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

NASA Astrophysics Data System (ADS)

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

2018-10-01

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

49 CFR 179.220-7 - Materials.

Code of Federal Regulations, 2013 CFR

2013-10-01

... indicated minimum tensile strength and elongation in the welded condition. (b) Carbon steel plate: The...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... Minimum tensile strength (p.s.i.) welded condition 1 Minimum elongation in 2 inches (percent) weld metal...

49 CFR 179.220-7 - Materials.

Code of Federal Regulations, 2012 CFR

2012-10-01

... indicated minimum tensile strength and elongation in the welded condition. (b) Carbon steel plate: The...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... Minimum tensile strength (p.s.i.) welded condition 1 Minimum elongation in 2 inches (percent) weld metal...

49 CFR 179.220-7 - Materials.

Code of Federal Regulations, 2011 CFR

2011-10-01

... indicated minimum tensile strength and elongation in the welded condition. (b) Carbon steel plate: The...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... Minimum tensile strength (p.s.i.) welded condition 1 Minimum elongation in 2 inches (percent) weld metal...

49 CFR 179.220-7 - Materials.

Code of Federal Regulations, 2014 CFR

2014-10-01

... indicated minimum tensile strength and elongation in the welded condition. (b) Carbon steel plate: The...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... Minimum tensile strength (p.s.i.) welded condition 1 Minimum elongation in 2 inches (percent) weld metal...

High-Powered, Ultrasonically Assisted Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, Robert

2013-01-01

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

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

DOEpatents

Trent, Jett B.; Murphy, Jimmy L.

1981-01-01

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

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

DOEpatents

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

1980-01-03

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

Metallic glass coating on metals plate by adjusted explosive welding technique

NASA Astrophysics Data System (ADS)

Liu, W. D.; Liu, K. X.; Chen, Q. Y.; Wang, J. T.; Yan, H. H.; Li, X. J.

2009-09-01

Using an adjusted explosive welding technique, an aluminum plate has been coated by a Fe-based metallic glass foil in this work. Scanning electronic micrographs reveal a defect-free metallurgical bonding between the Fe-based metallic glass foil and the aluminum plate. Experimental evidence indicates that the Fe-based metallic glass foil almost retains its amorphous state and mechanical properties after the explosive welding process. Additionally, the detailed explosive welding process has been simulated by a self-developed hydro-code and the bonding mechanism has been investigated by numerical analysis. The successful welding between the Fe-based metallic glass foil and the aluminum plate provides a new way to obtain amorphous coating on general metal substrates.

46 CFR 57.06-4 - Production testing specimen requirements.

Code of Federal Regulations, 2010 CFR

2010-10-01

... WELDING AND BRAZING Production Tests § 57.06-4 Production testing specimen requirements. (a) For test... to welding shall not throw the finished test plate out of line by an angle of over 5°. (c) Where the welding has warped the test plates, the plates shall be straightened before being stress-relieved. The...

46 CFR 57.06-4 - Production testing specimen requirements.

Code of Federal Regulations, 2012 CFR

2012-10-01

... WELDING AND BRAZING Production Tests § 57.06-4 Production testing specimen requirements. (a) For test... to welding shall not throw the finished test plate out of line by an angle of over 5°. (c) Where the welding has warped the test plates, the plates shall be straightened before being stress-relieved. The...

46 CFR 57.06-4 - Production testing specimen requirements.

Code of Federal Regulations, 2011 CFR

2011-10-01

... WELDING AND BRAZING Production Tests § 57.06-4 Production testing specimen requirements. (a) For test... to welding shall not throw the finished test plate out of line by an angle of over 5°. (c) Where the welding has warped the test plates, the plates shall be straightened before being stress-relieved. The...

46 CFR 57.06-4 - Production testing specimen requirements.

Code of Federal Regulations, 2013 CFR

2013-10-01

... WELDING AND BRAZING Production Tests § 57.06-4 Production testing specimen requirements. (a) For test... to welding shall not throw the finished test plate out of line by an angle of over 5°. (c) Where the welding has warped the test plates, the plates shall be straightened before being stress-relieved. The...

