet weld on the inside surface, as illustrated in Figure 2. The welding process may create loss of fusion defects in the weld that could develop into fatigue cracks and jeopardize the structural integrity of the Ares I-X vehicle. The CIFS analysis was conducted to determine the largest crack in the weld region that will not grow to failure within 4 lifetimes, as specified by NASA standard 5001 & 5019 [1].

Melting of SiC powders preplaced duplex stainless steel using TIG welding

NASA Astrophysics Data System (ADS)

Maleque, M. A.; Afiq, M.

2018-01-01

TIG torch welding technique is a conventional melting technique for the cladding of metallic materials. Duplex stainless steels (DSS) show decrease in performance under aggressive environment which may lead to unanticipated failure due to poor surface properties. In this research, surface modification is done by using TIG torch method where silicon carbide (SiC) particles are fused into DSS substrate in order to form a new intermetallic compound at the surface. The effect of particle size, feed rate of SiC preplacement, energy input and shielding gas flow rate on surface topography, microstructure, microstructure and hardness are investigated. Deepest melt pool (1.237 mm) is produced via TIG torch with highest energy input of 1080 J/mm. Observations of surface topography shows rippling marks which confirms that re-solidification process has taken place. Melt microstructure consist of dendritic and globular carbides precipitate as well as partially melted silicon carbides (SiC) particles. Micro hardness recorded at value ranging from 316 HV0.5 to 1277 HV0.5 which shows increment from base hardness of 260 HV0.5kgf. The analyzed result showed that incorporation of silicon carbide particles via TIG Torch method increase the hardness of DSS.

Characterization of the Microstructures and the Cryogenic Mechanical Properties of Electron Beam Welded Inconel 718

NASA Astrophysics Data System (ADS)

Kwon, Soon Il; Bae, Sang Hyun; Do, Jeong Hyeon; Jo, Chang Yong; Hong, Hyun Uk

2016-02-01

The microstructures and the cryogenic mechanical properties of electron beam (EB) welds between cast and forged Inconel 718 superalloys with a thickness of 10 mm were investigated in comparison with gas tungsten arc (GTA) welds. EB welding with a heat input lower than 250 J/mm caused the formation of liquation microfissuring in the cast-side heat-affected-zone (HAZ) of the EB welds. HAZ liquation microfissuring appeared to be associated with the constitutional liquation of primary NbC carbides at the grain boundaries. Compared with the GTA welding process, the EB welding produced welds with superior microstructure, exhibiting fine dendritic structure associated with the reduction in size and fraction of the Laves phase due to the rapid cooling rate. This result was responsible for the superior mechanical properties of the EB welds at 77 K (-196 °C). Laves particles in both welds were found to provide the preferential site for the crack initiation and propagation, leading to a significant decrease in the Charpy impact toughness at 77 K (-196 °C). Crack initiation and propagation induced by Charpy impact testing were discussed in terms of the dendrite arm spacing, the Laves size and the dislocation structure ahead of the crack arisen from the fractured Laves phase in the two welds.

Dual circuit embossed sheet heat transfer panel

DOEpatents

Morgan, G.D.

1984-02-21

A heat transfer panel provides redundant cooling for fusion reactors or the like environment requiring low-mass construction. Redundant cooling is provided by two independent cooling circuits, each circuit consisting of a series of channels joined to inlet and outlet headers. The panel comprises a welded joinder of two full-size and two much smaller partial-size sheets. The first full-size sheet is embossed to form first portions of channels for the first and second circuits, as well as a header for the first circuit. The second full-sized sheet is then laid over and welded to the first full-size sheet. The first and second partial-size sheets are then overlaid on separate portions of the second full-sized sheet, and are welded thereto. The first and second partial-sized sheets are embossed to form inlet and outlet headers, which communicate with channels of the second circuit through apertures formed in the second full-sized sheet. 6 figs.

Dual-circuit embossed-sheet heat-transfer panel

DOEpatents

Morgan, G.D.

1982-08-23

A heat transfer panel provides redundant cooling for fusion reactors or the like environment requiring low-mass construction. Redundant cooling is provided by two independent cooling circuits, each circuit consisting of a series of channels joined to inlet and outlet headers. The panel comprises a welded joinder of two full-size and two much smaller partial-size sheets. The first full-size sheet is embossed for form first portions of channels for the first and second circuits, as well as a header for the first circuit. The second full-sized sheet is then laid over and welded to the first full-size sheet. The first and second partial-size sheets are then overlaid on separate portions of the second full-sized sheet, and are welded thereto. The first and second partial-sized sheets are embossed to form inlet and outlet headers, which communicate with channels of the second circuit through apertures formed in the second full-sized sheet.

Dual circuit embossed sheet heat transfer panel

DOEpatents

Morgan, Grover D.

1984-01-01

A heat transfer panel provides redundant cooling for fusion reactors or the like environment requiring low-mass construction. Redundant cooling is provided by two independent cooling circuits, each circuit consisting of a series of channels joined to inlet and outlet headers. The panel comprises a welded joinder of two full-size and two much smaller partial-size sheets. The first full-size sheet is embossed to form first portions of channels for the first and second circuits, as well as a header for the first circuit. The second full-sized sheet is then laid over and welded to the first full-size sheet. The first and second partial-size sheets are then overlaid on separate portions of the second full-sized sheet, and are welded thereto. The first and second partial-sized sheets are embossed to form inlet and outlet headers, which communicate with channels of the second circuit through apertures formed in the second full-sized sheet.

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

PubMed

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

2014-12-01

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

Pulsed Nd:YAG laser welding of cardiac pacemaker batteries with reduced heat input

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

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

1997-03-01

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

Influences of Friction Stir Welding Parameters on Microstructural and Mechanical Properties of AA5456 (AlMg5) at Different Lap Joint Thicknesses

NASA Astrophysics Data System (ADS)

Pishevar, M. R.; Mohandesi, J. Aghazadeh; Omidvar, H.; Safarkhanian, M. A.

2015-10-01

Friction stir welding is suitable for joining series 5000 alloys because no fusion welding problems arise for the alloys in this process. The present study examined the effects of double-pass welding and tool rotational and travel speeds for the second-pass welding on the mechanical and microstructural properties of friction stir lap welding of AA5456 (AlMg5)-H321 (5 mm thickness) and AA5456 (AlMg5)-O (2.5 mm thickness). The first pass of all specimens was performed at a rotational speed of 650 rpm and a travel speed of 50 mm/min. The second pass was performed at rotational speeds of 250, 450, and 650 rpm and travel speeds of 25, 50, and 75 mm/min. The results showed that the second pass changed the grain sizes in the center of the nugget zone compared with the first pass. It was observed that the size of the hooking defect of the double-pass-welded specimens was higher than that for the single-pass-welded specimen. The size of the hooking defect was found to be a function of the rotational and travel speeds. The optimal joint tensile shear properties were achieved at a rotational speed of 250 rpm and travel a speed of 75 mm/min.

Effect of cooling after welding on microstructure and mechanical properties of 12 Pct Cr steel weld metals

NASA Astrophysics Data System (ADS)

Cai, Guang-Jun; Andrén, Hans-Olof; Svensson, Lars-Erik

1997-07-01

The microstructure of three 12 pct cr steel weld metals with different nickel and nitrogen contents was studied in as-welded condition and after postweld heat treatment with and without intercooling. Tensile strength and impact toughness of the weld metals were investigated in different postweld heat treatment conditions. In weld metals heat treated without intercooling, austenite decomposed by a eutectoid reaction that resulted in M23C6 aggregates around retained δ-ferrite. Two morphologies of M2N and MN precipitates were found in a low-dislocation α-ferrite. It was concluded that these phases were also transformed from austenite. In weld metals heat treated with intercooling, M23C6 precipitates were smaller and more homogeneously distributed. Different MN precipitates were found in the tempered martensite. The fracture mode of the weld metals at room temperature was mainly transgranular cleavage with some fibrous fracture. Intercooling treatment improved Charpy impact toughness of the 12 pct Cr steel weld metals substantially. It was found that the important microstructural factors affecting the impact toughness of the weld metals which were heat treated without intercooling were the sizes of the α-ferrite grains, nonmetallic inclusions, and M23C6 aggregates. For the weld metals heat treated with intercooling, the factors which affect the toughness of the weld metals were the sizes of martensite packets and nonmetallic inclusions.

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

NASA Astrophysics Data System (ADS)

Fu, Jianke; Jin, Jun

2017-01-01

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

The Measurement and Monitoring of Resistance Spot Welds Using Infrared Thermography

NASA Astrophysics Data System (ADS)

Brown, Bruce; Bangs, Edmund

1986-03-01

The ability to monitor the spot welding process and provide a real time inspection is of interest to the automotive, aircraft, and aircraft turbine industries. A series of experiments was performed using the infrared radiometer during the welding operation when welding coated and uncoated automotive gage steels. It has been determined that the isotherm radiated at the electrode/base material surface contains apometric information that can be used in the detection of the weld nugget and its quality. Weld nugget measurement and tensile shear tests results show good correlation between isotherm geometry, weld joint strength, and weld nugget size.

Study on Mg/Al Weld Seam Based on Zn–Mg–Al Ternary Alloy

PubMed Central

Liu, Liming; Liu, Fei; Zhu, Meili

2014-01-01

Based on the idea of alloying welding seams, a series of Zn–xAl filler metals was calculated and designed for joining Mg/Al dissimilar metals by gas tungsten arc (GTA) welding. An infrared thermography system was used to measure the temperature of the welding pool during the welding process to investigate the solidification process. It was found that the mechanical properties of the welded joints were improved with the increasing of the Al content in the Zn–xAl filler metals, and when Zn–30Al was used as the filler metal, the ultimate tensile strength could reach a maximum of 120 MPa. The reason for the average tensile strength of the joint increasing was that the weak zone of the joint using Zn–30Al filler metal was generated primarily by α-Al instead of MgZn2. When Zn–40Al was used as the filler metal, a new transition zone, about 20 μm-wide, appeared in the edge of the fusion zone near the Mg base metal. Due to the transition zones consisting of MgZn2- and Al-based solid solution, the mechanical property of the joints was deteriorated. PMID:28788508

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

[Submicron particles in smoke resulting from welding alloys and cast alloy in metalworking industry].

PubMed

Avino, P; Manigrasso, M; Fanizza, Carla; Carrai, P; Solfanelli, Linda

2013-01-01

The toxicity of welding fumes depends on both chemical composition and ability to penetrate and deposit deeply in the lungs. Their penetration and deposition in the regions of the respiratory system is mainly determined by their size. The knowledge of the size distribution of welding fumes is a crucial information towards the estimate of the doses of toxic compounds delivered into the respiratory tract. Particle number size distribution was continuously measured during different welding operations by means of a Fast Mobility Particle Sizer, which counts and classifies particles, according to their electrical mobility, in 32 size-channels, in the range from 5.6 to 523 nm, with is time resolution. The temporal evolution of submicrometric particles (6-523 nm), nucleation mode particles (6-16 nm) and the fraction 19-523 nm before, during and after the welding operations performed with/without local exhaust ventilation are reported and extensively discussed. Before welding, nucleation mode particles represent about 7% of submicrometric particles; after about 40 s from the welding start, the percent contribution of nucleation mode particles increases to 60%. Total and nucleation mode particle concentrations increase from 2.1 x 10(4) to 2.0 x 10(6) and from 1.6 x 10(3) to 1.0 x 10(6), respectively. The temporal variation of the particle number size distribution across the peaks, evidences the strong and fast-evolving contribution of nucleation mode particles: peak values are maintained for less than 10 s. The implication of such contribution on human health is linked to high deposition efficiency of the submicrometric particles in the alveolar interstitial region of the human respiratory system, where gas exchange occurs.

Workplace exposure to nanoparticles from gas metal arc welding process

NASA Astrophysics Data System (ADS)

Zhang, Meibian; Jian, Le; Bin, Pingfan; Xing, Mingluan; Lou, Jianlin; Cong, Liming; Zou, Hua

2013-11-01

Workplace exposure to nanoparticles from gas metal arc welding (GMAW) process in an automobile manufacturing factory was investigated using a combination of multiple metrics and a comparison with background particles. The number concentration (NC), lung-deposited surface area concentration (SAC), estimated SAC and mass concentration (MC) of nanoparticles produced from the GMAW process were significantly higher than those of background particles before welding ( P < 0.01). A bimodal size distribution by mass for welding particles with two peak values (i.e., 10,000-18,000 and 560-320 nm) and a unimodal size distribution by number with 190.7-nm mode size or 154.9-nm geometric size were observed. Nanoparticles by number comprised 60.7 % of particles, whereas nanoparticles by mass only accounted for 18.2 % of the total particles. The morphology of welding particles was dominated by the formation of chain-like agglomerates of primary particles. The metal composition of these welding particles consisted primarily of Fe, Mn, and Zn. The size distribution, morphology, and elemental compositions of welding particles were significantly different from background particles. Working activities, sampling distances from the source, air velocity, engineering control measures, and background particles in working places had significant influences on concentrations of airborne nanoparticle. In addition, SAC showed a high correlation with NC and a relatively low correlation with MC. These findings indicate that the GMAW process is able to generate significant levels of nanoparticles. It is recommended that a combination of multiple metrics is measured as part of a well-designed sampling strategy for airborne nanoparticles. Key exposure factors, such as particle agglomeration/aggregation, background particles, working activities, temporal and spatial distributions of the particles, air velocity, engineering control measures, should be investigated when measuring workplace exposure to nanoparticles.

On Improving the Quality of Gas Tungsten Arc Welded 18Ni 250 Maraging Steel Rocket Motor Casings

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Effect of electromagnetic interaction during fusion welding of AISI 2205 duplex stainless steel on the corrosion resistance

NASA Astrophysics Data System (ADS)

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

2017-02-01

The effect of electromagnetic interaction of low intensity (EMILI) applied during fusion welding of AISI 2205 duplex stainless steel on the resistance to localised corrosion in natural seawater was investigated. The heat affected zone (HAZ) of samples welded under EMILI showed a higher temperature for pitting initiation and lower dissolution under anodic polarisation in chloride containing solutions than samples welded without EMILI. The EMILI assisted welding process developed in the present work enhanced the resistance to localised corrosion due to a modification on the microstructural evolution in the HAZ and the fusion zone during the thermal cycle involved in fusion welding. The application of EMILI reduced the size of the HAZ, limited coarsening of the ferrite grains and promoted regeneration of austenite in this zone, inducing a homogeneous passive condition of the surface. EMILI can be applied during fusion welding of structural or functional components of diverse size manufactured with duplex stainless steel designed to withstand aggressive environments such as natural seawater or marine atmospheres.

Effect of friction stir welding parameters on defect formation

NASA Astrophysics Data System (ADS)

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

2015-10-01

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

Fiber Laser Welded AZ31 Magnesium Alloy: The Effect of Welding Speed on Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

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

2012-06-01

This study was aimed at characterizing microstructural change and evaluating tensile and fatigue properties of fiber laser welded AZ31B-H24 Mg alloy with special attention to the effect of welding speed. Laser welding led to the formation of equiaxed dendrites in the fusion zone and columnar dendrites near the fusion zone boundary along with divorced eutectic Mg17Al12 particles and recrystallized grains in the heat-affected zone. The lowest hardness across the weld appeared in the fusion zone. Although the yield strength, ductility, and fatigue life decreased, the hardening capacity increased after laser welding, with a joint efficiency reaching about 90 pct. A higher welding speed resulted in a narrower fusion zone, smaller grain size, higher yield strength, and longer fatigue life, as well as a slightly lower strain-hardening capacity mainly because of the smaller grain sizes. Tensile fracture occurred in the fusion zone, whereas fatigue failure appeared essentially in between the heat-affected zone and the fusion zone. Fatigue cracks initiated from the near-surface welding defects and propagated by the formation of fatigue striations together with secondary cracks.

Building A Simulation Model For The Prediction Of Temperature Distribution In Pulsed Laser Spot Welding Of Dissimilar Low Carbon Steel 1020 To Aluminum Alloy 6061

NASA Astrophysics Data System (ADS)

Yousef, Adel K. M.; Taha, Ziad. A.; Shehab, Abeer A.

2011-01-01

This paper describes the development of a computer model used to analyze the heat flow during pulsed Nd: YAG laser spot welding of dissimilar metal; low carbon steel (1020) to aluminum alloy (6061). The model is built using ANSYS FLUENT 3.6 software where almost all the environments simulated to be similar to the experimental environments. A simulation analysis was implemented based on conduction heat transfer out of the key hole where no melting occurs. The effect of laser power and pulse duration was studied. Three peak powers 1, 1.66 and 2.5 kW were varied during pulsed laser spot welding (keeping the energy constant), also the effect of two pulse durations 4 and 8 ms (with constant peak power), on the transient temperature distribution and weld pool dimension were predicated using the present simulation. It was found that the present simulation model can give an indication for choosing the suitable laser parameters (i.e. pulse durations, peak power and interaction time required) during pulsed laser spot welding of dissimilar metals.

In situ strain and temperature measurement and modelling during arc welding

DOE PAGES

Chen, Jian; Yu, Xinghua; Miller, Roger G.; ...

2014-12-26

In this study, experiments and numerical models were applied to investigate the thermal and mechanical behaviours of materials adjacent to the weld pool during arc welding. In the experiment, a new high temperature strain measurement technique based on digital image correlation (DIC) was developed and applied to measure the in situ strain evolution. In contrast to the conventional DIC method that is vulnerable to the high temperature and intense arc light involved in fusion welding processes, the new technique utilised a special surface preparation method to produce high temperature sustaining speckle patterns required by the DIC algorithm as well asmore » a unique optical illumination and filtering system to suppress the influence of the intense arc light. These efforts made it possible for the first time to measure in situ the strain field 1 mm away from the fusion line. The temperature evolution in the weld and the adjacent regions was simultaneously monitored by an infrared camera. Finally and additionally, a thermal–mechanical finite element model was applied to substantiate the experimental measurement.« less

Structure formation of 5083 alloy during friction stir welding

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Cancer incidence among welders: possible effects of exposure to extremely low frequency electromagnetic radiation (ELF) and to welding fumes.

PubMed Central

Stern, R M

1987-01-01

Epidemiological studies of cancer incidence among welders disclose a pooled total of 146 cases of leukemia observed versus 159.46 expected, a risk ratio of 0.92, and 40 cases of acute leukemia observed versus 43.39 expected, a risk ratio of 0.92. For respiratory tract cancer, the pooled total is 1789 cases observed versus 1290.7 expected, a risk ratio of 1.39. Most electric welders are exposed to extremely low frequency electromagnetic radiation (ELF) (magnetic flux densities of up to 100,000 microT), a suspected leukemogen, and to concentrated metallic aerosols (up to 200 mg/m3), which can contain the putative respiratory tract carcinogens Cr(VI) and Ni. The two exposures are usually coincident, since welding with an electric current produces welding fumes. The observation of an excess risk for respiratory tract cancer strongly suggests significant exposure both to fumes and to ELF. The absence of increased risk for all leukemia or for acute leukemia among ELF-exposed welders does not support the hypothesis that the observed excess risk for leukemia or acute leukemia among workers in the electrical trades is due to their ELF exposure, which on the average is lower than that of welders. PMID:3447902

Welding parameter optimization of alloy material by friction stir welding using Taguchi approach and design of experiments

NASA Astrophysics Data System (ADS)

Karwande, Amit H.; Rao, Seeram Srinivasa

2018-04-01

Friction stir welding (FSW) a welding process in which metals are joint by melting them at their solid state. In different engineering areas such as civil, mechanical, naval and aeronautical engineering beams are widely used of the magnesium alloys for different applications and that are joined by conventional inert gas welding process. Magnesium metal has less density and low melting point for that reason large heat generation in the common welding process so its necessity to adapt new welding process. FSW process increases the weld quality which observed under various mechanical testing by using different tool size.