46 CFR 57.06-4 - Production testing specimen requirements.

Code of Federal Regulations, 2014 CFR

2014-10-01

... WELDING AND BRAZING Production Tests § 57.06-4 Production testing specimen requirements. (a) For test... to welding shall not throw the finished test plate out of line by an angle of over 5°. (c) Where the welding has warped the test plates, the plates shall be straightened before being stress-relieved. The...

Evolution of Microstructure and Stress Corrosion Cracking Behavior of AA2219 Plate to Ring Weld Joints in 3.5 Wt Pct NaCl Solution

NASA Astrophysics Data System (ADS)

Venugopal, A.; Narayanan, P. Ramesh; Sharma, S. C.

2016-04-01

AA2219 aluminum alloy plate (T87) and ring (T851) were joined by tungsten inert gas (TIG) welding using multi-pass welding. The mechanical properties and stress corrosion cracking (SCC) resistance of the above base metals (BMs) in different directions (L, LT, and ST) were examined. Similarly, the weld metal joined by plate to plate and plate to ring (PR) joints was evaluated. The results revealed that the mechanical properties of the ring were comparatively lower than the plate. This was found to be due to the extremely coarse grain size of the ring along with severe Cu-rich segregation along the grain boundaries when compared to the plate material. The SCC resistance of the base and weldments were found to be good and not susceptible to SCC. This was shown to be due to high values of SCC index (>0.9) and the typical ductile cracking morphology of the BM and the weld joints after SCC test in the environment (3.5 wt pct NaCl) when compared to test performed in the control environment (air). However, the corrosion resistance of the weld interface between the FZ and ring was inferior to the FZ-plate interface.

A Study on the Saving Method of Plate Jigs in Hull Block Butt Welding

NASA Astrophysics Data System (ADS)

Ko, Dae-Eun

2017-11-01

A large amount of plate jigs is used for alignment of welding line and control of welding deformations in hull block assembly stage. Besides material cost, the huge working man-hours required for working process of plate jigs is one of the obstacles in productivity growth of shipyard. In this study, analysis method was proposed to simulate the welding deformations of block butt joint with plate jigs setting. Using the proposed analysis method, an example simulation was performed for actual panel block joint to investigate the saving method of plate jigs. Results show that it is possible to achieve two objectives of quality accuracy of the hull block and saving the plate jig usage at the same time by deploying the plate jigs at the right places. And the proposed analysis method can be used in establishing guidelines for the proper use of plate jigs in block assembly stage.

Capillary flow weld-bonding

NASA Technical Reports Server (NTRS)

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

1976-01-01

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

46 CFR 59.10-35 - Wrapper plates and back heads.

Code of Federal Regulations, 2010 CFR

2010-10-01

..., PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-35... staybolts where the thickness is approximately the same as the original construction. If welding is employed... plates of combustion chambers outside of stayed areas may be repaired by welding provided the welded...

46 CFR 59.10-35 - Wrapper plates and back heads.

Code of Federal Regulations, 2014 CFR

2014-10-01

..., PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-35... staybolts where the thickness is approximately the same as the original construction. If welding is employed... plates of combustion chambers outside of stayed areas may be repaired by welding provided the welded...

46 CFR 59.10-35 - Wrapper plates and back heads.

Code of Federal Regulations, 2011 CFR

2011-10-01

..., PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-35... staybolts where the thickness is approximately the same as the original construction. If welding is employed... plates of combustion chambers outside of stayed areas may be repaired by welding provided the welded...

46 CFR 59.10-35 - Wrapper plates and back heads.

Code of Federal Regulations, 2012 CFR

2012-10-01

..., PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-35... staybolts where the thickness is approximately the same as the original construction. If welding is employed... plates of combustion chambers outside of stayed areas may be repaired by welding provided the welded...

46 CFR 59.10-35 - Wrapper plates and back heads.

Code of Federal Regulations, 2013 CFR

2013-10-01

..., PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-35... staybolts where the thickness is approximately the same as the original construction. If welding is employed... plates of combustion chambers outside of stayed areas may be repaired by welding provided the welded...

Effects of fabrication procedures and weld melt-through on fatigue resistance of orthotropic steel deck welds.

DOT National Transportation Integrated Search

2008-12-01

A common practice for the fabrication of orthotropic bridge deck in the US involves using 80% partial-joint-penetration groove welds (PJP) to join : closed ribs to a deck plate. Avoiding weld melt-through with the thin rib plate may be difficult to a...

Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

NASA Astrophysics Data System (ADS)

Vasantharaja, P.; Vasudevan, M.

2012-02-01

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

Upgraded HFIR Fuel Element Welding System

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

Sease, John D

2010-02-01

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

The microstructure of aluminum A5083 butt joint by friction stir welding

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

Jasri, M. A. H. M.; Afendi, M.; Ismail, A.

This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the platemore » form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.« less

Effect of Backing Plate Thermal Property on Friction Stir Welding of 25-mm-Thick AA6061

NASA Astrophysics Data System (ADS)

Upadhyay, Piyush; Reynolds, Anthony

2014-04-01

By using backing plates made out of materials with widely varying thermal diffusivity this work seeks to elucidate the effects of the root side thermal boundary condition on weld process variables and resulting joint properties. Welds were made in 25.4-mm-thick AA6061 using ceramic, titanium, steel, and aluminum as backing plate (BP) material. Welds were also made using a "composite backing plate" consisting of longitudinal narrow strip of low diffusivity material at the center and two side plates of high diffusivity aluminum. Stir zone temperature during the welding was measured using two thermocouples spot welded at the core of the probe: one at the midplane height and another near the tip of the probe corresponding to the root of the weld. Steady state midplane probe temperatures for all the BPs used were found to be very similar. Near root peak temperature, however, varied significantly among weld made with different BPs all other things being equal. Whereas the near root and midplane temperature were the same in the case of ceramic backing plate, the root peak temperature was 318 K (45 °C) less than the midplane temperature in the case of aluminum BP. The trends of nugget hardness and grain size in through thickness direction were in agreement with the measured probe temperatures. Hardness and tensile test results show that the use of composite BP results in stronger joint compared to monolithic steel BP.

The effect of different rutile electrodes on mechanical properties of underwater wet welded AH-36 steel plates

NASA Astrophysics Data System (ADS)

Winarto, Winarto; Purnama, Dewin; Churniawan, Iwan

2018-04-01

Underwater welding is an important role in the rescue of ships and underwater structures, in case of emergency. In this study, the marine steel plates used are AH-36 steel as parent material. This type of steel is included in the High Strength Low Alloy (HSLA). Electrodes used for welding AH-36 steel plates are commonly the E6013 and E 7024 which are the type of based rutile electrodes. Those electrodes are widely available on the market and they would be compared with the original electrode for underwater which is the type of E7014 with the trade name of Broco UW-CS-1. Welding method used is Shielding Metal Arc Welding (SMAW) with the variation of 5 m and 10 m underwater depth and also varied with the electric current of 120A, 140A and 250A. It was found that hardness value of increased in the area of weld metal and HAZ. HAZ also tends to have the highest hardness compared to both of weld metal and base metal. Non destructive test by radiographed test (RT) on welds showed that there are found welding defects in the form of incomplete penetration on all variations of welding parameters, but there is no porosity defect detected. The results of the hardness tests of underwater wet welded steel plates show that the hardness value of both rutile electrodes (E6013 and E 7024) is apparently similar hardness value compared with the existing commercial electrode (E7014 of Broco UW-CS- 1). The tensile test results of underwater wet welded steel plates show that the use of rutile electrode of E6013 gives a better tensile properties than other rutile electrodes.

Flaw growth behavior in thick welded plates of 2219-T87 aluminum at room and cryogenic temperatures

NASA Technical Reports Server (NTRS)

Forman, R. G.; Glorioso, S. V.; Medlock, J. D.

1973-01-01

Axial load fatigue and fracture tests were conducted on thick welded plates of 2219-T87 aluminum alloy to determine the tensile strength properties and the flaw growth behavior in electron beam, gas metal arc, and pulse current gas tungsten arc welds for plates 6.35 centimeters (2.5 in.) thick. The tests were conducted in room temperature air and in liquid nitrogen environments. Specimens were tested in both the as-welded and the aged after welding conditions. The experimental crack growth rate were correlated with theoretical crack growth rate predictions for semielliptical surface flaws.