Manganese in occupational arc welding fumes--aspects on physiochemical properties, with focus on solubility.

PubMed

Taube, Fabian

2013-01-01

Physicochemical properties, such as particle sizes, composition, and solubility of welding fumes are decisive for the bioaccessibility of manganese and thereby for the manganese cytotoxic and neurotoxic effects arising from various welding fumes. Because of the diverse results within the research on welding fume solubility, this article aims to review and discuss recent literature on physicochemical properties of gas metal arc welding, shielded metal arc welding, and flux-cored arc welding fumes, with focus on solubility properties. This article also presents a short introduction to the literature on arc welding techniques, health effects from manganese, and occupational exposure to manganese among welders.

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

NASA Astrophysics Data System (ADS)

Yang, Guang

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

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

EB welding of launch vehicles

NASA Astrophysics Data System (ADS)

Szabo, Attila

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

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

NASA Astrophysics Data System (ADS)

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

2016-01-01

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

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

PubMed

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

2016-07-01

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

Aerosol characterization and pulmonary responses in rats after short-term inhalation of fumes generated during resistance spot welding of galvanized steel.

PubMed

Antonini, James M; Afshari, Aliakbar; Meighan, Terence G; McKinney, Walter; Jackson, Mark; Schwegler-Berry, Diane; Burns, Dru A; LeBouf, Ryan F; Chen, Bean T; Shoeb, Mohammad; Zeidler-Erdely, Patti C

2017-01-01

Resistance spot welding is a common process to join metals in the automotive industry. Adhesives are often used as sealers to seams of metals that are joined. Anti-spatter compounds sometimes are sprayed onto metals to be welded to improve the weldability. Spot welding produces complex aerosols composed of metal and volatile compounds (VOCs) which can cause lung disease in workers. Male Sprague-Dawley rats (n = 12/treatment group) were exposed by inhalation to 25 mg/m 3 of aerosol for 4 h/day × 8 days during spot welding of galvanized zinc (Zn)-coated steel in the presence or absence of a glue or anti-spatter spray. Controls were exposed to filtered air. Particle size distribution and chemical composition of the generated aerosol were determined. At 1 and 7 days after exposure, bronchoalveolar lavage (BAL) was performed to assess lung toxicity. The generated particles mostly were in the submicron size range with a significant number of nanometer-sized particles formed. The primary metals present in the fumes were Fe (72.5%) and Zn (26.3%). The addition of the anti-spatter spray and glue did affect particle size distribution when spot welding galvanized steel, whereas they had no effect on metal composition. Multiple VOCs (e.g., methyl methacrylate, acetaldehyde, ethanol, acetone, benzene, xylene) were identified when spot welding using either the glue or the anti-spatter spray that were not present when welding alone. Markers of lung injury (BAL lactate dehydrogenase) and inflammation (total BAL cells/neutrophils and cytokines/chemokines) were significantly elevated compared to controls 1 day after exposure to the spot welding fumes. The elevated pulmonary response was transient as lung toxicity mostly returned to control values by 7 days. The VOCs or the concentrations that they were generated during the animal exposures had no measurable effect on the pulmonary responses. Inhalation of galvanized spot welding fumes caused acute lung toxicity most likely due to the short-term exposure of particles that contain Zn.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

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.

Role of Oxygen as Surface-Active Element in Linear GTA Welding Process

NASA Astrophysics Data System (ADS)

Yadaiah, Nirsanametla; Bag, Swarup

2013-11-01

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

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

Numerical simulation of spatter formation during fiber laser welding of 5083 aluminum alloy at full penetration condition

NASA Astrophysics Data System (ADS)

Wu, Dongsheng; Hua, Xueming; Huang, Lijin; Zhao, Jiang

2018-03-01

The droplet escape condition in laser welding is established in this paper. A three-dimensional numerical model is developed to study the weld pool convection and spatter formation at full penetration during the fiber laser welding of 5083 aluminum alloy. It is found that when laser power is 9 kW, the bottom of the keyhole is dynamically opened and closed. When the bottom of the keyhole is closed, the molten metal at the bottom of the back keyhole wall flows upwards along the fusion line. When the bottom of the keyhole is opened, few spatters can be seen around the keyhole at the top surface, two flow patterns exists in the rear part of the keyhole: a portion of molten metal flows upwards along the fusion line, other portion of molten metal flows to the bottom of the keyhole, which promote the spatter formation at the bottom of the keyhole rear wall.

Automatic welding of stainless steel tubing

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1978-01-01

The use of automatic welding for making girth welds in stainless steel tubing was investigated as well as the reduction in fabrication costs resulting from the elimination of radiographic inspection. Test methodology, materials, and techniques are discussed, and data sheets for individual tests are included. Process variables studied include welding amperes, revolutions per minute, and shielding gas flow. Strip chart recordings, as a definitive method of insuring weld quality, are studied. Test results, determined by both radiographic and visual inspection, are presented and indicate that once optimum welding procedures for specific sizes of tubing are established, and the welding machine operations are certified, then the automatic tube welding process produces good quality welds repeatedly, with a high degree of reliability. Revised specifications for welding tubing using the automatic process and weld visual inspection requirements at the Kennedy Space Center are enumerated.

Studies on post weld heat treatment of dissimilar aluminum alloys by laser beam welding technique

NASA Astrophysics Data System (ADS)

Srinivas, B.; Krishna, N. Murali; Cheepu, Muralimohan; Sivaprasad, K.; Muthupandi, V.

2018-03-01

The present study mainly focuses on post weld heat treatment (PWHT) of AA5083 and AA6061 alloys by joining these using laser beam welding at three different laser power and two different beam spot sizes and three different welding speeds. Effects of these parameters on microstructural and mechanical properties like hardness, tensile strength were studied at PWHT condition and significant changes had been observed. The PWHT used was artificial aging technique. The microstructural observations revealed that there was a appreciable changes were taken place in the grain size. The microhardness observations proven that the change in the hardness profile in AA6061 was appreciable than in the AA5083. The tensile strength of 246 MPa was recorded as highest. The fractured surfaces observed are predominantly ductile in nature.

One-step femtosecond laser welding and internal machining of three glass substrates

NASA Astrophysics Data System (ADS)

Tan, Hua; Duan, Ji'an

2017-05-01

In this paper, it demonstrated one-step femtosecond laser welding and internal machining of three fused silica substrates in the optical- and non-optical-contact regimes by focusing 1030-nm laser pulses at the middle of the second substrate. Focusing laser pulses within the second glass in optical-contact and non-optical-contact samples induces permanent internal structural modification, leading to the three glass substrates bonding together simultaneously. The bonding mechanism is based on the internal modification of glass, and this mechanism is different from that of ordinary glass welding at the interface. Welding-spot size is affected by not only the gap distance (ablation effect) and heat transmission, but also by gravity through examining the sizes of the welding spots on the four contact welding surfaces. The maximum bonding strength of the lower interface (56.2 MPa) in the optical-contact regime is more than double that (27.6 MPa) in the non-optical-contact regime.

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

NASA Astrophysics Data System (ADS)

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

2016-03-01

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

Crack-free conditions in welding of glass by ultrashort laser pulse.

PubMed

Miyamoto, Isamu; Cvecek, Kristian; Schmidt, Michael

2013-06-17

The spatial distribution of the laser energy absorbed by nonlinear absorption process in bulk glass w(z) is determined and thermal cycles due to the successive ultrashort laser pulse (USLP) is simulated using w(z) based on the transient thermal conduction model. The thermal stress produced in internal melting of bulk glass by USLP is qualitatively analyzed based on a simple thermal stress model, and crack-free conditions are studied in glass having large coefficient of thermal expansion. In heating process, cracks are prevented when the laser pulse impinges into glass with temperatures higher than the softening temperature of glass. In cooling process, shrinkage stress is suppressed to prevent cracks, because the embedded molten pool produced by nonlinear absorption process behaves like an elastic body under the compressive stress field unlike the case of CW-laser welding where the molten pool having a free surface produced by linear absorption process is plastically deformed under the compressive stress field.

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.

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

PubMed

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

2016-10-01

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

Comparison of stainless and mild steel welding fumes in generation of reactive oxygen species.

PubMed

Leonard, Stephen S; Chen, Bean T; Stone, Samuel G; Schwegler-Berry, Diane; Kenyon, Allison J; Frazer, David; Antonini, James M

2010-11-03

Welding fumes consist of a wide range of complex metal oxide particles which can be deposited in all regions of the respiratory tract. The welding aerosol is not homogeneous and is generated mostly from the electrode/wire. Over 390,000 welders were reported in the U.S. in 2008 while over 1 million full-time welders were working worldwide. Many health effects are presently under investigation from exposure to welding fumes. Welding fume pulmonary effects have been associated with bronchitis, metal fume fever, cancer and functional changes in the lung. Our investigation focused on the generation of free radicals and reactive oxygen species from stainless and mild steel welding fumes generated by a gas metal arc robotic welder. An inhalation exposure chamber located at NIOSH was used to collect the welding fume particles. Our results show that hydroxyl radicals (.OH) were generated from reactions with H2O2 and after exposure to cells. Catalase reduced the generation of .OH from exposed cells indicating the involvement of H2O2. The welding fume suspension also showed the ability to cause lipid peroxidation, effect O2 consumption, induce H2O2 generation in cells, and cause DNA damage. Increase in oxidative damage observed in the cellular exposures correlated well with .OH generation in size and type of welding fumes, indicating the influence of metal type and transition state on radical production as well as associated damage. Our results demonstrate that both types of welding fumes are able to generate ROS and ROS-related damage over a range of particle sizes; however, the stainless steel fumes consistently showed a significantly higher reactivity and radical generation capacity. The chemical composition of the steel had a significant impact on the ROS generation capacity with the stainless steel containing Cr and Ni causing more damage than the mild steel. Our results suggest that welding fumes may cause acute lung injury. Since type of fume generated, particle size, and elapsed time after generation of the welding exposure are significant factors in radical generation and particle deposition these factors should be considered when developing protective strategies.

Comparison of stainless and mild steel welding fumes in generation of reactive oxygen species

PubMed Central

2010-01-01

Background Welding fumes consist of a wide range of complex metal oxide particles which can be deposited in all regions of the respiratory tract. The welding aerosol is not homogeneous and is generated mostly from the electrode/wire. Over 390,000 welders were reported in the U.S. in 2008 while over 1 million full-time welders were working worldwide. Many health effects are presently under investigation from exposure to welding fumes. Welding fume pulmonary effects have been associated with bronchitis, metal fume fever, cancer and functional changes in the lung. Our investigation focused on the generation of free radicals and reactive oxygen species from stainless and mild steel welding fumes generated by a gas metal arc robotic welder. An inhalation exposure chamber located at NIOSH was used to collect the welding fume particles. Results Our results show that hydroxyl radicals (.OH) were generated from reactions with H2O2 and after exposure to cells. Catalase reduced the generation of .OH from exposed cells indicating the involvement of H2O2. The welding fume suspension also showed the ability to cause lipid peroxidation, effect O2 consumption, induce H2O2 generation in cells, and cause DNA damage. Conclusion Increase in oxidative damage observed in the cellular exposures correlated well with .OH generation in size and type of welding fumes, indicating the influence of metal type and transition state on radical production as well as associated damage. Our results demonstrate that both types of welding fumes are able to generate ROS and ROS-related damage over a range of particle sizes; however, the stainless steel fumes consistently showed a significantly higher reactivity and radical generation capacity. The chemical composition of the steel had a significant impact on the ROS generation capacity with the stainless steel containing Cr and Ni causing more damage than the mild steel. Our results suggest that welding fumes may cause acute lung injury. Since type of fume generated, particle size, and elapsed time after generation of the welding exposure are significant factors in radical generation and particle deposition these factors should be considered when developing protective strategies. PMID:21047424

Cost and Performance Report: Innovative Welding Technologies Using Silicon Additives to Control Hazardous Air Pollutant (HAP) Emissions

DTIC Science & Technology

2013-08-30

turntable inside the hood to maintain a constant weld speed, while the ER308L stainless steel wire were fed by the welding gun. Figure 2. Fume chamber...size distribution, density and specific surface area of welding fumes from SMAW and GMAW mild- steel and stainless - steel consumables, American...shipyards. It uses mild or stainless steel filler material to join pieces of metal. The intense energy expended in the welding process results in the

A model for prediction of fume formation rate in gas metal arc welding (GMAW), globular and spray modes, DC electrode positive.

PubMed

Dennis, J H; Hewitt, P J; Redding, C A; Workman, A D

2001-03-01

Prediction of fume formation rate during metal arc welding and the composition of the fume are of interest to occupational hygienists concerned with risk assessment and to manufacturers of welding consumables. A model for GMAW (DC electrode positive) is described based on the welder determined process parameters (current, wire feed rate and wire composition), on the surface area of molten metal in the arc and on the partial vapour pressures of the component metals of the alloy wire. The model is applicable to globular and spray welding transfer modes but not to dip mode. Metal evaporation from a droplet is evaluated for short time increments and total evaporation obtained by summation over the life of the droplet. The contribution of fume derived from the weld pool and spatter (particles of metal ejected from the arc) is discussed, as are limitations of the model. Calculated droplet temperatures are similar to values determined by other workers. A degree of relationship between predicted and measured fume formation rates is demonstrated but the model does not at this stage provide a reliable predictive tool.

Weld geometry strength effect in 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

Physical and chemical characterization of airborne particles from welding operations in automotive plants.

PubMed

Dasch, Jean; D'Arcy, James

2008-07-01

Airborne particles were characterized from six welding operations in three automotive plants, including resistance spot welding, metal inert gas (MIG) welding and tungsten inert gas (TIG) welding of aluminum and resistance spot welding, MIG welding and weld-through sealer of galvanized steel. Particle levels were measured throughout the process area to select a sampling location, followed by intensive particle sampling over one working shift. Temporal trends were measured, and particles were collected on filters to characterize their size and chemistry. In all cases, the particles fell into a bimodal size distribution with very large particles >20 mum in diameter, possibly emitted as spatter or metal expulsions, and very small particles about 1 mum in diameter, possibly formed from condensation of vaporized metal. The mass median aerodynamic diameter was about 1 mum, with only about 7% of the particle mass present as ultrafine particles <100 nm. About half the mass of aluminum welding particles could be accounted for by chemical analysis, with the remainder possibly present as oxygen. Predominant species were organic carbon, elemental carbon, iron, and aluminum. More than 80% of the particle mass could be accounted for from steel welding, primarily present as iron, organic carbon, zinc, and copper. Particle concentrations and elemental concentrations were compared with allowable concentrations as recommended by the Occupational Safety and Health Administration and the American Conference of Governmental Industrial Hygienists. In all cases, workplace levels were at least 11 times lower than recommended levels.

Tensile Behavior of Electron Beam-Welded and Post-Weld Vacuum-Annealed Nb-10% Hf-1% Ti Refractory Alloy Weldments

NASA Astrophysics Data System (ADS)

Anil Kumar, V.; Gupta, R. K.; Venkateswaran, T.; Ram Kumar, P.

2018-02-01

Nb-10% Hf-1% Ti refractory alloy is a high performance material extensively used for high temperature applications. Electron beam welding is one of the most widely used techniques to join refractory and reactive alloys. Bigger sizes of nozzles for rocket propulsion applications can be either made through deep drawing and flow turning route or by roll bending and welding route both using sheets/plates as input material for fabrication. The latter is a more economical option for mass production of the hardware using such exotic and expensive alloys. In view of this, both as-welded (AW) coupon and weld plus post-weld vacuum-annealed (AW + VA) coupon have been prepared to study their mechanical behavior. It has been observed that tensile strength and ductility have not been reduced in both these conditions vis-à-vis the base metal, confirming weld efficiency of the alloy to be 100%. Microhardness is found to be 150-160 VHN in the base metal and 200-225 VHN in the weld fusion zone in AW condition, which became uniform (145-155 VHN) throughout the weldment in AW + VA condition. Microstructure of the weldment in AW condition is found to be consisting of grains solidified by epitaxial mode from base metal toward the weld centre. In AW + VA condition, improvement in tensile elongation is observed, which is found to be due to the presence of homogenized grains/more uniform microstructure near the heat-affected zone as compared to the steep gradient in grain size in different zones in the weld in AW condition.

Structural analysis of a reflux pool-boiler solar receiver

NASA Astrophysics Data System (ADS)

Hoffman, E. L.; Stone, C. M.

1991-06-01

Coupled thermal-structural finite element calculations of a reflux pool-boiler solar receiver were performed to characterize the operating stresses and to address issues affecting the service life of the receiver. Analyses performed using shell elements provided information for receiver material selection and design optimization. Calculations based on linear elastic fracture mechanics principles were performed using continuum elements to assess the vulnerability of a seam-weld to fatigue crack growth. All calculations were performed using ABAQUS, a general purpose finite element code, and elements specifically formulated for coupled thermal-structural analysis. Two materials were evaluated: 316L SS and Haynes 230 alloys. The receiver response was simulated for a combination of structural and thermal loads that represent the startup and operating conditions of the receiver. For both materials, maximum stresses in the receiver developed shortly after startup due to uneven temperature distribution across the receiver surface. The largest effective stress was near yield in the 316L SS receiver and below 39 percent of yield in the Haynes 230 receiver. The calculations demonstrated that stress reductions of over 25 percent could be obtained by reducing the aft dome thickness to one closer to the absorber. The fatigue calculations demonstrated that the stress distribution near the seam-weld notch depends primarily on the structural load created by internal pressurization of the receiver rather than the thermal, indicating that the thermal loads can be neglected when assessing the stress intensity near the seam-weld notch. The stress intensity factor, computed using the J-integral method and crack opening-displacement field equations, was significantly below the fatigue threshold for most steels. The calculations indicated that the weld notch was always loaded in compression, a condition which is not conducive to fatigue crack growth.

A comparison of LBW and GTAW processes in miniature closure welds

NASA Astrophysics Data System (ADS)

Knorovsky, G. A.; Fuerschbach, P. W.; Gianoulakis, S. E.; Burchett, S. N.

When small electronic components with glass-to-metal seals are closure welded, the residual stresses that develop in the glass are of concern. If these stresses exceed allowable tensile levels' the resulting weld-induced seal failure may cause the entire component to be scrapped or reworked at a substantial cost. Conventional wisdom says the best welding process for these applications is that which provides the least heat input, and so in that respect, Laser Beam Welding (LBW) provides less heat input than Gas Tungsten Arc Welding (GTAW), however, other concerns, such as weld fit-up, part variability, and material weldability, can modify the final choice of a welding process. In this paper, we compare the characteristic levels of heat input and the residual stresses generated in glass seals for two processes (as calculated by a 3D Finite Element Analysis) as a function of heat input and travel speed, and contrast some of the other manufacturing decisions that must be made in choosing a production process. The geometry chosen is that of a standing edge corner weld in a cylindrical container about 20 mm diameter by 35 mm tall. Four metal pins are glassed into the part lid. The stresses calculated from the resulting from continuous wave CO2 LBW are compared with those resulting from GTAW. The total energy required by the laser weld is significantly less than that needed for the equivalent size GTA weld. The energy input requirements for a given size weld is inversely proportional to the travel speed, but approaches a saturation level as the travel speed increases. LBW travel speeds ranging from 10 mm/s to 50 mm/s were examined.