46 CFR 57.06-2 - Production test plate interval of testing.

Code of Federal Regulations, 2010 CFR

2010-10-01

... WELDING AND BRAZING Production Tests § 57.06-2 Production test plate interval of testing. (a) At least one... follows: (1) When the extent of welding on a single vessel exceeds 50 lineal feet of either or both... joint. (2) When the extent of welding on vessels welded in succession exceeds 50 lineal feet of either...

46 CFR 57.06-2 - Production test plate interval of testing.

Code of Federal Regulations, 2014 CFR

2014-10-01

... WELDING AND BRAZING Production Tests § 57.06-2 Production test plate interval of testing. (a) At least one... follows: (1) When the extent of welding on a single vessel exceeds 50 lineal feet of either or both... joint. (2) When the extent of welding on vessels welded in succession exceeds 50 lineal feet of either...

46 CFR 57.06-2 - Production test plate interval of testing.

Code of Federal Regulations, 2012 CFR

2012-10-01

... WELDING AND BRAZING Production Tests § 57.06-2 Production test plate interval of testing. (a) At least one... follows: (1) When the extent of welding on a single vessel exceeds 50 lineal feet of either or both... joint. (2) When the extent of welding on vessels welded in succession exceeds 50 lineal feet of either...

46 CFR 57.06-2 - Production test plate interval of testing.

Code of Federal Regulations, 2011 CFR

2011-10-01

... WELDING AND BRAZING Production Tests § 57.06-2 Production test plate interval of testing. (a) At least one... follows: (1) When the extent of welding on a single vessel exceeds 50 lineal feet of either or both... joint. (2) When the extent of welding on vessels welded in succession exceeds 50 lineal feet of either...

46 CFR 57.06-2 - Production test plate interval of testing.

Code of Federal Regulations, 2013 CFR

2013-10-01

... WELDING AND BRAZING Production Tests § 57.06-2 Production test plate interval of testing. (a) At least one... follows: (1) When the extent of welding on a single vessel exceeds 50 lineal feet of either or both... joint. (2) When the extent of welding on vessels welded in succession exceeds 50 lineal feet of either...

Analysis of thermal stresses and metal movement during welding

NASA Technical Reports Server (NTRS)

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

1974-01-01

Finite element computer programs were developed to determine thermal stresses and metal movement during butt welding of flat plates and bead-on-plate welding along the girth of a cylindrical shell. Circular cylindrical shells of 6061 aluminum alloy were used for the tests. Measurements were made of changes in temperature and thermal strains during the welding process.

Failure analysis of blistered gold plating on spot welded electrical relays

NASA Technical Reports Server (NTRS)

Sokolowski, Witold; O'Donnell, Tim

1989-01-01

Gold-plated stainless-steel sideplates, part of a JPL Galileo spacecraft electronic-relay assembly, exhibited blistering after resistance spot welding. Unacceptable relays had heavy nonuniform gold electrodeposited layers with thicknesses 4.5-11.5 microns. SEM and metallographic investigations indicated much higher heat input generated during the resistance spot welding in unacceptable relays. The attributes of acceptable welded relays are contrasted with unacceptable relays; the possible mechanism of laminar formation of polymeric material in the gold plating is discussed; and some recommendations are provided to prevent similar problems.

Weldability evaluation of high tensile plates using GMAW process

NASA Astrophysics Data System (ADS)

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

1999-08-01

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

FSW between Al alloy and Mg Alloy: the comparative study

NASA Astrophysics Data System (ADS)

Jagadeesha, C. B.

2017-04-01

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

Development of ceramic-coated weld backing bars

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

Eggleston, B.R.

1994-10-20

In shipbuilding and many other industries, copper weld backing bars are used to draw the heat out of the weld. The problem that some users of these bars encounter is that these bars, on occasion, actually melt in spots and become welded to the weld plates. After this happens a number of times, the backing bar becomes so degraded that it must be either discarded or machined, both of which are very costly and time-consuming actions. To avoid this fusion between the backing bar and the weld plate, the weld processes that are used cannot be ones of high beatmore » input. This requirement is very limiting when thick plates are being welded. The plates must be beveled, and more weld passes must be run. These problems are also costly and time consuming. The aim of this project is to find a way to produce backing bars with nearly the same `chilling` effect but with both a greater resistance to molten metal and resistance to arcing to the backing bar itself. A possible solution currently being tested is to coat the copper bars with a thin layer of a ceramic coating. The procedure used was to coat the copper bars with either alumina or spinel by a plasma spraying method.« less

A Simplified Model for the Effect of Weld-Induced Residual Stresses on the Axial Ultimate Strength of Stiffened Plates

NASA Astrophysics Data System (ADS)

Chen, Bai-Qiao; Guedes Soares, C.