UNS S31603 Stainless Steel Tungsten Inert Gas Welds Made with Microparticle and Nanoparticle Oxides

PubMed Central

Tseng, Kuang-Hung; Lin, Po-Yu

2014-01-01

The purpose of this study was to investigate the difference between tungsten inert gas (TIG) welding of austenitic stainless steel assisted by microparticle oxides and that assisted by nanoparticle oxides. SiO2 and Al2O3 were used to investigate the effects of the thermal stability and the particle size of the activated compounds on the surface appearance, geometric shape, angular distortion, delta ferrite content and Vickers hardness of the UNS S31603 stainless steel TIG weld. The results show that the use of SiO2 leads to a satisfactory surface appearance compared to that of the TIG weld made with Al2O3. The surface appearance of the TIG weld made with nanoparticle oxide has less flux slag compared with the one made with microparticle oxide of the same type. Compared with microparticle SiO2, the TIG welding with nanoparticle SiO2 has the potential benefits of high joint penetration and less angular distortion in the resulting weldment. The TIG welding with nanoparticle Al2O3 does not result in a significant increase in the penetration or reduction of distortion. The TIG welding with microparticle or nanoparticle SiO2 uses a heat source with higher power density, resulting in a higher ferrite content and hardness of the stainless steel weld metal. In contrast, microparticle or nanoparticle Al2O3 results in no significant difference in metallurgical properties compared to that of the C-TIG weld metal. Compared with oxide particle size, the thermal stability of the oxide plays a significant role in enhancing the joint penetration capability of the weld, for the UNS S31603 stainless steel TIG welds made with activated oxides. PMID:28788704

UNS S31603 Stainless Steel Tungsten Inert Gas Welds Made with Microparticle and Nanoparticle Oxides.

PubMed

Tseng, Kuang-Hung; Lin, Po-Yu

2014-06-20

The purpose of this study was to investigate the difference between tungsten inert gas (TIG) welding of austenitic stainless steel assisted by microparticle oxides and that assisted by nanoparticle oxides. SiO₂ and Al₂O₃ were used to investigate the effects of the thermal stability and the particle size of the activated compounds on the surface appearance, geometric shape, angular distortion, delta ferrite content and Vickers hardness of the UNS S31603 stainless steel TIG weld. The results show that the use of SiO₂ leads to a satisfactory surface appearance compared to that of the TIG weld made with Al₂O₃. The surface appearance of the TIG weld made with nanoparticle oxide has less flux slag compared with the one made with microparticle oxide of the same type. Compared with microparticle SiO₂, the TIG welding with nanoparticle SiO₂ has the potential benefits of high joint penetration and less angular distortion in the resulting weldment. The TIG welding with nanoparticle Al₂O₃ does not result in a significant increase in the penetration or reduction of distortion. The TIG welding with microparticle or nanoparticle SiO₂ uses a heat source with higher power density, resulting in a higher ferrite content and hardness of the stainless steel weld metal. In contrast, microparticle or nanoparticle Al₂O₃ results in no significant difference in metallurgical properties compared to that of the C-TIG weld metal. Compared with oxide particle size, the thermal stability of the oxide plays a significant role in enhancing the joint penetration capability of the weld, for the UNS S31603 stainless steel TIG welds made with activated oxides.

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

Risk of ischemic heart disease following occupational exposure to welding fumes: a systematic review with meta-analysis.

PubMed

Mocevic, Emina; Kristiansen, Pernille; Bonde, Jens Peter

2015-04-01

Air pollution has been linked to an increased risk of ischemic heart disease (IHD), but less is known about occupational exposure to welding fumes and the risk of IHD. The objective of this paper was to review the epidemiological evidence on causal links between welding fume exposure and risk of IHD and to investigate whether the risk of IHD depends on specific welding characteristics. A systematic search in Medline 1979-2013 and EMBASE 1974-2013 identified 18 epidemiological studies with at least one risk estimate of IHD morbidity or mortality among workers exposed to welding fumes. Following an assessment of completeness of reporting, confounding, and bias, each risk estimate was characterized as more or less reliable. Pooled risk estimates were computed across studies by random effect meta-analyses. The weighted relative risk (RR) for IHD following exposure to welding fumes was 1.09 [95 % confidence interval (CI) 1.00, 1.19]. We calculated a RR of 1.39 (95 % CI 0.96, 2.02) among studies using an internal reference group and 1.08 (95 % CI 0.99, 1.18) for studies using an external reference group. An increased risk was observed for acute myocardial infarction RR = 1.69 (95 % CI 1.18, 2.42) and other IHDs RR = 1.06 (95 % CI 0.98, 1.14). There was too limited evidence to evaluate the risk of IHD related to specific welding characteristics. Several studies indicate that welding is associated with a moderately increased risk of IHD; however, bias and confounding cannot be ruled out with reasonable confidence.

Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

PubMed

Topham, Nathan; Wang, Jun; Kalivoda, Mark; Huang, Joyce; Yu, Kuei-Min; Hsu, Yu-Mei; Wu, Chang-Yu; Oh, Sewon; Cho, Kuk; Paulson, Kathleen

2012-03-01

Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium.

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.

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Microstructural investigation of hardfacing weld deposit obtained from CrB paste

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

Kr. Ray, S.; Sarker, B.; Kr. Bhattacharya, S.

Hardfacing weld deposits are used as a protective layer on engineering components and tools subjected to different modes of wear. Cheaper iron-based alloys with chromium and carbon or relatively expensive alloys with some niobium or titanium have long been used as standard hardfacing materials. In recent years boron has substituted the costlier alloying elements and the newly developed Fe-B-C alloys have shown encouraging results. The microstructure of the welded hardfacing deposit is one of the most important factors that determine its performance. The amount, size, distribution and hardness of the individual constituents play important roles in imparting the desired properties.more » Recently Colomonoy sweat on paste containing fine CrB particles (of about 12 {mu}m average size) suspended in an organic binder has been marketed as the new generation hardfacing material. A thin coating of the paste is applied on the component surface, allowed to dry and welded. The welded deposit has been found to offer good wear resistance in many industrial applications. This paper reports the microstructural investigation of the welded deposit obtained from this paste.« less

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

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Gleeson, Sean T.

2014-02-01

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

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

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

Na, Jeong K.; Gleeson, Sean T.

2014-02-18

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

Microstructure and hydrogen induced failure mechanisms in iron-nickel weldments

NASA Astrophysics Data System (ADS)

Fenske, Jamey Alan

A recent series of inexplicable catastrophic failures of specific subsea dissimilar metal Fe-Ni butter welds has illuminated a fundamental lack of understanding of both the microstructure created along the fusion line as well as its impact on the hydrogen susceptibility of these interfaces. In order to remedy this, the present work compares and contrasts the microstructure and hydrogen-induced fracture morphology of AISI 8630-IN 625 and F22-IN 625 dissimilar metal weld interfaces as a function of post-weld heat treatment duration. A variety of techniques were used to study details of both the microstructure and fracture morphology including optical microscopy, scanning electron microscopy, secondary ion mass spectrometry, transmission electron microscopy, electron backscatter diffraction, and energy dispersive x-ray spectroscopy. For both systems, the microstructure along the weld interface consisted of a coarse grain heat-affected zone in the Fe-base metal followed by discontinuous martensitic partially-mixed zones and a continuous partially-mixed zone on the Ni-side of the fusion line. Within the partially mixed zone on the Ni-side there exists a 200 nm-wide transition zone within a 20 mum-wide planar solidification region followed by a cellular dendritic region with Nb-Mo rich carbides decorating the dendrite boundaries. The size, area fraction and composition of the discontinuous PMZ were determined to be controlled by uneven mixing in the liquid weld pool influenced by convection currents produced from the welding procedure. The virgin martensitic microstructure produced in these regions is formed as consequence of a both the local composition and the post-weld heat treatment. The local higher Ni content results in these regions being retransformed into austenite during the post-weld heat treatment and then virgin martensite while cooling to room temperature. Although there were differences in the volume of the discontinuous partially mixed-zones, the major difference in the weld metal interfaces was the presence of M 7C3 precipitates in the planar solidification region. The formation of these precipitates, which were found in what was previously referred to as the "featureless-zone," were determined to be dependent on the carbon content of the Fe-base metal and the duration of the post-weld heat treatment. A high density of these ordered 100 nm-long by 10 nm-wide needle-like precipitates were found in the AISI 8630-IN 625 weldment in the 10 hour post-weld heat treatment condition while only the initial stages of their nucleation were evident in the F22-IN 625 15 hour post-weld heat treatment specimen. The study of the fractured specimens revealed that the M7C 3 carbides play a key role in the susceptibility to hydrogen embrittlement of the Fe-Ni butter weldments. The fractures initially nucleate along the isolated Fe-base metal -- discontinuous partially mixed zone interfaces. The M7C3 carbides accumulate hydrogen and then provide a low energy fracture path between the discontinuous partially mixed zones leading to catastrophic failure. The result is a fracture morphology that alternates between flat regions produced by fracture along the discontinuous partially mixed zones and cleavage-like fracture regions produced by fracture along the ordered carbide matrix interfaces.

Method for laser spot welding monitoring

NASA Astrophysics Data System (ADS)

Manassero, Giorgio

1994-09-01

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

Hot Forging of a Cladded Component by Automated GMAW Process

NASA Astrophysics Data System (ADS)

Rafiq, Muhammad; Langlois, Laurent; Bigot, Régis

2011-01-01

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

Welding and Lung Cancer in a Pooled Analysis of Case-Control Studies

PubMed Central

Kendzia, Benjamin; Behrens, Thomas; Jöckel, Karl-Heinz; Siemiatycki, Jack; Kromhout, Hans; Vermeulen, Roel; Peters, Susan; Van Gelder, Rainer; Olsson, Ann; Brüske, Irene; Wichmann, H.-Erich; Stücker, Isabelle; Guida, Florence; Tardón, Adonina; Merletti, Franco; Mirabelli, Dario; Richiardi, Lorenzo; Pohlabeln, Hermann; Ahrens, Wolfgang; Landi, Maria Teresa; Caporaso, Neil; Consonni, Dario; Zaridze, David; Szeszenia-Dabrowska, Neonila; Lissowska, Jolanta; Gustavsson, Per; Marcus, Michael; Fabianova, Eleonora; ‘t Mannetje, Andrea; Pearce, Neil; Tse, Lap Ah; Yu, Ignatius Tak-sun; Rudnai, Peter; Bencko, Vladimir; Janout, Vladimir; Mates, Dana; Foretova, Lenka; Forastiere, Francesco; McLaughlin, John; Demers, Paul; Bueno-de-Mesquita, Bas; Boffetta, Paolo; Schüz, Joachim; Straif, Kurt; Pesch, Beate; Brüning, Thomas

2013-01-01

Several epidemiologic studies have indicated an increased risk of lung cancer among welders. We used the SYNERGY project database to assess welding as a risk factor for developing lung cancer. The database includes data on 15,483 male lung cancer cases and 18,388 male controls from 16 studies in Europe, Canada, China, and New Zealand conducted between 1985 and 2010. Odds ratios and 95% confidence intervals between regular or occasional welding and lung cancer were estimated, with adjustment for smoking, age, study center, and employment in other occupations associated with lung cancer risk. Overall, 568 cases and 427 controls had ever worked as welders and had an odds ratio of developing lung cancer of 1.44 (95% confidence interval: 1.25, 1.67) with the odds ratio increasing for longer duration of welding. In never and light smokers, the odds ratio was 1.96 (95% confidence interval: 1.37, 2.79). The odds ratios were somewhat higher for squamous and small cell lung cancers than for adenocarcinoma. Another 1,994 cases and 1,930 controls had ever worked in occupations with occasional welding. Work in any of these occupations was associated with some elevation of risk, though not as much as observed in regular welders. Our findings lend further support to the hypothesis that welding is associated with an increased risk of lung cancer. PMID:24052544

Welding and lung cancer in a pooled analysis of case-control studies.

PubMed

Kendzia, Benjamin; Behrens, Thomas; Jöckel, Karl-Heinz; Siemiatycki, Jack; Kromhout, Hans; Vermeulen, Roel; Peters, Susan; Van Gelder, Rainer; Olsson, Ann; Brüske, Irene; Wichmann, H-Erich; Stücker, Isabelle; Guida, Florence; Tardón, Adonina; Merletti, Franco; Mirabelli, Dario; Richiardi, Lorenzo; Pohlabeln, Hermann; Ahrens, Wolfgang; Landi, Maria Teresa; Caporaso, Neil; Consonni, Dario; Zaridze, David; Szeszenia-Dabrowska, Neonila; Lissowska, Jolanta; Gustavsson, Per; Marcus, Michael; Fabianova, Eleonora; 't Mannetje, Andrea; Pearce, Neil; Tse, Lap Ah; Yu, Ignatius Tak-Sun; Rudnai, Peter; Bencko, Vladimir; Janout, Vladimir; Mates, Dana; Foretova, Lenka; Forastiere, Francesco; McLaughlin, John; Demers, Paul; Bueno-de-Mesquita, Bas; Boffetta, Paolo; Schüz, Joachim; Straif, Kurt; Pesch, Beate; Brüning, Thomas

2013-11-15

Several epidemiologic studies have indicated an increased risk of lung cancer among welders. We used the SYNERGY project database to assess welding as a risk factor for developing lung cancer. The database includes data on 15,483 male lung cancer cases and 18,388 male controls from 16 studies in Europe, Canada, China, and New Zealand conducted between 1985 and 2010. Odds ratios and 95% confidence intervals between regular or occasional welding and lung cancer were estimated, with adjustment for smoking, age, study center, and employment in other occupations associated with lung cancer risk. Overall, 568 cases and 427 controls had ever worked as welders and had an odds ratio of developing lung cancer of 1.44 (95% confidence interval: 1.25, 1.67) with the odds ratio increasing for longer duration of welding. In never and light smokers, the odds ratio was 1.96 (95% confidence interval: 1.37, 2.79). The odds ratios were somewhat higher for squamous and small cell lung cancers than for adenocarcinoma. Another 1,994 cases and 1,930 controls had ever worked in occupations with occasional welding. Work in any of these occupations was associated with some elevation of risk, though not as much as observed in regular welders. Our findings lend further support to the hypothesis that welding is associated with an increased risk of lung cancer.

Characterization of nitrogen effects in high energy density weldments of Nitronic 40 stainless steel

NASA Astrophysics Data System (ADS)

Pfeif, Erik Andrew

Variation in the welding environment for laser beam welding and electron beam welding can alter the resulting weld chemical composition, microstructure and therefore the mechanical properties. The room temperature mechanical properties of Nitronic 40 stainless steel weld metal from three different heats containing 0.24, 0.28, and 0.31 wt. pct. nitrogen were evaluated for continuous mode Ytterbium doped Fiber laser welds conducted with argon and nitrogen shielding gases, and for electron beam welds. The bulk nitrogen contents were monitored and the resulting properties were then related to microstructural features measured using Electron BackScatter Diffraction (EBSD). Traditional tensile testing of weld metal is conducted on composite tensile bars consisting of base metal and weld metal often leading to failure in the region adjacent to the weld due to strength mismatch at the weld interface. These tests provide composite strength but do not specifically determine the mechanical properties of the heterogeneous weld metal. In this research, microtensile testing was conducted to characterize the properties of the different regions of the weld. The microtensile testing procedures were developed using two geometries of tensile bars measuring the properties through the thickness of 3 mm full penetration welds. In all cases an increase in the strength of the weld metal was found to occur, though the electron beam welds exhibited a higher strength than the laser welds. Standard predictive equations were found to under-predict the strength of the laser welds, even when average grain size or intercept distances were measured. The contribution of nitrogen solid solution strengthening was consistent at approximately 513 MPa per wt. pct. nitrogen. Similar cooling rates and heat inputs allow for a comparison across high energy density welding techniques. Though microstructural differences through the depth of the weld metal were observed as nitrogen vaporization decreased and cooling rates increased. Vermicular ferrite, lacy ferrite and intercellular ferrite were identified as predicted in prior research done on high nitrogen austenitic stainless steels. The resulting laser weld metal microstructures were analyzed with EBSD for grain size and ferrite content measurements, while grain boundary character was determined for a Hansen model used for multi-scale mechanical property measurements. It was found that the low angle grain boundaries were the predominant microstructural feature responsible for strengthening within the weld metal and that this contribution must be accounted for when predicting yield strength of the weld metal.

Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits II: Local welding

NASA Astrophysics Data System (ADS)

Carey, R. J.; Houghton, B. F.; Thordarson, T.

2008-03-01

As an alternative to classical welding models of fall deposits due to the progressive accumulation of hot tephra which then weld, we describe here welded deposits on the northern 1875 caldera rim of Askja volcano that have welded due to the influence of hot, discrete spatter bombs impacting into and supplying heat to a halo of surrounding tephra. This style of welding we term 'local welding' in contrast to 'regional welding' which is described elsewhere [Carey, R.J., Houghton, B.F., Thordarson, T., 2008. Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits I: Regional welding. J. Volcanol. Geotherm. Res. 171, 1-19. doi:10.1016/j.jvolgeores.2007.11.020]. Locally welded deposits are associated with the rhyolitic Plinian phase of the 1875 eruption of Askja volcano. Two distinct welding units (W1 and W2) are interbedded with Plinian fall on the northern caldera rim, and grade outwards to weakly dispersed non-welded fall. Spatter bombs are found in both welding units but vary in their characteristic sizes and internal features. In the W1 unit simple bombs with homogeneous internal characteristics up to ˜ 60 cm in diameter are found. In the W2 unit, large discrete spatter bombs with complex internal features range up to 9 m in diameter. We describe here two case studies showing the effects of a) single small spatter bombs; b) multiple small spatter bombs and c) large discrete spatter bombs varying in size. Vertical and lateral profiles through welding zones reveal that the primary controls on local welding are the availability of supplied or added heat and the loading capacity of the spatter bomb. Local welding grades are much higher than that of regional welding, as the combined effects of heat, compaction and insulation can provide suitable conditions which lead to dense welding and, proximal to the spatter bomb, rheomorphic flowage. If heating and loading exceed the critical requirement for welding, porosity loss via matrix welding and vesicle collapse occurs to a point where further strain must be accommodated as shearing and ductile flowage. The spatter bombs are found only within the weakly dispersed welding units and are the final erupted products of each fountaining phase. Their low viscosities are evident by their deformation on impact and fluidal forms, and hold some important clues to eruption dynamics in the shallow conduit and vent regions.

Microstructure, Hardness, and Residual Stress Distributions in T-Joint Weld of HSLA S500MC Steel

NASA Astrophysics Data System (ADS)

Frih, Intissar; Montay, Guillaume; Adragna, Pierre-Antoine

2017-03-01

This paper investigates the characterization of the microstructure, hardness, and residual stress distributions of MIG-welded high-strength low-alloy S500MC steel. The T-joint weld for 10-mm-thick plates was joined using a two passes MIG welding technology. The contour method was performed to measure longitudinal welding residual stress. The obtained results highlighted a good correlation between the metallurgical phase constituents and hardness distribution within the weld zones. In fact, the presence of bainite and smaller ferrite grain size in the weld-fusion zone might be the reason for the highest hardness measured in this region. A similar trend of the residual stress and hardness distributions was also obtained.

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

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

Denys, R.M.; Lefevre, T.

1997-06-01

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

Gas tungsten arc welding and friction stir welding of ultrafine grained AISI 304L stainless steel: Microstructural and mechanical behavior characterization

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

Sabooni, S., E-mail: s.sabooni@ma.iut.ac.ir; Karimzadeh, F.; Enayati, M.H.

In the present study, an ultrafine grained (UFG) AISI 304L stainless steel with the average grain size of 650 nm was successfully welded by both gas tungsten arc welding (GTAW) and friction stir welding (FSW). GTAW was applied without any filler metal. FSW was also performed at a constant rotational speed of 630 rpm and different welding speeds from 20 to 80 mm/min. Microstructural characterization was carried out by High Resolution Scanning Electron Microscopy (HRSEM) with Electron Backscattered Diffraction (EBSD) and Transmission Electron Microscopy (TEM). Nanoindentation, microhardness measurements and tensile tests were also performed to study the mechanical properties ofmore » the base metal and weldments. The results showed that the solidification mode in the GTAW welded sample is FA (ferrite–austenite) type with the microstructure consisting of an austenite matrix embedded with lath type and skeletal type ferrite. The nugget zone microstructure in the FSW welded samples consisted of equiaxed dynamically recrystallized austenite grains with some amount of elongated delta ferrite. Sigma phase precipitates were formed in the region ahead the rotating tool during the heating cycle of FSW, which were finally fragmented into nanometric particles and distributed in the weld nugget. Also there is a high possibility that the existing delta ferrite in the microstructure rapidly transforms into sigma phase particles during the short thermal cycle of FSW. These suggest that high strain and deformation during FSW can promote sigma phase formation. The final austenite grain size in the nugget zone was found to decrease with increasing Zener–Hollomon parameter, which was obtained quantitatively by measuring the peak temperature, calculating the strain rate during FSW and exact examination of hot deformation activation energy by considering the actual grain size before the occurrence of dynamic recrystallization. Mechanical properties observations showed that the welding efficiency of the FSW welded sample is around 70%, which is more than 20% higher than the GTAW welded sample. - Highlights: • Microstructure and mechanical properties of UFG 304L stainless steel were studied during GTAW and FSW. • Sigma phase formation mechanism was studied during FSW of 304L stainless steel. • THERMOCALC analysis was performed to obtain possible formation temperatures for sigma phase. • Nano-mechanical twins were found in the TMAZ region.« less

Electrode carrying wire for GTAW welding

NASA Technical Reports Server (NTRS)

Morgan, Gene E. (Inventor); Dyer, Gerald E. (Inventor)

1990-01-01

A welding torch for gas tungsten arc welding apparatus has a hollow tungsten electrode including a ceramic liner and forms the filler metal wire guide. The wire is fed through the tungsten electrode thereby reducing the size of the torch to eliminate clearance problems which exist with external wire guides. Since the wire is preheated from the tungsten more wire may be fed into the weld puddle, and the wire will not oxidize because it is always within the shielding gas.

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

PubMed Central

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

2011-01-01

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

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

PubMed

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

2011-06-01

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

49 CFR 178.56 - Specification 4AA480 welded steel cylinders.

Code of Federal Regulations, 2011 CFR

2011-10-01

...) Type, size, and service pressure. A DOT 4AA480 cylinder is a welded steel cylinder having a water capacity (nominal) not over 1,000 pounds water capacity and a service pressure of 480 psig. Closures welded... that the calculated wall stress at the minimum test pressure (in paragraph (i) of this section) may not...

Autogeneous Friction Stir Weld Lack-of-Penetration Defect Detection and Sizing Using Directional Conductivity Measurements with MWM Eddy Current Sensor

NASA Technical Reports Server (NTRS)

Goldfine, Neil; Zilberstei, Vladimir; Lawson, Ablode; Kinchen, David; Arbegast, William

2000-01-01

Al 2195-T8 plate specimens containing Friction Stir Welds (FSW), provided by Lockheed Martin, were inspected using directional conductivity measurements with the MWM sensor. Sensitivity to lack-of-penetration (LOP) defect size has been demonstrated. The feature used to determine defect size was the normalized longitudinal component of the MWM conductivity measurements. This directional conductivity component was insensitive to the presence of a discrete crack. This permitted correlation of MWM conductivity measurements with the LOP defect size as changes in conductivity were apparently associated with metallurgical features within the first 0.020 in. of the LOP defect zone. Transverse directional conductivity measurements also provided an indication of the presence of discrete cracks. Continued efforts are focussed on inspection of a larger set of welded panels and further refinement of LOP characterization tools.

Mechanical Properties and Wear Behavior of AA5182/WC Nanocomposite Fabricated by Friction Stir Welding at Different Tool Traverse Speeds

NASA Astrophysics Data System (ADS)

Paidar, Moslem; Asgari, Ali; Ojo, Olatunji Oladimeji; Saberi, Abbas

2018-03-01

Grain growth inhibition at the heat-affected zone, improved weld strength and superior tribological properties of welds are desirable attributes of modern manufacturing. With the focused on these attributes, tungsten carbide (WC) nanoparticles were employed as reinforcements for the friction stir welding of 5-mm-thick AA5182 aluminum alloy by varying tool traverse speeds. The microstructure, microhardness, ultimate tensile strength, fracture and wear behavior of the resultant WC-reinforced welds were investigated, while unreinforced AA5182 welds were employed as controls for the study. The result shows that the addition of WC nanoparticles causes substantial grain refinement within the weld nugget. A decrease in traverse speed caused additional particle fragmentation, improved hardness value and enhanced weld strength in the reinforced welds. Improved wear rate and friction coefficient of welds were attained at a reduced traverse speed of 100 mm/min in the WC-reinforced welds. This improvement is attributed to the effects of reduced grain size/grain fragmentation and homogeneous dispersion of WC nanoparticles within the WC-reinforced weld nugget.

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.

Weld repair method for aluminum lithium seam

NASA Technical Reports Server (NTRS)

McGee, William Floyd (Inventor); Rybicki, Daniel John (Inventor)

1998-01-01

Aluminum-lithium plates are butt-welded by juxtaposing the plates and making a preliminary weld from the rear or root side of the seam. An initial weld is then made from the face side of the seam, which may cause a defect in the root portion. A full-size X-ray is made and overlain over the seam to identify the defects. The defect is removed from the root side, and rewelded. Material is then removed from the face side, and the cavity is rewelded. The procedure repeats, alternating from the root side to the face side, until the weld is sound.

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.

Effect of heat input on the microstructure, residual stresses and corrosion resistance of 304L austenitic stainless steel weldments

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

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

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

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.

Definition of Beam Diameter for Electron Beam Welding

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

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

Tool For Friction Stir Tack Welding of Aluminum Alloys

NASA Technical Reports Server (NTRS)

Bjorkman, Gerald W.; Dingler, Johnny W.; Loftus, Zachary

2003-01-01

A small friction-stir-welding tool has been developed for use in tack welding of aluminum-alloy workpieces. It is necessary to tack-weld the workpieces in order to hold them together during friction stir welding because (1) in operation, a full-size friction-stir-welding tool exerts a large force that tends to separate the workpieces and (2) clamping the workpieces is not sufficient to resist this force. It is possible to tack the pieces together by gas tungsten arc welding, but the process can be awkward and time-consuming and can cause sufficient damage to necessitate rework. Friction stir tack welding does not entail these disadvantages. In addition, friction stir tack welding can be accomplished by use of the same automated equipment (except for the welding tool) used in subsequent full friction stir welding. The tool for friction stir tack welding resembles the tool for full friction stir welding, but has a narrower shoulder and a shorter pin. The shorter pin generates a smaller workpiece-separating force so that clamping suffices to keep the workpieces together. This tool produces a continuous or intermittent partial-penetration tack weld. The tack weld is subsequently consumed by action of the larger tool used in full friction stir welding tool.

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

PubMed

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

2008-09-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Study of 2219 aluminum alloy using direct current A-TIG welding

NASA Astrophysics Data System (ADS)

Li, Hui; Zou, Jiasheng

2017-07-01

Direct current A-TIG (DCEN A-TIG) welding using special active agent had eliminated the pores and the oxidation of 2219 high-strength aluminum alloy in welding. Addition of AlF3-25% LiF active agent to DCEN A-TIG welding and arc morphology showed a trailing phenomenon. However, the change in arc morphology was not remarkable when AlF3-75% LiF active agent was added. Addition of AlF3-75% LiF active agent can refine the grain size of DCEN A-TIG joint. The mechanical properties of the weld were optimal at 10% AlF3-75% LiF active agent. Compared with AC TIG and AC A-TIG welding, DCEN A-TIG welding yielded better results for 2219 Al alloy.

Transient Response of Arc Temperature and Iron Vapor Concentration Affected by Current Frequency with Iron Vapor in Pulsed Arc

NASA Astrophysics Data System (ADS)

Tanaka, Tatsuro; Maeda, Yoshifumi; Yamamoto, Shinji; Iwao, Toru

2016-10-01

TIG arc welding is chemically a joining technology with melting the metallic material and it can be high quality. However, this welding should not be used in high current to prevent cathode melting. Thus, the heat transfer is poor. Therefore, the deep penetration cannot be obtained and the weld defect sometimes occurs. The pulsed arc welding has been used for the improvement of this defect. The pulsed arc welding can control the heat flux to anode. The convention and driving force in the weld pool are caused by the arc. Therefore, it is important to grasp the distribution of arc temperature. The metal vapor generate from the anode in welding. In addition, the pulsed current increased or decreased periodically. Therefore, the arc is affected by such as a current value and current frequency, the current rate of increment and the metal vapor. In this paper, the transient response of arc temperature and the iron vapor concentration affected by the current frequency with iron vapor in pulsed arc was elucidated by the EMTF (ElectroMagnetic Thermal Fluid) simulation. As a result, the arc temperature and the iron vapor were transient response as the current frequency increase. Thus, the temperature and the electrical conductivity decreased. Therefore, the electrical field increased in order to maintain the current continuity. The current density and electromagnetic force increased at the axial center. In addition, the electronic flow component of the heat flux increased at the axial center because the current density increased. However, the heat conduction component of the heat flux decreased.

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

PubMed

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

2016-03-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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

Effect of laser welding on the titanium composite tensile bond strength.

PubMed

Galo, Rodrigo; Ribeiro, Ricardo Faria; Rodrigues, Renata Cristina Silveira; Pagnano, Valéria de Oliveira; de Mattos, Maria da Glória Chiarello

2009-01-01

The aim of this study was to analyze the shear bond strength between commercially pure titanium, with and without laser welding, after airbone-particle abrasion (Al(2)O(3)) and 2 indirect composites. Sixty-four specimens were cast and divided into 2 groups with and without laser welding. Each group was divided in 4 subgroups, related to Al(2)O(3) grain size: A - 250 microm; B - 180 microm; C- 110 microm; and D - 50 microm. Composite rings were formed around the rods and light polymerized using UniXS unit. Specimens were invested and their shear bond strength at failure was measured with a universal testing machine at a crosshead speed of 2.0 mm/min. Statistical analysis was carried out with ANOVA and Tukey's test (alpha=0.05). The highest bond strength means were recorded in 250 microm group without laser welding. The lowest shear bond strength means were recorded in 50 microm group with laser welding. Statistically significant differences (p<0.05) were found between all groups. In conclusion, airborne particle abrasion yielded significantly lower bond strength as the Al(2)O(3) particle size decreased. Shear bond strength decreased in the laser welded specimens.

Nugget Structure Evolution with Rotation Speed for High-Rotation-Speed Friction-Stir-Welded 6061 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Zhang, H. J.; Wang, M.; Zhu, Z.; Zhang, X.; Yu, T.; Wu, Z. Q.

2018-03-01

High-rotation-speed friction stir welding (HRS-FSW) is a promising technique to reduce the welding loads during FSW and thus facilitates the application of FSW for in situ fabrication and repair. In this study, 6061 aluminum alloy was friction stir welded at high-rotation speeds ranging from 3000 to 7000 rpm at a fixed welding speed of 50 mm/min, and the effects of rotation speed on the nugget zone macro- and microstructures were investigated in detail in order to illuminate the process features. Temperature measurements during HRS-FSW indicated that the peak temperature did not increase consistently with rotation speed; instead, it dropped remarkably at 5000 rpm because of the lowering of material shear stress. The nugget size first increased with rotation speed until 5000 rpm and then decreased due to the change of the dominant tool/workpiece contact condition from sticking to sliding. At the rotation speed of 5000 rpm, where the weld material experienced weaker thermal effect and higher-strain-rate plastic deformation, the nugget exhibited relatively small grain size, large textural intensity, and high dislocation density. Consequently, the joint showed superior nugget hardness and simultaneously a slightly low tensile ductility.

Structural Properties of EB-Welded AlSi10Mg Thin-Walled Pressure Vessels Produced by AM-SLM Technology

NASA Astrophysics Data System (ADS)

Nahmany, Moshe; Stern, Adin; Aghion, Eli; Frage, Nachum

2017-10-01

Additive manufacturing of metals by selective laser melting (AM-SLM) is hampered by significant limitations in product size due to the limited dimensions of printing trays. Electron beam welding (EBW) is a well-established process that results in relatively minor metallurgical modifications in workpieces due to the ability of EBW to pass high-density energy to the related substance. The present study aims to evaluate structural properties of EB-welded AlSi10Mg thin-walled pressure vessels produced from components prepared by SLM technology. Following the EB welding process, leak and burst tests were conducted, as was fractography analysis. The welded vessels showed an acceptable holding pressure of 30 MPa, with a reasonable residual deformation up to 2.3% and a leak rate better than 1 × 10-8 std-cc s-1 helium. The failures that occurred under longitudinal stresses reflected the presence of two weak locations in the vessels, i.e., the welded joint region and the transition zone between the vessel base and wall. Fractographic analysis of the fracture surfaces of broken vessels displayed the ductile mode of the rupture, with dimples of various sizes, depending on the failure location.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

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.

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

Investigation of Laser Parameters in Silicon Pulsed Laser Conduction Welding

NASA Astrophysics Data System (ADS)

Shayganmanesh, Mahdi; Khoshnoud, Afsaneh

2016-03-01

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

Room temperature mechanical properties of electron beam welded zircaloy-4 sheet

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

Parga, C. J.; Rooyen, I. J.; Coryell, B. D.

Room temperature mechanical properties of electron beam welded and plain Zircaloy-4 sheet (1.6mm thick) have been measured and compared. Various welding parameters were utilized to join sheet material. Electron beam welded specimens and as-received sheet specimens show comparable mechanical properties. Zr-4 sheet displays anisotropy; tensile properties measured for transverse display higher elastic modulus, yield strength, reduction of area and slightly lower ductility than for the longitudinal (rolling direction). Higher welding power increases the alloy’s hardness, elastic modulus and yield strength, with a corresponding decrease in tensile strength and ductility. The hardness measured at weld is comparable to the parent metalmore » hardness. Hardness at heat-affected-zone is slightly higher. Electron microscopic examination shows distinct microstructure morphology and grain size at the weld zone, HAZ and parent metal. A correlation between welding parameters, mechanical properties and microstructural features was established for electron beam welded Zircaloy-4 sheet material.« less

Room temperature mechanical properties of electron beam welded zircaloy-4 sheet

DOE PAGES

Parga, C. J.; Rooyen, I. J.; Coryell, B. D.; ...

2017-11-04

Room temperature mechanical properties of electron beam welded and plain Zircaloy-4 sheet (1.6mm thick) have been measured and compared. Various welding parameters were utilized to join sheet material. Electron beam welded specimens and as-received sheet specimens show comparable mechanical properties. Zr-4 sheet displays anisotropy; tensile properties measured for transverse display higher elastic modulus, yield strength, reduction of area and slightly lower ductility than for the longitudinal (rolling direction). Higher welding power increases the alloy’s hardness, elastic modulus and yield strength, with a corresponding decrease in tensile strength and ductility. The hardness measured at weld is comparable to the parent metalmore » hardness. Hardness at heat-affected-zone is slightly higher. Electron microscopic examination shows distinct microstructure morphology and grain size at the weld zone, HAZ and parent metal. A correlation between welding parameters, mechanical properties and microstructural features was established for electron beam welded Zircaloy-4 sheet material.« less

Repulsive Interaction of Sulfide Layers on Compressor Impeller Blades Remanufactured Through Plasma Spray Welding

NASA Astrophysics Data System (ADS)

Chang, Y.; Zhou, D.; Wang, Y. L.; Huang, H. H.

2016-12-01

This study investigated the repulsive interaction of sulfide layers on compressor impeller blades remanufactured through plasma spray welding (PSW). Sulfide layers on the blades made of FV(520)B steel were prepared through multifarious corrosion experiments, and PSW was utilized to remanufacture blade specimens. The specimens were evaluated through optical microscopy, scanning electron microscopy, energy-dispersive spectroscopy, 3D surface topography, x-ray diffraction, ImageJ software analysis, Vicker's micro-hardness test and tensile tests. Results showed a large number of sulfide inclusions in the fusion zone generated by sulfide layers embodied into the molten pool during PSW. These sulfide inclusions seriously degraded the mechanical performance of the blades remanufactured through PSW.

Analysis of metal transfer in gas metal arc welding

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

Kim, Y.S.; Eager, T.W.

1993-06-01

Droplet sizes produced in GMAW are predicted using both the static force balance theory and the pinch instability theory as a function of welding current, and the results are compared with experimental measurements. The causes for the deviation of predicted droplet size from measured size are discussed with suggestions for modification of the theories in order to more accurately model metal transfer in GMAW. The mechanism of repelled metal transfer is also discussed. The transition of metal transfer mode has been considered as a critical phenomenon which changes dramatically over a narrow range of welding current. This transition has beenmore » investigated experimentally using high-speed videography which shows that the transition is much more gradual than is generally believed. The mechanism of the transition is discussed using a modified static force balance theory.« less

Definition of the Mathematical Model Coefficients on the Weld Size of Butt Joint Without Edge Preparation

NASA Astrophysics Data System (ADS)

Sidorov, Vladimir P.; Melzitdinova, Anna V.

2017-10-01

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

Three-dimensional transient thermoelectric currents in deep penetration laser welding of austenite stainless steel

NASA Astrophysics Data System (ADS)

Chen, Xin; Pang, Shengyong; Shao, Xinyu; Wang, Chunming; Xiao, Jianzhong; Jiang, Ping

2017-04-01

The existence of thermoelectric currents (TECs) in workpieces during the laser welding of metals has been common knowledge for more than 15 years. However, the time-dependent evolutions of TECs in laser welding remain unclear. The present study developed a novel three-dimensional theoretical model of thermoelectric phenomena in the fiber laser welding of austenite stainless steel and used it to observe the time-dependent evolutions of TECs for the first time. Our model includes the complex physical effects of thermal, electromagnetic, fluid and phase transformation dynamics occurring at the millimeter laser ablated zone, which allowed us to simulate the TEC, self-induced magnetic field, Lorentz force, keyhole and weld pool behaviors varying with the welding time for different parameters. We found that TECs are truly three-dimensional, time-dependent, and uneven with a maximum current density of around 107 A/m2 located at the liquid-solid (L/S) interface near the front or bottom part of the keyhole at a laser power of 1.5 kW and a welding speed of 3 m/min. The TEC formed three-dimensional circulations moving from the melting front to solidification front in the solid part of workpiece, after which the contrary direction was followed in the liquid part. High frequency oscillation characteristics (2.2-8.5 kHz) were demonstrated in the TEC, which coincides with that of the keyhole instability (2.0-5.0 kHz). The magnitude of the self-induced magnetic field and Lorentz force can reach 0.1 mT and 1 kN/m3, respectively, which are both consistent with literature data. The predicted results of the weld dimensions by the proposed model agree well with the experimental results. Our findings could enhance the fundamental understanding of thermoelectric phenomena in laser welding.

Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

NASA Astrophysics Data System (ADS)

Patterson, Erin E.; Hovanski, Yuri; Field, David P.

2016-06-01

This work focuses on the microstructural characterization of aluminum to steel friction stir welded joints. Lap weld configuration coupled with scribe technology used for the weld tool have produced joints of adequate quality, despite the significant differences in hardness and melting temperatures of the alloys. Common to friction stir processes, especially those of dissimilar alloys, are microstructural gradients including grain size, crystallographic texture, and precipitation of intermetallic compounds. Because of the significant influence that intermetallic compound formation has on mechanical and ballistic behavior, the characterization of the specific intermetallic phases and the degree to which they are formed in the weld microstructure is critical to predicting weld performance. This study used electron backscatter diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers micro-hardness indentation to explore and characterize the microstructures of lap friction stir welds between an applique 6061-T6 aluminum armor plate alloy and a RHA homogeneous armor plate steel alloy. Macroscopic defects such as micro-cracks were observed in the cross-sectional samples, and binary intermetallic compound layers were found to exist at the aluminum-steel interfaces of the steel particles stirred into the aluminum weld matrix and across the interfaces of the weld joints. Energy dispersive spectroscopy chemical analysis identified the intermetallic layer as monoclinic Al3Fe. Dramatic decreases in grain size in the thermo-mechanically affected zones and weld zones that evidenced grain refinement through plastic deformation and recrystallization. Crystallographic grain orientation and texture were examined using electron backscatter diffraction. Striated regions in the orientations of the aluminum alloy were determined to be the result of the severe deformation induced by the complex weld tool geometry. Many of the textures observed in the weld zone and thermo-mechanically affected zones exhibited shear texture components; however, there were many textures that deviated from ideal simple shear. Factors affecting the microstructure which are characteristic of the friction stir welding process, such as post-recrystallization deformation and complex deformation induced by tool geometry were discussed as causes for deviation from simple shear textures.

Method of manufacturing corrosion resistant tubing from welded stock of titanium or titanium base alloy

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

Meredith, S.E.; Benjamin, J.F.

1993-07-13

A method is described of manufacturing corrosion resistant tubing from seam welded stock of a titanium or titanium based alloy, comprising: cold pilgering a seam welded tube hollow of titanium or titanium based alloy in a single pass to a final sized tubing, the tube hollow comprising a strip which has been bent and welded along opposed edges thereof to form the tube hollow, the tube hollow optionally being heat treated prior to the cold pilgering step provided the tube hollow is not heated to a temperature which would transform the titanium or titanium alloy into the beta phase, themore » cold pilgering effecting a reduction in cross sectional area of the tube hollow of at least 50% and a reduction of wall thickness of at least 50%, in order to achieve a radially oriented crystal structure; and annealing the final sized tubing at a temperature and time sufficient to effect complete recrystallization and reform grains in a weld area along the seam into smaller, homogeneous grains.« less

Tensile Properties of Friction Stir Welded Joints of AA 2024-T6 Alloy at Different Welding Speeds

NASA Astrophysics Data System (ADS)

Avula, Dhananjayulu; Devuri, Venkateswarlu; Cheepu, Muralimohan; Dwivedi, Dheerendra Kumar

2018-03-01

The influence of welding speed on the friction stir welded joint properties of hardness, tensile properties, defects and microstructure characterization are studied in the present study. The friction stir welding was conducted on AA2014-T6 heat treated alloy with 5 mm thickness plate in butt joint configuration. The welding speed was varied from 8 mm/min to 120 mm/min at the fixed travel speed and load conditions. It is observed that the welding speeds at higher rate with wide range can be possible to weld this alloy at higher rates of tool revolution suggesting that the inherent capability of friction stir welding technique for aluminum 2014 alloys. The strength of the joints gradually increases with enhancing of welding speed. The micro structural observations exhibited the formation of equiaxed grains in the stir zone and slightly in the thermo-mechanically affected zone. In addition, the size of the grains decreases with increase in welding speed owing to the presence of low heat input. Hence the hardness of the joints slightly increased in the stir zones over the other zones of the weld nugget. The joint strength initially increases with the welding speed and starts to decreases after reaching to the maximum value. The relationship between the welding conditions and friction stir welded joint properties has been discussed.

Towards and FVE-FAC Method for Determining Thermocapillary Effects on Weld Pool Shape

NASA Technical Reports Server (NTRS)

Canright, David; Henson, Van Emden

1996-01-01

Several practical materials processes, e.g., welding, float-zone purification, and Czochralski crystal growth, involve a pool of molten metal with a free surface, with strong temperature gradients along the surface. In some cases, the resulting thermocapillary flow is vigorous enough to convect heat toward the edges of the pool, increasing the driving force in a sort of positive feedback. In this work we examine this mechanism and its effect on the solid-liquid interface through a model problem: a half space of pure substance with concentrated axisymmetric surface heating, where surface tension is strong enough to keep the liquid free surface flat. The numerical method proposed for this problem utilizes a finite volume element (FVE) discretization in cylindrical coordinates. Because of the axisymmetric nature of the model problem, the control volumes used are torroidal prisms, formed by taking a polygonal cross-section in the (r, z) plane and sweeping it completely around the z-axis. Conservation of energy (in the solid), and conservation of energy, momentum, and mass (in the liquid) are enforced globally by integrating these quantities and enforcing conservation over each control volume. Judicious application of the Divergence Theorem and Stokes' Theorem, combined with a Crank-Nicolson time-stepping scheme leads to an implicit algebraic system to be solved at each time step. It is known that near the boundary of the pool, that is, near the solid-liquid interface, the full conduction-convection solution will require extremely fine length scales to resolve the physical behavior of the system. Furthermore, this boundary moves as a function of time. Accordingly, we develop the foundation of an adaptive refinement scheme based on the principles of Fast Adaptive Composite Grid methods (FAC). Implementation of the method and numerical results will appear in a later report.

Weld bead profile of laser welding dissimilar joints stainless steel

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

NASA Technical Reports Server (NTRS)

Nishioka, Owen S.

1997-01-01

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

Laser based spot weld characterization

NASA Astrophysics Data System (ADS)

Jonietz, Florian; Myrach, Philipp; Rethmeier, Michael; Suwala, Hubert; Ziegler, Mathias

2016-02-01

Spot welding is one of the most important joining technologies, especially in the automotive industry. Hitherto, the quality of spot welded joints is tested mainly by random destructive tests. A nondestructive testing technique offers the benefit of cost reduction of the testing procedure and optimization of the fabrication process, because every joint could be examined. This would lead to a reduced number of spot welded joints, as redundancies could be avoided. In the procedure described here, the spot welded joint between two zinc-coated steel sheets (HX340LAD+Z100MB or HC340LA+ZE 50/50) is heated optically on one side. Laser radiation and flash light are used as heat sources. The melted zone, the so called "weld nugget" provides the mechanical stability of the connection, but also constitutes a thermal bridge between the sheets. Due to the better thermal contact, the spot welded joint reveals a thermal behavior different from the surrounding material, where the heat transfer between the two sheets is much lower. The difference in the transient thermal behavior is measured with time resolved thermography. Hence, the size of the thermal contact between the two sheets is determined, which is directly correlated to the size of the weld nugget, indicating the quality of the spot weld. The method performs well in transmission with laser radiation and flash light. With laser radiation, it works even in reflection geometry, thus offering the possibility of testing with just one-sided accessibility. By using heating with collimated laser radiation, not only contact-free, but also remote testing is feasible. A further convenience compared to similar thermographic approaches is the applicability on bare steel sheets without any optical coating for emissivity correction. For this purpose, a proper way of emissivity correction was established.

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.

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.

Experimental Investigation on Friction Stir Welding of Cryorolled AA2219 Aluminum Alloy Joints

NASA Astrophysics Data System (ADS)

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

2017-07-01

In this paper, experimental investigation on cryorolled aluminum AA2219-T87 plate by using friction stir welding (FSW) process is carried out. AA2219-T87 plates with a size of 200×100×22.4 mm were rolled and reduced to 12.2mm thickness (more than 45% of reduction in total thickness of the base material) at cryogenic temperature (operating temperature range -90--30∘C). The cryorolled (CR) plates have reduced grain size, improved hardness and increased corrosion resistance property compared with the uncryorolled AA2219-T87 plates. FSW joints of cryorolled AA2219-T87 plates were prepared using cylindrical threaded FSW tool pin profile. Mechanical and metallurgical behaviors of friction stir welded joints were analyzed and the effects of the FSW process parameters are discussed in this paper. The variation of microhardness in the FSW joint regions were correlated with the microstructure of FSW joints. Cryorolled plate and FSW joints were tested for corrosion resistance using potentiodynamic polarization test. FSW joints shows better result during the corrosion resistance analysis compared to base AA2219-T87. The X-ray diffraction (XRD) test results showed that fine α-Al grains with eutectic phase (Al2Cu) were present in the weld nugget (WN). The large clusters of strengthening precipitates were reduced in size and merged with the weld nugget portion.

Welding processes for Inconel 718- A brief review

NASA Astrophysics Data System (ADS)

Tharappel, Jose Tom; Babu, Jalumedi

2018-03-01

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

Automatic Welding of Stainless Steel Tubing

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1978-01-01

To determine if the use of automatic welding would allow reduction of the radiographic inspection requirement, and thereby reduce fabrication costs, a series of welding tests were performed. In these tests an automatic welder was used on stainless steel tubing of 1/2, 3/4, and 1/2 inch diameter size. The optimum parameters were investigated to determine how much variation from optimum in machine settings could be tolerate and still result in a good quality weld. The process variables studied were the welding amperes, the revolutions per minute as a function of the circumferential weld travel speed, and the shielding gas flow. The investigation showed that the close control of process variables in conjunction with a thorough visual inspection of welds can be relied upon as an acceptable quality assurance procedure, thus permitting the radiographic inspection to be reduced by a large percentage when using the automatic process.

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

NASA Astrophysics Data System (ADS)

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

2003-11-01

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

Exposure of healthy subjects with emissions from a gas metal arc welding process: part 1--exposure technique and external exposure.

PubMed

Brand, P; Havlicek, P; Steiners, M; Holzinger, K; Reisgen, U; Kraus, T; Gube, M

2013-01-01

Studies concerning welding fume-related adverse health effects in welders are hampered by the heterogeneity of workplace situations, resulting in complex and non-standardized exposure conditions. In order to carry out welding fume exposure studies under controlled and standardized conditions, the Aachen Workplace Simulation Laboratory was developed. This laboratory consists of an emission room, in which welding fume is produced, and an exposure room in which human subjects are exposed to these fumes. Both rooms are connected by a ventilation system which allows the welding fume concentration to be regulated. Particle mass concentration was measured with a TEOM microbalance and the particle number-size distribution using a Grimm SMPS device. In a study, which is the subject of this paper, it has been shown that welding fume concentration can easily be regulated between 1 and about 3 mg m(-3). The chosen concentration can be kept constant for more than 8 h. However, transport of the particles from the emission room into the exposure room leads to a change in particle size distribution, which is probably due to coagulation of the fraction of smallest particles. The Aachen Workplace Simulation Laboratory is suitable for controlled exposure studies with human subjects.

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.

Cluster formation in in-service thermally aged pressurizer welds

NASA Astrophysics Data System (ADS)

Lindgren, Kristina; Boåsen, Magnus; Stiller, Krystyna; Efsing, Pål; Thuvander, Mattias

2018-06-01

Thermal aging of reactor pressure vessel steel welds at elevated temperatures may affect the ductile-to-brittle transition temperature. In this study, unique weld material from a pressurizer, with a composition similar to that of the reactor pressure vessel, that has been in operation for 28 years at 345 °C is examined. Despite the relatively low temperature, the weld becomes hardened during operation. This is attributed to nanometre sized Cu-rich clusters, mainly located at Mo- and C-enriched dislocation lines and on boundaries. The welds have been characterized using atom probe tomography, and the characteristics of the precipitates/clusters is related to the hardness increase, giving the best agreement for the Russell-Brown model.

Mechanical Properties and Microstructure of Dissimilar Friction Stir Welds of 11Cr-Ferritic/Martensitic Steel to 316 Stainless Steel

NASA Astrophysics Data System (ADS)

Sato, Yutaka S.; Kokawa, Hiroyuki; Fujii, Hiromichi T.; Yano, Yasuhide; Sekio, Yoshihiro

2015-12-01

Dissimilar joints between ferritic and austenitic steels are of interest for selected applications in next generation fast reactors. In this study, dissimilar friction-stir welding of an 11 pct Cr ferritic/martensitic steel to a 316 austenitic stainless steel was attempted and the mechanical properties and microstructure of the resulting welds were examined. Friction-stir welding produces a stir zone without macroscopic weld-defects, but the two dissimilar steels are not intermixed. The two dissimilar steels are interleaved along a sharp zigzagging interface in the stir zone. During small-sized tensile testing of the stir zone, this sharp interface did not act as a fracture site. Furthermore, the microstructure of the stir zone was refined in both the ferritic/martensitic steel and the 316 stainless steel resulting in improved mechanical properties over the adjacent base material regions. This study demonstrates that friction-stir welding can produce welds between dissimilar steels that contain no macroscopic weld-defects and display suitable mechanical properties.

Laser welding of fused quartz

DOEpatents

Piltch, Martin S.; Carpenter, Robert W.; Archer, III, McIlwaine

2003-06-10

Refractory materials, such as fused quartz plates and rods are welded using a heat source, such as a high power continuous wave carbon dioxide laser. The radiation is optimized through a process of varying the power, the focus, and the feed rates of the laser such that full penetration welds may be accomplished. The process of optimization varies the characteristic wavelengths of the laser until the radiation is almost completely absorbed by the refractory material, thereby leading to a very rapid heating of the material to the melting point. This optimization naturally occurs when a carbon dioxide laser is used to weld quartz. As such this method of quartz welding creates a minimum sized heat-affected zone. Furthermore, the welding apparatus and process requires a ventilation system to carry away the silicon oxides that are produced during the welding process to avoid the deposition of the silicon oxides on the surface of the quartz plates or the contamination of the welds with the silicon oxides.

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.

Abnormal macropore formation during double-sided gas tungsten arc welding of magnesium AZ91D alloy

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

Shen Jun; You Guoqiang; Long Siyuan

2008-08-15

One of the major concerns during gas tungsten arc (GTA) welding of cast magnesium alloys is the presence of large macroporosity in weldments, normally thought to occur from the presence of gas in the castings. In this study, a double-sided GTA welding process was adopted to join wrought magnesium AZ91D alloy plates. Micropores were formed in the weld zone of the first side that was welded, due to precipitation of H{sub 2} as the mushy zone freezes. When the reverse side was welded, the heat generated caused the mushy zone in the initial weld to reform. The micropores in themore » initial weld then coalesced and expanded to form macropores by means of gas expansion through small holes that are present at the grain boundaries in the partially melted zone. Macropores in the partially melted zone increase with increased heat input, so that when a filler metal is used the macropores are smaller in number and in size.« less

Remote Laser Welding of Zinc Coated Steel Sheets in an Edge Lap Configuration with Zero Gap

NASA Astrophysics Data System (ADS)

Roos, Christian; Schmidt, Michael

Remote Laser Welding (RLW) of zinc-coated steel sheets is a great challenge for the automotive industry but offers high potentials with respect to flexibility and costs. In state of the art applications, sheets are joined in overlap configuration with a preset gap for a stable zinc degassing. This paper investigates RLW of fillets without a preset gap and conditions for a stable process. The influence of process parameters on weld quality and process stability is shown. Experimental data give evidence, that the degassing of zinc through the capillary and the rear melt pool are the major degassing mechanisms. Furthermore the paper gives experimental validation of the zinc degassing in advance of the process zone to the open side of the fillet. Chemical analysis of the hot-dip galvanized zinc coating proof the iron-zinc-alloys to be the reason for a limited effectiveness of this mechanism in comparison to pure zinc as intermediate.

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.

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

NASA Astrophysics Data System (ADS)

Sham, Kin-Ling

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

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

NASA Technical Reports Server (NTRS)

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

1975-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

Personal exposure to ultrafine particles from PVC welding and concrete work during tunnel rehabilitation.

PubMed

Jørgensen, Rikke Bramming; Buhagen, Morten; Føreland, Solveig

2016-07-01

To investigate the exposure to number concentration of ultrafine particles and the size distribution in the breathing zone of workers during rehabilitation of a subsea tunnel. Personal exposure was measured using a TSI 3091 Fast Mobility Particle Sizer (FMPS), measuring the number concentration of submicrometre particles (including ultrafine particles) and the particle size distribution in the size range 5.6-560 nm. The measurements were performed in the breathing zone of the operators by the use of a conductive silicone tubing. Working tasks studied were operation of the slipforming machine, operations related to finishing the verge, and welding the PVC membrane. In addition, background levels were measured. Arithmetic mean values of ultrafine particles were in the range 6.26×10(5)-3.34×10(6). Vertical PVC welding gave the highest exposure. Horizontal welding was the work task with the highest maximum peak exposure, 8.1×10(7) particles/cm(3). Background concentrations of 4.0×10(4)-3.1×10(5) were found in the tunnel. The mobility diameter at peak particle concentration varied between 10.8 nm during horizontal PVC welding and during breaks and 60.4 nm while finishing the verge. PVC welding in a vertical position resulted in very high exposure of the worker to ultrafine particles compared to other types of work tasks. In evaluations of worker exposure to ultrafine particles, it seems important to distinguish between personal samples taken in the breathing zone of the worker and more stationary work area measurements. There is a need for a portable particle-sizing instrument for measurements of ultrafine particles in working environments. Published by the BMJ Publishing Group Limited. For permission to use (where not already granted under a licence) please go to http://www.bmj.com/company/products-services/rights-and-licensing/

Automated Agricultural Field Extraction from Multi-temporal Web Enabled Landsat Data

NASA Astrophysics Data System (ADS)

Yan, L.; Roy, D. P.

2012-12-01

Agriculture has caused significant anthropogenic surface change. In many regions agricultural field sizes may be increasing to maximize yields and reduce costs resulting in decreased landscape spatial complexity and increased homogenization of land uses with potential for significant biogeochemical and ecological effects. To date, studies of the incidence, drivers and impacts of changing field sizes have not been undertaken over large areas because of computational constraints and because consistently processed appropriate resolution data have not been available or affordable. The Landsat series of satellites provides near-global coverage, long term, and appropriate spatial resolution (30m) satellite data to document changing field sizes. The recent free availability of all the Landsat data in the U.S. Landsat archive now provides the opportunity to study field size changes in a global and consistent way. Commercial software can be used to extract fields from Landsat data but are inappropriate for large area application because they require considerable human interaction. This paper presents research to develop and validate an automated computational Geographic Object Based Image Analysis methodology to extract agricultural fields and derive field sizes from Web Enabled Landsat Data (WELD) (http://weld.cr.usgs.gov/). WELD weekly products (30m reflectance and brightness temperature) are classified into Satellite Image Automatic Mapper™ (SIAM™) spectral categories and an edge intensity map and a map of the probability of each pixel being agricultural are derived from five years of 52 weeks of WELD and corresponding SIAM™ data. These data are fused to derive candidate agriculture field segments using a variational region-based geometric active contour model. Geometry-based algorithms are used to decompose connected segments belonging to multiple fields into coherent isolated field objects with a divide and conquer strategy to detect and merge partial circle segments. Results are presented for several 5000 x 5000 30m pixel WELD tiles encompassing rectangular and circular (pivot irrigation) fields in Texas and California and the results are validated qualitatively by comparison with high spatial resolution images obtained from the National Geospatial-Intelligence Agency (NGA) Commercial Archive. Implications and recommendations for algorithm refinement and application to decadal conterminous United States WELD data are discussed.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Corneal tissue welding with infrared laser irradiation after clear corneal incision.