2018-03-01

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

Numerical Simulation and Artificial Neural Network Modeling for Predicting Welding-Induced Distortion in Butt-Welded 304L Stainless Steel Plates

NASA Astrophysics Data System (ADS)

Narayanareddy, V. V.; Chandrasekhar, N.; Vasudevan, M.; Muthukumaran, S.; Vasantharaja, P.

2016-02-01

In the present study, artificial neural network modeling has been employed for predicting welding-induced angular distortions in autogenous butt-welded 304L stainless steel plates. The input data for the neural network have been obtained from a series of three-dimensional finite element simulations of TIG welding for a wide range of plate dimensions. Thermo-elasto-plastic analysis was carried out for 304L stainless steel plates during autogenous TIG welding employing double ellipsoidal heat source. The simulated thermal cycles were validated by measuring thermal cycles using thermocouples at predetermined positions, and the simulated distortion values were validated by measuring distortion using vertical height gauge for three cases. There was a good agreement between the model predictions and the measured values. Then, a multilayer feed-forward back propagation neural network has been developed using the numerically simulated data. Artificial neural network model developed in the present study predicted the angular distortion accurately.

Pulsed ultrasonic stir welding system

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2013-01-01

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

Effects Of Heat Sinks On VPPA Welds

NASA Technical Reports Server (NTRS)

Nunes, Arthur C.; Steranka, Paul O., Jr.

1991-01-01

Report describes theoretical and experimental study of absorption of heat by metal blocks in contact with metal plate while plate subjected to variable-polarity plasma-arc (VPPA) welding. Purpose of study to contribute to development of comprehensive mathematical model of temperature in weld region. Also relevant to welding of thin sheets of metal to thick blocks of metal, heat treatment of metals, and hotspots in engines.

[Effects of laser welding on bond of porcelain fused cast pure titanium].

PubMed

Zhu, Juan-fang; He, Hui-ming; Gao, Bo; Wang, Zhong-yi

2006-04-01

To investigate the influence of the laser welding on bond of porcelain fused to cast pure titanium. Twenty cast titanium plates were divided into two groups: laser welded group and control group. The low-fusing porcelain was fused to the laser welded cast pure titanium plates at fusion zone. The bond strength of the porcelain to laser welded cast pure titanium was measured by the three-point bending test. The interface of titanium and porcelain was investigated by scanning electron microscopy (SEM) and energy depressive X-ray detector (EDX). The non-welded titanium plates were used as comparison. No significant difference of the bond strength was found between laser-welded samples [(46.85 +/- 0.76) MPa] and the controls [(41.71 +/- 0.55) MPa] (P > 0.05). The SEM displayed the interface presented similar irregularities with a predominance. The titanium diffused to low-fusing porcelain, while silicon and aluminum diffused to titanium basement. Laser welding does not affect low-fusing porcelain fused to pure titanium.

Pulsed ultrasonic stir welding method

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2013-01-01

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

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

The Development and Microstructure Analysis of High Strength Steel Plate NVE36 for Large Heat Input Welding

NASA Astrophysics Data System (ADS)

Peng, Zhang; Liangfa, Xie; Ming, Wei; Jianli, Li

In the shipbuilding industry, the welding efficiency of the ship plate not only has a great effect on the construction cost of the ship, but also affects the construction speed and determines the delivery cycle. The steel plate used for large heat input welding was developed sufficiently. In this paper, the composition of the steel with a small amount of Nb, Ti and large amount of Mn had been designed in micro-alloyed route. The content of C and the carbon equivalent were also designed to a low level. The technology of oxide metallurgy was used during the smelting process of the steel. The rolling technology of TMCP was controlled at a low rolling temperature and ultra-fast cooling technology was used, for the purpose of controlling the transformation of the microstructure. The microstructure of the steel plate was controlled to be the mixed microstructure of low carbon bainite and ferrite. Large amount of oxide particles dispersed in the microstructure of steel, which had a positive effects on the mechanical property and welding performance of the steel. The mechanical property of the steel plate was excellent and the value of longitudinal Akv at -60 °C is more than 200 J. The toughness of WM and HAZ were excellent after the steel plate was welded with a large heat input of 100-250 kJ/cm. The steel plate processed by mentioned above can meet the requirement of large heat input welding.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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.

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.

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.

Optical measurements of flyer plate acceleration by emulsion explosive

NASA Astrophysics Data System (ADS)

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

2001-04-01

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

Study of gas tungsten arc welding procedures for tantalum alloy T-111 (Ta-8 W-2Hf) plate

NASA Technical Reports Server (NTRS)

Gold, R. E.; Kesterson, R. L.

1973-01-01

Methods of eliminating or reducing underbread cracking in multipass GTA welds in thick T-111 plate were studied. Single V butt welds prepared using experimental filler metal compositions and standard weld procedures resulted in only moderate success in reducing underbread cracking. Subsequent procedural changes incorporating manual welding, slower weld speeds, and three or fewer fill passes resulted in crack-free single V welds only when the filler metal was free of hafnium. The double V joint design with successive fill passes on opposite sides of the joint produced excellent welds. The quality of each weld was determined metallographically since the cracking, when present, was very slight and undetectable using standard NDT techniques. Tensile and bend tests were performed on selected weldments. The inherent filler metal strength and the joint geometry determined the strength of the weldment. Hardness and electron beam microprobe traverses were made on selected specimens with the result that significant filler metal-base metal dilution as well as hafnium segregation was detected. A tentative explanation of T-111 plate underbread cracking is presented based on the intrinsic effects of hafnium in the weldment.

Double-Sided Single-Pass Submerged Arc Welding for 2205 Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Luo, Jian; Yuan, Yi; Wang, Xiaoming; Yao, Zongxiang

2013-09-01

The duplex stainless steel (DSS), which combines the characteristics of ferritic steel and austenitic steel, is used widely. The submerged arc welding (SAW) method is usually applied to join thick plates of DSS. However, an effective welding procedure is needed in order to obtain ideal DSS welds with an appropriate proportion of ferrite (δ) and austenite (γ) in the weld zone, particularly in the melted zone and heat-affected zone. This study evaluated the effectiveness of a high efficiency double-sided single-pass (DSSP) SAW joining method for thick DSS plates. The effectiveness of the converse welding procedure, characterizations of weld zone, and mechanical properties of welded joint are analyzed. The results show an increasing appearance and continuous distribution feature of the σ phase in the fusion zone of the leading welded seam. The converse welding procedure promotes the σ phase to precipitate in the fusion zone of leading welded side. The microhardness appears to significantly increase in the center of leading welded side. Ductile fracture mode is observed in the weld zone. A mixture fracture feature appears with a shear lip and tears in the fusion zone near the fusion line. The ductility, plasticity, and microhardness of the joints have a significant relationship with σ phase and heat treatment effect influenced by the converse welding step. An available heat input controlling technology of the DSSP formation method is discussed for SAW of thick DSS plates.

Initial Study of Friction Pull Plug Welding

NASA Technical Reports Server (NTRS)

Rich, Brian S.

1999-01-01

Pull plug friction welding is a new process being developed to conveniently eliminate defects from welded plate tank structures. The general idea is to drill a hole of precise, optimized dimensions and weld a plug into it, filling the hole perfectly. A conically-shaped plug is rotated at high angular velocity as it is brought into contact with the plate material in the hole. As the plug is pulled into the hole, friction rapidly raises the temperature to the point at which the plate material flows plastically. After a brief heating phase, the plug rotation is terminated. The plug is then pulled upon with a forging force, solidly welding the plug into the hole in the plate. Three aspects of this process were addressed in this study. The transient temperature distribution was analyzed based on slightly idealized boundary conditions for different plug geometries. Variations in hole geometry and ram speed were considered, and a program was created to calculate volumes of displaced material and empty space, as well as many other relevant dimensions. The relation between the axially applied forging force and the actual forging pressure between the plate and plug surfaces was determined for various configurations.