PubMed

Rasier, Rfat; Ozeren, Mediha; Artunay, Ozgür; Bahçecioğlu, Halil; Seçkin, Ismail; Kalaycoğlu, Hamit; Kurt, Adnan; Sennaroğlu, Alphan; Gülsoy, Murat

2010-09-01

The aim of this study was to investigate the potential of infrared lasers for corneal welding to seal corneal cuts done in an experimental animal model. Full-thickness corneal cuts on freshly enucleated bovine eyes were irradiated with infrared (809-nm diode, 980-nm diode, 1070-nm YLF, and 1980-nm Tm:YAP) lasers to get immediate laser welding. An 809-nm laser was used with the topical application of indocyanine green to enhance the photothermal interaction at the weld site. In total, 60 bovine eyes were used in this study; 40 eyes were used in the first part of the study for the determination of optimal welding parameters (15 eyes were excluded because of macroscopic carbonization, opacification, or corneal shrinkage; 2 eyes were used for control), and 20 eyes were used for further investigation of more promising lasers (YLF and Tm:YAP). Laser wavelength, irradiating power, exposure time, and spot size were the dose parameters, and optimal dose for immediate closure with minimal thermal damage was estimated through histological examination of welded samples. In the first part of the study, results showed that none of the applications was satisfactory. Full-thickness success rates were 28% (2 of 7) for 809-nm and for 980-nm diode lasers and 67% (2 of 3) for 1070-nm YLF and (4 of 6) for 1980-nm Tm:YAP lasers. In the second part of the study, YLF and Tm:YAP lasers were investigated with bigger sample size. Results were not conclusive but promising again. Five corneal incisions were full-thickness welded out of 10 corneas with 1070-nm laser, and 4 corneal incisions were partially welded out of 10 corneas with 1980-nm laser in the second part of the study. Results showed that noteworthy corneal welding could be obtained with 1070-nm YLF laser and 1980-nm Tm:YAP laser wavelengths. Furthermore, in vitro and in vivo studies will shed light on the potential usage of corneal laser welding technique.

The structural significance of HAZ sigma phase formation in welded 25%Cr super duplex pipework

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

Wiesner, C.S.; Garwood, S.J.; Bowden, P.L.

1993-12-31

The welding of 25%Cr duplex stainless steel can lead to the formation of sigma phase in both weld metal and heat affected zone (HAZ) regions. It has generally been accepted that this can be avoided by the adoption of appropriate welding procedure controls, generally aimed at reducing heat input and promoting rapid cooling rates. However, experience during pipe spool fabrication for the Marathon East Brae Project has shown that it is extremely difficult to satisfy a welding specification requiring sigma free HAZs. This has proved a particular problem with thin wall pipe welds made in the 2G/5G or 6G fixedmore » positions, where the joint geometry reduces heat flow away from the weld and welding conditions tend to result in the use of higher heat inputs. This paper examines the effect of sigma phase on the fracture toughness of 25%Cr super duplex steel (UNS S32760). It is shown that the CTOD toughness at {minus}20 C decreases as soon as any sigma phase is present and continues to decrease with increasing sigma levels. The toughness of the sigmatized specimens produced by heat treatment was shown to be conservative compared to the toughness measured in the HAZ of 14.2mm and 7.1mm thick pipe weldments, made with welding parameters chosen to enhance HAZ sigma phase formation. Based on the CTOD versus percent sigma level relationship derived from the laboratory specimens, fracture assessment calculations of tolerable flaw sizes were performed. These demonstrated that under the severest design conditions, assuming the maximum flaw sizes which could remain undetected in the pipework, sigma levels up to 2.5% can be tolerated safely. The conservatism of the fracture assessments for predicting the performance of weldments was demonstrated by full scale tensile testing of 2 inch nominal bore x 2.77 mm wall thickness pipe butt welds containing through-thickness circumferential fatigue cracks located in the sigmatized HAZ.« less

Assembly of 5.5-Meter Diameter Developmental Barrel Segments for the Ares I Upper Stage

NASA Technical Reports Server (NTRS)

Carter, Robert W.

2011-01-01

Full scale assembly welding of Ares I Upper Stage 5.5-Meter diameter cryogenic tank barrel segments has been performed at the Marshall Space Flight Center (MSFC). One full-scale developmental article produced under the Ares 1 Upper Stage project is the Manufacturing Demonstration Article (MDA) Barrel. This presentation will focus on the welded assembly of this barrel section, and associated lessons learned. Among the MDA articles planned on the Ares 1 Program, the Barrel was the first to be completed, primarily because the process of manufacture from piece parts (barrel panels) utilized the most mature friction stir process planned for use on the Ares US program: Conventional fixed pin Friction Stir Welding (FSW). This process is in use on other space launch systems, including the Shuttle s External Tank, the Delta IV common booster core, the Delta II, and the Atlas V rockets. The goals for the MDA Barrel development were several fold: 1) to prove out Marshall Space Flight Center s new Vertical Weld Tool for use in manufacture of cylindrical barrel sections, 2) to serve as a first run for weld qualification to a new weld specification, and 3) to provide a full size cylindrical section for downstream use in precision cleaning and Spray-on Foam Insulation development. The progression leading into the welding of the full size barrel included sub scale panel welding, subscale cylinder welding, a full length confidence weld, and finally, the 3 seamed MDA barrel processing. Lessons learned on this MDA program have been carried forward into the production tooling for the Ares 1 US Program, and in the use of the MSFC VWT in processing other large scale hardware, including two 8.4 meter diameter Shuttle External Tank barrel sections that are currently being used in structural analysis to validate shell buckling models.

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

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

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

NASA Astrophysics Data System (ADS)

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

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

The algorithm of verification of welding process for plastic pipes

NASA Astrophysics Data System (ADS)

Rzasinski, R.

2017-08-01

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

Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

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

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

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

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

NASA Astrophysics Data System (ADS)

Li, Caixia; Zhang, Xiaofeng; Wang, Jing

2018-04-01

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

Process Simulation of Gas Metal Arc Welding Software

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

Murray, Paul E.

2005-09-06

ARCWELDER is a Windows-based application that simulates gas metal arc welding (GMAW) of steel and aluminum. The software simulates the welding process in an accurate and efficient manner, provides menu items for process parameter selection, and includes a graphical user interface with the option to animate the process. The user enters the base and electrode material, open circuit voltage, wire diameter, wire feed speed, welding speed, and standoff distance. The program computes the size and shape of a square-groove or V-groove weld in the flat position. The program also computes the current, arc voltage, arc length, electrode extension, transfer ofmore » droplets, heat input, filler metal deposition, base metal dilution, and centerline cooling rate, in English or SI units. The simulation may be used to select welding parameters that lead to desired operation conditions.« less

Shear strength of fillet welds in aluminum alloy 2219. [for use on the solid rocket motor and external tank

NASA Technical Reports Server (NTRS)

Lovoy, C. V.

1978-01-01

Fillet size is discussed in terms of theoretical or design dimensions versus as-welded dimensions, drawing attention to the inherent conservatism in the design load sustaining capabilities of fillet welds. Emphasis is placed on components for the solid rocket motor, external tank, and other aerospace applications. Problems associated with inspection of fillet welds are addresses and a comparison is drawn between defect counts obtained by radiographic inspection and by visual examination of the fracture plane. Fillet weld quality is related linearly to ultimate shear strength. Correlation coefficients are obtained by simple straight line regression analysis between the variables of ultimate shear strength and accumulative discontinuity summation. Shear strength allowables are found to be equivalent to 57 percent of butt weld A allowables (F sub tu.)

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Characterisation of metallic glass incorporated Zircaloy-2 weldments

NASA Astrophysics Data System (ADS)

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

1995-12-01

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

Imrovement of operation stability of crucial parts and constructions when repairing dredges and other mining machines exploited in conditions of North

NASA Astrophysics Data System (ADS)

Broido, V. L.; Krasnoshtanov, S. U.

2018-03-01

The problems of a choice of rational technoloqy and materials for restoring crucial parts and large-sized welded constructions of dredges and other mining machines with use of methods of welding and surfasing are considered. Welding and surfacing occupy a significant share in the overall labor intensity of performing repair work at mining enterprises. Both manual arc welding and surfacing as well as mechanized methods are used, which ensure a 24-fold increase in productivity. The work shows examples of using the technology of restoring parts and structures at gold mining enterprises in Irkutsk region. Some marks of welding and surfasing materials are shown, which production is mastered by Irkutsk Heavy Engineering Plant (IZTM)

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

An Integrated Study on the Evolution of Inclusions in EH36 Shipbuilding Steel with Mg Addition: From Casting to Welding

NASA Astrophysics Data System (ADS)

Zou, Xiaodong; Zhao, Dapeng; Sun, Jincheng; Wang, Cong; Matsuura, Hiroyuki

2018-04-01

Inclusion evolution behaviors, in terms of composition, size, and number density, and associated influence on the microstructures of the as-cast slabs, rolled plates, and simulated welded samples of plain EH36 and EH36-Mg shipbuilding steels have been systematically investigated. The results indicate that the inclusions in the as-cast plain EH36 are almost Al-Ca-S-O-(Mn) complex oxides with sizes ranging from 1.0 to 2.0 μm. After Mg addition, a large amount of individually fine MnS precipitates and Mg-containing Ti-Al-Mg-O-(Mn-S) complex inclusions are generated, which significantly refine the microstructure and are conducive to the nucleation of acicular ferrite in the rolled and welded sample. Moreover, after rolling and welding thermal simulation, the number of individual MnS decreases gradually due to its precipitation on the surface of Ti-Al-Mg-O oxides.

Welding polarity effects on weld spatters and bead geometry of hyperbaric dry GMAW

NASA Astrophysics Data System (ADS)

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

2016-03-01

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

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

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.

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.

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.

Internal wire guide for GTAW welding

NASA Technical Reports Server (NTRS)

Morgan, Gene E. (Inventor); Dyer, Gerald E. (Inventor)

1989-01-01

A welding torch for gas tungsten arc welding apparatus has a filler metal wire guide positioned within the torch, and within the shielding gas nozzle. The wire guide is adjacent to the tungsten electrode and has a ceramic liner through which the wire is fed. This reduces the size of the torch and eliminates the outside clearance problems that exit with external wire guides. Additionally, since the wire is always within the shielding gas, oxidizing of the wire is eliminated.

Deformation behavior of laser welds in high temperature oxidation resistant Fe-Cr-Al alloys for fuel cladding applications

NASA Astrophysics Data System (ADS)

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

2014-11-01

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

Experimental Investigation of Mechanical Properties of Welded Corten Steel A588 Grade Plate Using ER70S - 6 Filler Material for Construction Application

NASA Astrophysics Data System (ADS)

Deepak, J. R.; Bupesh Raja, V. K.; Janardhan Guptha, Mittapalli; Durga Prasad, Palaparthi Hari; Sriram, V.

2017-05-01

ASTM A588 Grade A steel plate is a high strength, low alloy structural steel with 0.19 % of carbon content. When exposed to the atmosphere, A588 Grade A is suitable for construction in the bare (paint - free) condition. The main problems are lack of fusion, lack of penetration and corrosion on heat affected zone. In this research work Corten ASTM A588 Grade steel of 3mm thickness is electroplated with copper and then both raw and copper electroplated are welded by GMAW welding process with ER70S-6 as a filler material. The welded ASTM A588 is cut according to ASTM size for further testing of mechanical properties. Considering its welding strength after the process of electroplating, this research clearly states the metal can be utilized for better results in any given field. Here both the tensile and hardness are higher in copper electroplated welded when compare to raw welded.

The effect of travel speed on thermal response in CO2 laser welding of small electronic components

NASA Astrophysics Data System (ADS)

Gianoulakis, S. E.; Burchett, S. N.; Fuerschbach, P. W.; Knorovsky, G. A.

A comprehensive three-dimensional numerical investigation of the effect of beat source travel speed on temperatures and resulting thermal stresses was performed for CO2-laser welding. The test specimen was a small thermal battery header containing several stress-sensitive glass-to-metal seals surrounding the electrical connections and a temperature sensitive ignitor located under the header near the center. Predictions of the thermal stresses and temperatures in the battery header were made for several travel speeds of the laser. The travel speeds examined ranged from 10mm/sec to 50mm/sec. The results indicate that faster weld speeds result in lower temperatures and stresses for the same size weld. This is because the higher speed welds are more efficient, requiring less energy to produce a given weld. Less energy absorbed by the workpiece results in lower temperatures, which results in lower stresses.

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

PubMed Central

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

2016-01-01

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

Continuous internal channels formed in aluminum fusion welds

NASA Technical Reports Server (NTRS)

Gault, J.; Sabo, W.

1967-01-01

Process produces continuous internal channel systems on a repeatable basis in 2014-T6 aluminum. Standard machining forms the initial channel, which is filled with tungsten carbide powder. TIG machine fusion welding completes formation of the channel. Chem-mill techniques enlarge it to the desired size.

SRF test facility for the superconducting LINAC ``RAON'' — RRR property and e-beam welding

NASA Astrophysics Data System (ADS)

Jung, Yoochul; Hyun, Myungook; Joo, Jongdae; Joung, Mijoung

2015-02-01

Equipment, such as a vacuum furnace, high pressure rinse (HPR), eddy current test (ECT) and buffered chemical polishing (BCP), are installed in the superconducting radio frequency (SRF) test facility. Three different sizes of cryostats (diameters of 600 mm for a quarter wave resonator (QWR), 900 mm for a half wave resonator (HWR), and 1200 mm for single spoke resonator 1&2 (SSR 1&2)) for vertical RF tests are installed for testing cavities. We confirmed that as-received niobium sheets (ASTM B393, RRR300) good electrical properties because they showed average residual resistance ratio (RRR) values higher than 300. However, serious RRR degradation occurred after joining two pieces of Nb by e-beam welding because the average RRR values of the samples were ˜179, which was only ˜60% of as-received RRR value. From various e-beam welding experiments in which the welding current and a speed at a fixed welding voltage were changed, we confirmed that good welding results were obtained at a 53 mA welding current and a 20-mm/s welding speed at a fixed welding voltage of 150 kV.

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

NASA Astrophysics Data System (ADS)

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

2015-03-01

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

Microstructure and Mechanical Performance of Friction Stir Spot-Welded Aluminum-5754 Sheets

NASA Astrophysics Data System (ADS)

Pathak, N.; Bandyopadhyay, K.; Sarangi, M.; Panda, Sushanta Kumar

2013-01-01

Friction stir spot welding (FSSW) is a recent trend of joining light-weight sheet metals while fabricating automotive and aerospace body components. For the successful application of this solid-state welding process, it is imperative to have a thorough understanding of the weld microstructure, mechanical performance, and failure mechanism. In the present study, FSSW of aluminum-5754 sheet metal was tried using tools with circular and tapered pin considering different tool rotational speeds, plunge depths, and dwell times. The effects of tool design and process parameters on temperature distribution near the sheet-tool interface, weld microstructure, weld strength, and failure modes were studied. It was found that the peak temperature was higher while welding with a tool having circular pin compared to tapered pin, leading to a bigger dynamic recrystallized stir zone (SZ) with a hook tip bending towards the upper sheet and away from the keyhole. Hence, higher lap shear separation load was observed in the welds made from circular pin compared to those made from tapered pin. Due to influence of size and hardness of SZ on crack propagation, three different failure modes of weld nugget were observed through optical cross-sectional micrograph and SEM fractographs.

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

NASA Astrophysics Data System (ADS)

Sifa, A.; Endramawan, T.; Badruzzaman

2017-03-01

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

Milestones in welding technology

NASA Astrophysics Data System (ADS)

Dolby, Richard E.

2013-09-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-07-01

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

Effects of welding and post-weld heat treatments on nanoscale precipitation and mechanical properties of an ultra-high strength steel hardened by NiAl and Cu nanoparticles

DOE PAGES

Jiao, Z. B.; Luan, J. H.; Guo, W.; ...

2016-09-01

The effects of welding and post-weld heat treatment (PWHT) on nanoscale co-precipitation, grain structure, and mechanical properties of an ultra-high strength steel were studied through a combination of atom probe tomography (APT) and mechanical tests. Our results indicate that the welding process dissolves all pre-existing nanoparticles and causes grain coarsening in the fusion zone, resulting in a soft and ductile weld without any cracks in the as-welded condition. A 550 °C PWHT induces fine-scale re-precipitation of NiAl and Cu co-precipitates with high number densities and ultra-fine sizes, leading to a large recovery of strength but a loss of ductility withmore » intergranular failure, whereas a 600 °C PWHT gives rise to coarse-scale re-precipitation of nanoparticles together with the formation of a small amount of reverted austenite, resulting in a great recovery in both strength and ductility. Our analysis indicates that the degree of strength recovery is dependent mainly upon the re-precipitation microstructure of nanoparticles, together with grain size and reversion of austenite, while the ductility recovery is sensitive to the grain-boundary structure. In conclusion, APT reveals that the grain-boundary segregation of Mn and P may be the main reason for the 550 °C embrittlement, and the enhanced ductility at 600 °C is ascribed to a possible reduction of the segregation and reversion of austenite.« less

Effects of welding and post-weld heat treatments on nanoscale precipitation and mechanical properties of an ultra-high strength steel hardened by NiAl and Cu nanoparticles

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

Jiao, Z. B.; Luan, J. H.; Guo, W.

The effects of welding and post-weld heat treatment (PWHT) on nanoscale co-precipitation, grain structure, and mechanical properties of an ultra-high strength steel were studied through a combination of atom probe tomography (APT) and mechanical tests. Our results indicate that the welding process dissolves all pre-existing nanoparticles and causes grain coarsening in the fusion zone, resulting in a soft and ductile weld without any cracks in the as-welded condition. A 550 °C PWHT induces fine-scale re-precipitation of NiAl and Cu co-precipitates with high number densities and ultra-fine sizes, leading to a large recovery of strength but a loss of ductility withmore » intergranular failure, whereas a 600 °C PWHT gives rise to coarse-scale re-precipitation of nanoparticles together with the formation of a small amount of reverted austenite, resulting in a great recovery in both strength and ductility. Our analysis indicates that the degree of strength recovery is dependent mainly upon the re-precipitation microstructure of nanoparticles, together with grain size and reversion of austenite, while the ductility recovery is sensitive to the grain-boundary structure. In conclusion, APT reveals that the grain-boundary segregation of Mn and P may be the main reason for the 550 °C embrittlement, and the enhanced ductility at 600 °C is ascribed to a possible reduction of the segregation and reversion of austenite.« less

Radiation and annealing response of WWER 440 beltline welding seams

NASA Astrophysics Data System (ADS)

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

2015-01-01

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

Friction Stir Weld Restart+Reweld Repair Allowables

NASA Technical Reports Server (NTRS)

Clifton, Andrew

2008-01-01

A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

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

PubMed

Mroczka, K; Dutkiewicz, J; Pietras, A

2010-03-01

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

Direct welding of glass and metal by 1  kHz femtosecond laser pulses.