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.

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

DTIC Science & Technology

2015-12-01

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

Friction-Stir Welding and Mathematical Modeling

NASA Technical Reports Server (NTRS)

Rostant, Victor D.

1999-01-01

The friction-stir welding process is a remarkable way for making butt and lap joints in aluminum alloys. This process operates by passing a rotating tool between two closely butted plates. Through this process it generates a lot of heat and heated material is stirred from both sides of the plates in which the outcome will one high quality weld. My research has been done to study the FSW through mathematical modeling, and using modeling to better understand what take place during the friction-stir weld.

Solid State Welding Development at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Ding, Robert J.; Walker, Bryant

2012-01-01

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

Fatigue Crack Growth Rate Test Results for Al-Li 2195 Parent Metal, Variable Polarity Plasma Arc Welds and Friction Stir Welds

NASA Technical Reports Server (NTRS)

Hafley, Robert A.; Wagner, John A.; Domack, Marcia S.

2000-01-01

The fatigue crack growth rate of aluminum-lithium (Al-Li) alloy 2195 plate and weldments was determined at 200-F, ambient temperature and -320-F. The effects of stress ratio (R), welding process, orientation and thickness were studied. Results are compared with plate data from the Space Shuttle Super Lightweight Tank (SLWT) allowables program. Data from the current series of tests, both plate and weldment, falls within the range of data generated during the SLWT allowables program.

Ultrasonically-assisted Thermal Stir Welding System

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2014-01-01

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

FE Analysis of Buckling Behavior Caused by Welding in Thin Plates of High Tensile Strength Steel

NASA Astrophysics Data System (ADS)

Wang, Jiangchao; Rashed, Sherif; Murakawa, Hidekazu

2014-12-01

The target of this study was to investigate buckling behavior during the entire welding process which consists of the heating and the cooling processes. For thin plate structures made of high tensile strength steel, not only residual buckling during or after cooling down but also transient buckling during heating may occur. The thermal elastic plastic FE analysis to investigate welding-induced buckling during the entire welding process is presented. Because of the high yield stress of high tensile strength steel, larger longitudinal compressive thermal stress is produced near the welding line compared with that in the case of carbon steel. Therefore, the plate may buckle due to thermal expansion, before the material nears yielding. During cooling down, the longitudinal compressive thermal stress close to the welding line disappears, and longitudinal tensile residual stress is produced due to contraction. Meanwhile, longitudinal compressive residual stress occurs far from the welding line to balance the tensile stress close to the welding line. This distribution of longitudinal residual stress would change the deformed dish shape of transient buckling into a saddle buckling type when the stress exceeds the critical buckling condition.

Quasi-Rayleigh waves in butt-welded thick steel plate

NASA Astrophysics Data System (ADS)

Kamas, Tuncay; Giurgiutiu, Victor; Lin, Bin

2015-03-01

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

Molten core retention assembly

DOEpatents

Lampe, Robert F.

1976-06-22

Molten fuel produced in a core overheating accident is caught by a molten core retention assembly consisting of a horizontal baffle plate having a plurality of openings therein, heat exchange tubes having flow holes near the top thereof mounted in the openings, and a cylindrical, imperforate baffle attached to the plate and surrounding the tubes. The baffle assembly is supported from the core support plate of the reactor by a plurality of hanger rods which are welded to radial beams passing under the baffle plate and intermittently welded thereto. Preferably the upper end of the cylindrical baffle terminates in an outwardly facing lip to which are welded a plurality of bearings having slots therein adapted to accept the hanger rods.

Weld repair of carbon-moly coke drums without postweld heat treatment

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

Moore, D.E.

1996-06-01

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

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.