PubMed

Zhang, Guodong; Cheng, Guanghua

2015-10-20

In the welding process between similar or dissimilar materials, inserting an intermediate layer and pressure assistance are usually thought to be necessary. In this paper, the direct welding between alumina-silicate glass and metal (aluminum, copper, and steel), under exposure from 1 kHz femtosecond laser pulses without any auxiliary processes, is demonstrated. The micron/nanometer-sized metal particles induced by laser ablation were considered to act as the adhesive in the welding process. The welding parameters were optimized by varying the pulse energy and the translation velocity of the sample. The shear joining strength characterized by a shear force testing equipment was as high as 2.34 MPa. This direct bonding technology has potential for applications in medical devices, sensors, and photovoltaic devices.

Characterization of Microstructure and Texture of 13Cr4Ni Martensitic Stainless Steel Weld Before and After Tempering =

NASA Astrophysics Data System (ADS)

Mokhtabad Amrei, Mohsen

13Cr4Ni martensitic stainless steels are known for their outstanding performances in the hydroelectric industry, where they are mainly used in the construction of turbine components. Considering the size and geometry of turbine runners and blades, multi-pass welding procedures are commonly used in the fabrication and repair of such turbines. The final microstructure and mechanical properties of the weld are sensitive to the welding process parameters and thermal history. In the case of 13Cr4Ni steel, the thermal cycles imposed by the multi-pass welding operation have significant effects on the complex weld microstructure. Additionally, post-weld heat treatments are commonly used to reduce weld heterogeneity and improve the material's mechanical properties by tempering the microstructure and by forming a "room-temperature-stable austenite." In the first phase of this research, the microstructures and crystallographic textures of aswelded single-pass and double-pass welds were studied as a basis to studying the more complex multi-pass weld microstructure. This study found that the maximum hardness is obtained in high temperature heat affected zone inside the base metal. In particular, the results showed that the heat cycle exposed by the second pass increases the hardness of the previous pass because it produces a finer martensite microstructure. In areas of heat affected zone, a tempering effect is reported from 3 up to 6 millimeters far from the fusion line. Finding austenite phase in these areas are matter of interest and it can be indicative of the microstructure complexity of multi-pass welds. In the second phase of research, the microstructure of multi-pass welds was found to be more heterogeneous than that of single- and double-pass welds. Any individual pass in a multi-pass weld consists of several regions formed by adjacent weld passes heat cycle. Results showed that former austenite grains modification occurred in areas close to the subsequent weld passes. Furthermore, low angle interface laths were observed inside martensite sub-blocks over different regions. The hardness profile of a multi-pass weld was explained by the overlaying heat effects of surrounding passes. In some regions, a tempered matrix was observed, while in other regions a double-quenched microstructure was found. The final aspect of this study focused on the effects of post-weld heat treatments on reformed austenite and carbide formations, and evolution of hardness. The effects of tempering duration and temperature on microstructure were investigated. The study found that nanometer-sized carbides form at martensite lath interfaces and sub-block boundaries. Additionally, it was determined that for any holding duration, the maximum austenite percentage is achievable by tempering at 610 °C. Similarly, the maximum softening was reported for tempering at 610 °C, for any given holding period.

Beam Splitter For Welding-Torch Vision System

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.

1991-01-01

Compact welding torch equipped with along-the-torch vision system includes cubic beam splitter to direct preview light on weldment and to reflect light coming from welding scene for imaging. Beam splitter integral with torch; requires no external mounting brackets. Rugged and withstands vibrations and wide range of temperatures. Commercially available, reasonably priced, comes in variety of sizes and optical qualities with antireflection and interference-filter coatings on desired faces. Can provide 50 percent transmission and 50 percent reflection of incident light to exhibit minimal ghosting of image.

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.

Technique of laser chromosome welding for chromosome repair and artificial chromosome creation.

PubMed

Huang, Yao-Xiong; Li, Lin; Yang, Liu; Zhang, Yi

2018-04-01

Here we report a technique of laser chromosome welding that uses a violet pulse laser micro-beam for welding. The technique can integrate any size of a desired chromosome fragment into recipient chromosomes by combining with other techniques of laser chromosome manipulation such as chromosome cutting, moving, and stretching. We demonstrated that our method could perform chromosomal modifications with high precision, speed and ease of use in the absence of restriction enzymes, DNA ligases and DNA polymerases. Unlike the conventional methods such as de novo artificial chromosome synthesis, our method has no limitation on the size of the inserted chromosome fragment. The inserted DNA size can be precisely defined and the processed chromosome can retain its intrinsic structure and integrity. Therefore, our technique provides a high quality alternative approach to directed genetic recombination, and can be used for chromosomal repair, removal of defects and artificial chromosome creation. The technique may also have applicability on the manipulation and extension of large pieces of synthetic DNA.

Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys

NASA Astrophysics Data System (ADS)

Hamilton, C.; Kopyściański, M.; Dymek, S.; Węglowska, A.; Pietras, A.

2018-03-01

Wrought aluminum alloys 5083 and 2017A were each joined with cast aluminum alloy AlSi9Mg through friction stir welding in butt weld configurations. For each material system, the wrought and cast alloy positions, i.e., the advancing side or the retreating side, were exchanged between welding trials. The produced weldments were free from cracks and discontinuities. For each alloy configuration, a well-defined nugget comprised of alternating bands of the welded alloys characterized the microstructure. The degree of mixing, however, strongly depended on which wrought alloy was present and on its position during processing. In all cases, the cast AlSi9Mg alloy dominated the weld center regardless of its position during welding. Electron backscattered diffraction analysis showed that the grain size in both alloys (bands) constituting the nugget was similar and that the majority of grain boundaries exhibited a high angle character (20°-60°). Regardless of the alloy, however, all grains were elongated along the direction of the material plastic flow during welding. A numerical simulation of the joining process visualized the material flow patterns and temperature distribution and helped to rationalize the microstructural observations. The hardness profiles across the weld reflected the microstructure formed during welding and correlated well with the temperature changes predicted by the numerical model. Tensile specimens consistently fractured in the cast alloy near the weld nugget.

Detailed Microstructural Characterization and Restoration Mechanisms of Duplex and Superduplex Stainless Steel Friction-Stir-Welded Joints

NASA Astrophysics Data System (ADS)

Santos, T. F. A.; Torres, E. A.; Lippold, J. C.; Ramirez, A. J.

2016-12-01

Duplex stainless steels are successfully used in a wide variety of applications in areas such as the food industry, petrochemical installations, and sea water desalination plants, where high corrosion resistance and high mechanical strength are required. However, during fusion welding operations, there can be changes to the favorable microstructure of these materials that compromise their performance. Friction stir welding with a non-consumable pin enables welded joints to be obtained in the solid state, which avoids typical problems associated with solidification of the molten pool, such as segregation of alloying elements and the formation of solidification and liquefaction cracks. In the case of superduplex stainless steels, use of the technique can avoid unbalanced proportions of ferrite and austenite, formation of deleterious second phases, or growth of ferritic grains in the heat-affected zone. Consolidated joints with full penetration were obtained for 6-mm-thick plates of UNS S32101 and S32205 duplex stainless steels, and S32750 and S32760 superduplex steels. The welding heat cycles employed avoided the conditions required for formation of deleterious phases, except in the case of the welded joint of the S32760 steel, where SEM images indicated the formation of secondary phases, as corroborated by decreased mechanical performance. Analysis using EBSD and transmission electron microscopy revealed continuous dynamic recrystallization by the formation of cellular arrays of dislocations in the ferrite and discontinuous dynamic recrystallization in the austenite. Microtexture evaluation indicated the presence of fibers typical of shear in the thermomechanically affected zone. These fibers were not obviously present in the stir zone, probably due to the intensity of microstructural reformulation to which this region was subjected.

[18F](2S,4R)4-Fluoroglutamine PET Detects Glutamine Pool Size Changes in Triple Negative Breast Cancer in Response to Glutaminase Inhibition

PubMed Central

Pantel, Austin R.; Li, Shihong; Lieberman, Brian P.; Ploessl, Karl; Choi, Hoon; Blankemeyer, Eric; Lee, Hsiaoju; Kung, Hank F.; Mach, Robert H.

2017-01-01

Glutaminolysis is a metabolic pathway adapted by many aggressive cancers, including triple-negative breast cancers (TNBC), to utilize glutamine for survival and growth. In this study, we examined the utility of [18F](2S,4R)4-fluoroglutamine ([18F]4F-Gln) PET to measure tumor cellular glutamine pool size, whose change might reveal the pharmacodynamic (PD) effect of drugs targeting this cancer-specific metabolic pathway. High glutaminase (GLS) activity in TNBC tumors resulted in low cellular glutamine pool size assayed via high-resolution 1H magnetic resonance spectroscopy (MRS). GLS inhibition significantly increased glutamine pool size in TNBC tumors. MCF-7 tumors, with inherently low GLS activity compared to TNBC, displayed a larger baseline glutamine pool size that did not change as much in response to GLS inhibition. The tumor-to-blood-activity-ratios (T/B) obtained from [18F]4F-Gln PET images matched the distinct glutamine pool sizes of both tumor models at baseline. After a short course of GLS inhibitor treatment, the T/B values increased significantly in TNBC, but did not change in MCF-7 tumors. Across both tumor types and after GLS inhibitor or vehicle treatment, we observed a strong positive correlation between T/B values and tumor glutamine pool size measured using MRS (R2=0.71). In conclusion, [18F]4F-Gln PET tracked cellular glutamine pool size in breast cancers with differential GLS activity and detected increases in cellular glutamine pool size induced by GLS inhibitors. This study accomplished the first necessary step towards validating [18F]4F-Gln PET as a PD marker for glutaminase-targeting drugs. PMID:28202527

PWHT effect on the mechanical properties of borated stainless steel GTA weldments for nuclear shield

NASA Astrophysics Data System (ADS)

Park, T.-D.; Baek, K.-K.; Kim, D.-S.

1997-02-01

To improve ductility of the welded joint of B-added austenitic stainless steels, postweld annealing effect has been studied. Gas Tungsten Arc (GTA) welds of AlSI 304-B3 stainless steel plates were annealed either at 700 1100°C for 1 hour or at 1100°C and 1200°C, for 1 7 hours. Bending test of the welds in as-welded and annealed conditions resulted in cracks propagated along the welds' fusion line except the one annealed at 1200°C, which revealed no cracks. Tensile elongations of the as-welded and annealed welds at the temperature up to 1000°C were only a half value of the base metal, whereas the welds annealed at 1200°C had fully recovered the original elongation of the base metal. Charpy impact test result exhibited the same tendency with annealing temperature. Elongated and accicular morphology of Y-(Cr, Fe)2B eutectic phase at the Partially Melted Heat Affected Zone (P.M.HAZ) of welds seemed to be responsible for the poor ductility of the welds. The welds annealed at 1200°C for various durations, on the other hand, showed fully spheroidized eutectic phases at the P.M.HAZ with its size increased with annealing durations, suggesting that postweld annealing at the temperature as high as 1200°C is required for the welds to have ductility matching that of base metal.

Ductility dip cracking susceptibility of Inconel Filler Metal 52 and Inconel Alloy 690

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

Kikel, J.M.; Parker, D.M.

1998-06-01

Alloy 690 and Filler Metal 52 have become the materials of choice for commercial nuclear steam generator applications in recent years. Filler Metal 52 exhibits improved resistance to weld solidification and weld-metal liquation cracking as compared to other nickel-based filler metals. However, recently published work indicates that Filler Metal 52 is susceptible to ductility dip cracking (DDC) in highly restrained applications. Susceptibility to fusion zone DDC was evaluated using the transverse varestraint test method, while heat affected zone (HAZ) DDC susceptibility was evaluated using a newly developed spot-on-spot varestraint test method. Alloy 690 and Filler Metal 52 cracking susceptibility wasmore » compared to the DDC susceptibility of Alloy 600, Filler Metal 52, and Filler Metal 625. In addition, the effect of grain size and orientation on cracking susceptibility was also included in this study. Alloy 690, Filler Metal 82, Filler Metal 52, and Filler Metal 625 were found more susceptible to fusion zone DDC than Alloy 600. Filler Metal 52 and Alloy 690 were found more susceptible to HAZ DDC when compared to wrought Alloy 600, Filler Metal 82 and Filler Metal 625. Filler Metal 52 exhibited the greatest susceptibility to HAZ DDC of all the weld metals evaluated. The base materials were found much more resistant to HAZ DDC in the wrought condition than when autogenously welded. A smaller grain size was found to offer greater resistance to DDC. For weld metal where grain size is difficult to control, a change in grain orientation was found to improve resistance to DDC.« less

The particle size distribution, density, and specific surface area of welding fumes from SMAW and GMAW mild and stainless steel consumables.

PubMed

Hewett, P

1995-02-01

Particle size distributions were measured for fumes from mild steel (MS) and stainless steel (SS); shielded metal arc welding (SMAW) and gas metal arc welding (GMAW) consumables. Up to six samples of each type of fume were collected in a test chamber using a micro-orifice uniform deposit (cascade) impactor. Bulk samples were collected for bulk fume density and specific surface area analysis. Additional impactor samples were collected using polycarbonate substrates and analyzed for elemental content. The parameters of the underlying mass distributions were estimated using a nonlinear least squares analysis method that fits a smooth curve to the mass fraction distribution histograms of all samples for each type of fume. The mass distributions for all four consumables were unimodal and well described by a lognormal distribution; with the exception of the GMAW-MS and GMAW-SS comparison, they were statistically different. The estimated mass distribution geometric means for the SMAW-MS and SMAW-SS consumables were 0.59 and 0.46 micron aerodynamic equivalent diameter (AED), respectively, and 0.25 micron AED for both the GMAW-MS and GMAW-SS consumables. The bulk fume densities and specific surface areas were similar for the SMAW-MS and SMAW-SS consumables and for the GMAW-MS and GMAW-SS consumables, but differed between SMAW and GMAW. The distribution of metals was similar to the mass distributions. Particle size distributions and physical properties of the fumes were considerably different when categorized by welding method. Within each welding method there was little difference between MS and SS fumes.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Analysis of plasma characteristics and conductive mechanism of laser assisted pulsed arc welding

NASA Astrophysics Data System (ADS)

Liu, Shuangyu; Chen, Shixian; Wang, Qinghua; Li, Yanqing; Zhang, Hong; Ding, Hongtao

2017-05-01

This study aims to investigate the arc plasma shape and the spectral characteristics during the laser assisted pulsed arc welding process. The arc plasma shape was synchronously observed using a high speed camera, and the emission spectrum of plasma was obtained by spectrometer. The well-known Boltzmann plot method and Stark broadening were used to calculate the electron temperature and density respectively. The conductive mechanism of arc ignition in laser assisted arc hybrid welding was investigated, and it was found that the plasma current moved to the arc anode under the action of electric field. Thus, a significant parabolic channel was formed between the keyhole and the wire tip. This channel became the main method of energy transformation between the arc and the molten pool. The calculation results of plasma resistivity show that the laser plasma has low resistivity as the starting point of conductive channel formation. When the laser pulse duration increases, the intensity of the plasma radiation spectrum and the plasma electron density will increase, and the electron temperature will decrease.

The Effect of Oscillating Traverse Welding on Performance of Cr-Fe-C Hardfacing Alloys

NASA Astrophysics Data System (ADS)

Lai, Hsuan-Han; Hsieh, Chih-Chun; Wang, Jia-Siang; Lin, Chi-Ming; Wu, Weite

2015-11-01

In this study, a series of experiments involving Cr-Fe-C hardfacing alloys is conducted to evaluate the effect of oscillating traverse welding on microstructure and performance of clad alloys. The alloys are designed to exhibit hypoeutectic, eutectic, and hypereutectic morphology. The morphology of the heat-affected zone (HAZ) of the unmelted metal, the solidified remelted metal, and the fusion boundary exhibited distinct characteristics. In the hypoeutectic and the eutectic alloys, the same lamellar eutectic structure can be observed as the solidified structure, and they also showed the same evolution in the HAZ. In the hypereutectic alloy, the incomplete weld pool blending results in a eutectic morphology instead of a fully hypereutectic morphology. The hardness result reveals that, for the hypereutectic alloy, the eutectic region, instead of the HAZ, is the weak point. The wear test shows that the hypoeutectic alloy exhibits the same wear behaviors in both the remelted metal and the HAZ, and so is the hypereutectic alloy; the eutectic alloy remelted metal and the HAZ have different wear morphologies.

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

Manufacturing and assembly of IWS support rib and lower bracket for ITER vacuum vessel

NASA Astrophysics Data System (ADS)

Laad, R.; Sarvaiya, Y.; Pathak, H. A.; Raval, J. R.; Choi, C. H.

2017-04-01

ITER Vacuum Vessel (VV) is made of double walls connected by ribs structure and flexible housings. Space between these walls is filled up with In Wall Shielding (IWS) blocks to (1) shield neutrons streaming out of plasma and (2) reduce toroidal magnetic field ripple. These blocks will be connected to the VV through a supporting structure of Support Rib (SR) and Lower Bracket (LB) assembly. SR and LB are two independent components manufactured from SS 316L(N)-IG, Total 1584 support ribs and 3168 lower bracket of different sizes and shapes will be manufactured for the IWS. Two lower brackets will be welded with one support rib to make an assembly. The welding between SR and LB is a full penetration welding. Total 1584 assemblies of different sizes and shapes will be manufactured. Sufficient experience gained from manufacturing and testing of mock ups, final manufacturing of IWS support rib and lower bracket has been started at the site of IWS manufacturer M/s. Avasarala Technologies Limited (ATL). This paper will describe, optimization of water jet cutting speed on IWS material, selection criteria for K type weld joint, unique features of fixture of assembly, manufacturing of Mock ups, and welding processes with NDTs.

Characterization of Tungsten Inert Gas (TIG) Welding Fume Generated by Apprentice Welders

PubMed Central

Graczyk, Halshka; Lewinski, Nastassja; Zhao, Jiayuan; Concha-Lozano, Nicolas; Riediker, Michael

2016-01-01

Tungsten inert gas welding (TIG) represents one of the most widely used metal joining processes in industry. Its propensity to generate a greater portion of welding fume particles at the nanoscale poses a potential occupational health hazard for workers. However, current literature lacks comprehensive characterization of TIG welding fume particles. Even less is known about welding fumes generated by welding apprentices with little experience in welding. We characterized TIG welding fume generated by apprentice welders (N = 20) in a ventilated exposure cabin. Exposure assessment was conducted for each apprentice welder at the breathing zone (BZ) inside of the welding helmet and at a near-field (NF) location, 60cm away from the welding task. We characterized particulate matter (PM4), particle number concentration and particle size, particle morphology, chemical composition, reactive oxygen species (ROS) production potential, and gaseous components. The mean particle number concentration at the BZ was 1.69E+06 particles cm−3, with a mean geometric mean diameter of 45nm. On average across all subjects, 92% of the particle counts at the BZ were below 100nm. We observed elevated concentrations of tungsten, which was most likely due to electrode consumption. Mean ROS production potential of TIG welding fumes at the BZ exceeded average concentrations previously found in traffic-polluted air. Furthermore, ROS production potential was significantly higher for apprentices that burned their metal during their welding task. We recommend that future exposure assessments take into consideration welding performance as a potential exposure modifier for apprentice welders or welders with minimal training. PMID:26464505

Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

NASA Astrophysics Data System (ADS)

Stavinoha, Joe N.

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

Friction Stir Welding of Al Alloy 2219-T8: Part I-Evolution of Precipitates and Formation of Abnormal Al2Cu Agglomerates

NASA Astrophysics Data System (ADS)

Kang, Ju; Feng, Zhi-Cao; Frankel, G. S.; Huang, I. Wen; Wang, Guo-Qing; Wu, Ai-Ping

2016-09-01

Friction stir welding was performed on AA2219-T8 plates with 6.31 wt pct Cu. The thermal cycles were measured in different regions of the joint during welding. Differential scanning calorimetry and transmission electron microscopy were utilized to analyze the evolution of precipitates in the joint. The relationships between welding peak temperature, precipitate evolution, and microhardness distribution are discussed. The temperature in the heat-affected zone (HAZ) ranged from 453 K to 653 K (180 °C to 380 °C). The θ″ and some θ' phases redissolved into the HAZ matrix, while the rest of the θ' phases coarsened. In the thermomechanically affected zone (TMAZ), the temperature range was from 653 K to 673 K (380 °C to 400 °C), causing both θ″ phase and θ' phase to redissolve. In the weld nugget zone (WNZ), all the θ″, θ', and some of the θ phase (Al2Cu) redissolved. Abnormal θ particles were observed in the WNZ, including agglomerated θ with sizes around 100 to 1000 µm and a ring-shaped distribution of normal size θ particles. The formation of abnormal θ particles resulted from metal plastic flow during welding and the high content of Cu in AA2219. No abnormal θ particles were observed in joints of another AA2219 plate, which had a lower Cu content of 5.83 wt pct.

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.

Study of fatigue behavior of longitudinal welded pipes

NASA Astrophysics Data System (ADS)

Simion, P.; Dia, V.; Istrate, B.; Hrituleac, G.; Hrituleac, I.; Munteanu, C.

2016-08-01

During transport and storage of the various fluids, welded pipes are subjected to cyclic loading due to pressure fluctuations that often exceed the prescribed values for normal operation. These cyclic loading can significantly reduce the life of the pipes; as a result the design should be based on the fatigue strength not only on static resistance. In general the fatigue strength of pipes is dependent by strength, pipe geometry and surface quality. In case of the electric longitudinal welded pipes, the fatigue strength is significantly limited by concentration of residual stress and the size of existing defects in the weld seam. This paper presents the fatigue behaviour of the electric welded pipes by high frequency, under conditions that simulate real operating conditions pipes. Fatigue testing was performed on welded pipes made of micro alloyed carbon steels. Some of these pipes were previously subjected to a heat treatment of normalization, in order to also determine the influence of heat treatment on the fatigue strength of welded pipes. To determine and correlate the different factors affecting the fatigue strength, welded pipes were also subjected to various tests: tensile tests, impact tests, measurement of micro hardness, microstructural analysis by optical microscopy and scanning electron microscopy.

The Simulation of Precipitation Evolutions and Mechanical Properties in Friction Stir Welding with Post-Weld Heat Treatments

NASA Astrophysics Data System (ADS)

Zhang, Z.; Wan, Z. Y.; Lindgren, L.-E.; Tan, Z. J.; Zhou, X.

2017-12-01

A finite element model of friction stir welding capable of re-meshing is used to simulate the temperature variations. Re-meshing of the finite element model is used to maintain a fine mesh resolving the gradients of the solution. The Kampmann-Wagner numerical model for precipitation is then used to study the relation between friction stir welds with post-weld heat treatment (PWHT) and the changes in mechanical properties. Results indicate that the PWHT holding time and PWHT holding temperature need to be optimally designed to obtain FSW with better mechanical properties. Higher precipitate number with lower precipitate sizes gives higher strength in the stirring zone after PWHT. The coarsening of precipitates in HAZ are the main reason to hinder the improvement of mechanical property when PWHT is used.

Dummy Cup Helps Robot-Welder Programmers

NASA Technical Reports Server (NTRS)

Gordon, Stephen S.

1990-01-01

Dummy gas cup used on torch of robotic welder during programming and practice runs. Made of metal or plastic, dummy cup inexpensive and durable. Withstands bumps caused by programming errors, and is sized for special welding jobs within limited clearances. After robot satisfactorily programmed, replaced by ceramic cup of same dimensions for actual welding.

Hot-cracking studies of Inconel 718 weld- heat-affected zones

NASA Technical Reports Server (NTRS)

Thompson, E. G.

1969-01-01

Hot ductility tests, gas-tungsten-arc fillerless fusion tests, and circle patch-weld-restraint tests were conducted on Inconel 718 to better understand and correlate the weldability /resistance to hot cracking/ of the alloy. A correlation of the test results with composition, heat-treat condition, grain size, and microstructure was made.

Metallography studies and hardness measurements on ferritic/martensitic steels irradiated in STIP

NASA Astrophysics Data System (ADS)

Zhang, H.; Long, B.; Dai, Y.

2008-06-01

In this work metallography investigations and microhardness measurements have been performed on 15 ferritic/martensitic (FM) steels and 6 weld metals irradiated in the SINQ Target Irradiation Program (STIP). The results demonstrate that all the steels have quite similar martensite lath structures. However, the sizes of the prior austenite grain (PAG) of these steels are quite different and vary from 10 to 86 μm. The microstructure in the fusion zones (FZ) of electron-beam welds (EBWs) of 5 steels (T91, EM10, MANET-II, F82H and Optifer-IX) is similar in respect to the martensite lath structure and PAG size. The FZ of the inert-gas-tungsten weld (TIGW) of the T91 steel shows a duplex structure of large ferrite gains and martensite laths. The microhardness measurements indicate that the normalized and tempered FM steels have rather close hardness values. The unusual high hardness values of the EBW and TIGW of the T91 steel were detected, which suggests that these materials are without proper tempering or post-welding heat treatment.

Effect of the combination of different welding parameters on melting characteristics of grade 1 titanium with a pulsed Nd-Yag laser.

PubMed

Bertrand, C; Laplanche, O; Rocca, J P; Le Petitcorps, Y; Nammour, S

2007-11-01

The laser is a very attractive tool for joining dental metallic alloys. However, the choice of the setting parameters can hardly influence the welding performances. The aim of this research was to evaluate the impact of several parameters (pulse shaping, pulse frequency, focal spot size...) on the quality of the microstructure. Grade 1 titanium plates have been welded with a pulsed Nd-Yag laser. Suitable power, pulse duration, focal spot size, and flow of argon gas were fixed by the operator. Five different pulse shapes and three pulse frequencies were investigated. Two pulse shapes available on this laser unit were eliminated because they considerably hardened the metal. As the pulse frequency rose, the metal was more and more ejected, and a plasma on the surface of the metal increased the oxygen contamination in the welded area. Frequencies of 1 or 2 Hz are optimum for a dental use. Three pulse shapes can be used for titanium but the rectangular shape gives better results.

Estimation of regional pulmonary deposition and exposure for fumes from SMAW and GMAW mild and stainless steel consumables.

PubMed

Hewett, P

1995-02-01

The particle size distributions and bulk fume densities for mild steel and stainless steel welding fumes generated using two welding processes (shielded metal arc welding [SMAW] and gas metal arc welding [GMAW]) were used in mathematical models to estimate regional pulmonary deposition (the fraction of each fume expected to deposit in each region of the pulmonary system) and regional pulmonary exposure (the fraction of each fume expected to penetrate to each pulmonary region and would be collected by a particle size-selective sampling device). Total lung deposition for GMAW fumes was estimated at 60% greater than that of SMAW fumes. Considering both the potential for deposition and the fume specific surface areas, it is likely that for equal exposure concentrations GMAW fumes deliver nearly three times the particle surface area to the lungs as SMAW fumes. This leads to the hypothesis that exposure to GMAW fumes constitutes a greater pulmonary hazard than equal exposure to SMAW fumes. The implications of this hypothesis regarding the design of future health studies of welders is discussed.

Effect of composition on the tensile properties and fracture toughness of A7N01S-T5 aluminum alloys welded joints

NASA Astrophysics Data System (ADS)

Liu, Yali; Gou, Guoqing; Chen, Jia; Chen, Hui; Wang, Wanjng; Li, Xiaodong; Che, Xiaoli; Wang, Yirong

2017-07-01

In this paper, welded joints of four types of A7N01S-T5 aluminum alloy with different chemical compositions were investigated. The welding process was under 70% environmental humidity conditions at 10∘C with single-pulse GMAW welding technology. The strength and fracture toughness of the four types of samples were tested, and the microstructures were investigated by micro-X-ray fluorescence (SR-LXRF) technology and backscattered electron diffraction (EBSD) technology. The results showed that the #2 alloy that is composed of Zn: 4.59 wt.%, Mg: 1.56 wt.% Mn: 0.22 wt.%, Cr: 0.14 wt.%, Zr: 0.01 wt.% and Ti: 0.027 wt.% had the best combination of tensile strength and elongation, with the values of 302.35 MPa and 3.74%, respectively. The better result for the combination of the strength and elongation was mainly determined by the volume fraction and size. The fine grain size and compositions played important roles to obtain high fracture toughness.

Microstructure characterization and charpy toughness of P91 weldment for as-welded, post-weld heat treatment and normalizing & tempering heat treatment

NASA Astrophysics Data System (ADS)

Pandey, Chandan; Mahapatra, M. M.; Kumar, Pradeep; Giri, A.

2017-09-01

The effect of weld groove design and heat treatment on microstructure evolution and Charpy toughness of P91 pipe weldments was studied. The P91 pipe weldments were subjected to subcritical post weld heat treatment (760 °C-2 h) and normalizing/tempering conditions (normalized-1040 °C/40 min, air cooled; tempered 760 °C/2 h, air cooled) were employed. The influence of subsequent PWHT and N&T treatment on the microstructure of various zone of P91 pipe weldments were also investigated. The present investigation also described the effect of PWHT and N&T treatment on hardness, grain size, precipitate size, inter-particle spacing and fraction area of precipitates present in each zone of P91 pipe weldments. The result indicated great impact of heat treatment on the Charpy toughness and microstructure evolution of P91 weldments. The N&T treatment was found to be more effective heat treatment compared to subsequent PWHT. Charpy toughness value was found to be higher for narrow-groove design as compared to conventional V-groove design.

Experimental and numerical investigation of laser shock synchronous welding and forming of Copper/Aluminum

NASA Astrophysics Data System (ADS)

Wang, Xiao; Zhang, Hongfeng; Shen, Zongbao; Li, Jianwen; Qian, Qing; Liu, Huixia

2016-11-01

A novel laser shock synchronous welding and forming method is introduced, which utilizes laser-induced shock waves to accelerate the flyer plate towards the base plate to achieve the joining of dissimilar metals and forming in a specific shape of mold. The samples were obtained with different laser energies and standoff distances. The surface morphology and roughness of the samples were greatly affected by the laser energy and standoff distances. Fittability was investigated to examine the forming accuracy. The results showed that the samples replicate the mold features well. Straight and wavy interfaces with un-bonded regions in the center were observed through metallographic analysis. Moreover, Energy Disperse Spectroscopy analysis was conducted on the welding interface, and the results indicated that a short-distance elemental diffusion emerged in the welding interface. The nanoindentation hardness of the welding regions was measured to evaluate the welding interface. In addition, the Smoothed Particle Hydrodynamics method was employed to simulate the welding and forming process. It was shown that different standoff distances significantly affected the size of the welding regions and interface waveform characteristics. The numerical analysis results indicated that the opposite shear stress direction and effective plastic strain above a certain threshold are essential to successfully obtain welding and forming workpiece.

Effect of friction stir welding and post-weld heat treatment on a nanostructured ferritic alloy

DOE PAGES

Mazumder, Baishakhi; Yu, Xinghua; Edmondson, Philip D.; ...

2015-12-08

Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygenenriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the sizemore » of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.« less

Effect of friction stir welding and post-weld heat treatment on a nanostructured ferritic alloy

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

Mazumder, Baishakhi; Yu, Xinghua; Edmondson, Philip D.

Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygenenriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the sizemore » of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.« less

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

NASA Astrophysics Data System (ADS)

Taweejun, Nipon; Poapongsakorn, Piyamon; Kanchanomai, Chaosuan

2017-04-01

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

Effect of laser welding on the titanium ceramic tensile bond strength.

PubMed

Galo, Rodrigo; Ribeiro, Ricardo Faria; Rodrigues, Renata Cristina Silveira; Pagnano, Valéria de Oliveira; Mattos, Maria da Glória Chiarello de

2011-08-01

Titanium reacts strongly with elements, mainly oxygen at high temperature. The high temperature of titanium laser welding modifies the surface, and may interfere on the metal-ceramic tensile bond strength. The influence of laser welding on the titanium-ceramic bonding has not yet been established. The purpose of this in vitro study was to analyze the influence of laser welding applied to commercially pure titanium (CpTi) substructure on the bond strength of commercial ceramic. The influence of airborne particle abrasion (Al2O3) conditions was also studied. Forty CpTi cylindrical rods (3 mm x 60 mm) were cast and divided into 2 groups: with laser welding (L) and without laser welding (WL). Each group was divided in 4 subgroups, according to the size of the particles used in airborne particle abrasion: A - Al2O3 (250 µm); B - Al2O3 (180 µm); C - Al2O3 (110 µm); D - Al2O3 (50 µm). Ceramic rings were fused around the CpTi rods. Specimens were invested and their tensile strength was measured at fracture with a universal testing machine at a crosshead speed of 2.0 mm/min and 200 kgf load cell. Statistical analysis was carried out with analysis of variance and compared using the independent t test (p<0.05). Significant differences were found among all subgroups (p<0.05). The highest and the lowest bond strength means were recorded in subgroups WLC (52.62 MPa) and LD (24.02 MPa), respectively. Airborne particle abrasion yielded significantly lower bond strength as the Al2O3 particle size decreased. Mechanical retention decreased in the laser-welded specimens, i.e. the metal-ceramic tensile bond strength was lower.

Dye-enhanced laser welding for skin closure.

PubMed

DeCoste, S D; Farinelli, W; Flotte, T; Anderson, R R

1992-01-01

The use of a laser to weld tissue in combination with a topical photosensitizing dye permits selective delivery of energy to the target tissue. A combination of indocyanine green (IG), absorption peak 780 nm, and the near-infrared (IR) alexandrite laser was studied with albino guinea pig skin. IG was shown to bind to the outer 25 microns of guinea pig dermis and appeared to be bound to collagen. The optical transmittance of full-thickness guinea pig skin in the near IR was 40% indicating that the alexandrite laser should provide adequate tissue penetration. Laser "welding" of skin in vivo was achieved at various concentrations of IG from 0.03 to 3 mg/cc using the alexandrite at 780 nm, 250-microseconds pulse duration, 8 Hz, and a 4-mm spot size. A spectrum of welds was obtained from 1- to 20-W/cm2 average irradiance. Weak welds occurred with no thermal damage obtained at lower irradiances: stronger welds with thermal damage confined to the weld site occurred at higher irradiances. At still higher irradiances, local vaporization occurred with failure to "weld." Thus, there was an optimal range of irradiances for "welding," which varied inversely with dye concentration. Histology confirmed the thermal damage results that were evident clinically. IG dye-enhanced laser welding is possible in skin and with further optimization may have practical application.

Emissions of chromium (VI) from arc welding.

PubMed

Heung, William; Yun, Myoung-Jin; Chang, Daniel P Y; Green, Peter G; Halm, Chris

2007-02-01

The presence of Cr in the +6 oxidation state (Cr[VI]) is still observed in ambient air samples in California despite steps taken to reduce emissions from plating operations. One known source of emission of Cr(VI) is welding, especially with high Cr-content materials, such as stainless steels. An experimental effort was undertaken to expand and update Cr(VI) emission factors by conducting tests on four types of arc-welding operations: gas-metal arc welding (GMAW), shielded metal arc welding (SMAW), fluxcore arc welding, and pulsed GMAW. Standard American Welding Society hood results were compared with a total enclosure method that permitted isokinetic sampling for particle size-cut measurement, as well as total collection of the aerosol. The fraction of Cr(VI) emitted per unit mass of Cr electrode consumed was determined. Consistent with AP-42 data, initial results indicate that a significant fraction of the total Cr in the aerosol is in the +6 oxidation state. The fraction of Cr(VI) and total aerosol mass produced by the different arc welding methods varies with the type of welding process used. Self-shielded electrodes that do not use a shield gas, for example, SMAW, produce greater amounts of Cr(VI) per unit mass of electrode consumed. The formation of Cr(VI) from standard electrode wires used for welding mild steel was below the method detection limit after eliminating an artifact in the analytical method used.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

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

PubMed

Lee, Jaesun; Park, Junpil; Cho, Younho

2016-05-01

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

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.

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

NASA Astrophysics Data System (ADS)

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

2015-12-01

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

Mitigating Abnormal Grain Growth for Friction Stir Welded Al-Li 2195 Spun Formed Domes

NASA Technical Reports Server (NTRS)

Chen, Po-Shou; Russell, Carolyn

2012-01-01

Formability and abnormal grain growth (AGG) are the two major issues that have been encountered for Al alloy spun formed dome development using friction stir welded blanks. Material properties that have significant influence on the formability include forming range and strain hardening exponent. In this study, tensile tests were performed for two 2195 friction stir weld parameter sets at 400 F to study the effects of post weld anneal on the forming range and strain hardening exponent. It was found that the formability can be enhanced by applying a newly developed post weld anneal to heat treat the friction stir welded panels. This new post weld anneal leads to a higher forming range and much improved strain hardening exponent. AGG in the weld nugget is known to cause a significant reduction of ductility and fracture toughness. This study also investigated how AGG may be influenced by the heating rate to the solution heat treatment temperature. After post-weld annealing, friction stir welds were strained to 15% and 39% by compression at 400 F before they were subjected to SHT at 950 F for 1 hour. Salt bath SHT is very effective in reducing the grain size as it helps arrest the onset of AGG and promote normal recrystallization and grain growth. However, heat treating a 18 ft dome using a salt bath is not practical. Efforts are continuing at Marshall Space Flight Center to identify the welding parameters and heat treating parameters that can help mitigate the AGG in the friction stir welds.

Conceptual design of modular fixture for frame welding and drilling process integration case study: Student chair in UNS industrial engineering integrated practicum

NASA Astrophysics Data System (ADS)

Darmawan, Tofiq Dwiki; Priadythama, Ilham; Herdiman, Lobes

2018-02-01

Welding and drilling are main processes of making chair frame from metal material. Commonly, chair frame construction includes many arcs which bring difficulties for its welding and drilling process. In UNS industrial engineering integrated practicum there are welding fixtures which use to fixing frame component position for welding purpose. In order to achieve exact holes position for assembling purpose, manual drilling processes were conducted after the frame was joined. Unfortunately, after it was welded the frame material become hard and increase drilling tools wear rate as well as reduce holes position accuracy. The previous welding fixture was not equipped with clamping system and cannot accommodate drilling process. To solve this problem, our idea is to reorder the drilling process so that it can be execute before welding. Thus, this research aims to propose conceptual design of modular fixture which can integrate welding and drilling process. We used Generic Product Development Process to address the design concept. We collected design requirements from 3 source, jig and fixture theoretical concepts, user requirements, and clamping part standards. From 2 alternatives fixture tables, we propose the first which equipped with mounting slots instead of holes. We test the concept by building a full sized prototype and test its works by conducting welding and drilling of a student chair frame. Result from the welding and drilling trials showed that the holes are on precise position after welding. Based on this result, we conclude that the concept can be a consideration for application in UNS Industrial Engineering Integrated Practicum.