Evaluation of Surface Residual Stresses in Friction Stir Welds Due to Laser and Shot Peening

NASA Technical Reports Server (NTRS)

Hatamleh, Omar; Rivero, Iris V.; Lyons, Jed

2007-01-01

The effects of laser, and shot peening on the residual stresses in Friction Stir Welds (FSW) has been investigated. The surface residual stresses were measured at five different locations across the weld in order to produce an adequate residual stress profile. The residual stresses before and after sectioning the coupon from the welded plate were also measured, and the effect of coupon size on the residual stress relaxation was determined and characterized. Measurements indicate that residual stresses were not uniform along the welded plate, and large variation in stress magnitude could be exhibited at various locations along the FSW plate. Sectioning resulted in significant residual stress relaxation in the longitudinal direction attributed to the large change in dimensions in this direction. Overall, Laser and shot peening resulted in a significant reduction in tensile residual stresses at the surface of the specimens.

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.

Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates

NASA Technical Reports Server (NTRS)

Petter, George E.; Figert, John D.; Rybicki, Daniel J.; Burns, Timothy

2006-01-01

A method of heat treatment has been developed to reverse some of the deleterious effects of friction stir welding of plates of aluminum alloy 7050. This alloy is considered unweldable by arc and high-energy-density beam fusion welding processes. The alloy can be friction stir welded, but as-welded workpieces exhibit low ductility, low tensile and yield strengths, and low resistance to stress corrosion cracking. Heat treatment according to the present method increases tensile and yield strengths, and minimizes or eliminates stress corrosion cracking. It also increases ductility. This method of heat treatment is a superior alternative to a specification-required heat treatment that caused the formation of large columnar grains, which are undesired. Workpieces subjected to the prior heat treatment exhibited elongations <2 percent, and standard three-point bend specimens shattered. The development of the present heat treatment method was guided partly by the principles that (1) by minimizing grain sizes and relieving deformation stresses, one can minimize or eliminate stress corrosion cracking and (2) the key to maximizing strength and eliminating residual stresses is to perform post-weld solution heating for as long a time as possible while incurring little or no development of large columnar grains in friction stir weld nuggets. It is necessary to perform some of the solution heat treatment (to soften the alloy and improve machine welding parameters) before welding. The following is an example of thickness- dependent pre- and post-weld heat treatments according to the present method: For plates 0.270 in. (approx.6.86 mm) thick milled from plates 4.5 in. (114.3 mm) thick, perform pre-weld solution heating at 890 F (477 C) for 1 hour, then cool in air. After friction stir welding, perform solution heating for 10 minutes, quench, hold at room temperature for 96 hours, then age at 250 F (121 C) for 5 hours followed by 325 F (163 C) for 27 hours.

Weld Repair of Thin Aluminum Sheet

NASA Technical Reports Server (NTRS)

Beuyukian, C. S.; Mitchell, M. J.

1986-01-01

Weld repairing of thin aluminum sheets now possible, using niobium shield and copper heat sinks. Refractory niobium shield protects aluminum adjacent to hole, while copper heat sinks help conduct heat away from repair site. Technique limits tungsten/inert-gas (TIG) welding bombardment zone to melt area, leaving surrounding areas around weld unaffected. Used successfully to repair aluminum cold plates on Space Shuttle, Commercial applications, especially in sealing fractures, dents, and holes in thin aluminum face sheets or clad brazing sheet in cold plates, heat exchangers, coolers, and Solar panels. While particularly suited to thin aluminum sheet, this process also used in thicker aluminum material to prevent surface damage near weld area.

A reliability analysis framework with Monte Carlo simulation for weld structure of crane's beam

NASA Astrophysics Data System (ADS)

Wang, Kefei; Xu, Hongwei; Qu, Fuzheng; Wang, Xin; Shi, Yanjun

2018-04-01

The reliability of the crane product in engineering is the core competitiveness of the product. This paper used Monte Carlo method analyzed the reliability of the weld metal structure of the bridge crane whose limit state function is mathematical expression. Then we obtained the minimum reliable welding feet height value for the welds between cover plate and web plate on main beam in different coefficients of variation. This paper provides a new idea and reference for the growth of the inherent reliability of crane.

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

NASA Astrophysics Data System (ADS)

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

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

Weld bead reinforcement removal: A method of improving the strength and ductility of peaked welds in 2219-T87 aluminum alloy plate

NASA Technical Reports Server (NTRS)

Lovoy, C. V.

1979-01-01

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

Transitional behaviour of thickness effects in shipbuilding materials (MS plate)

NASA Astrophysics Data System (ADS)

Mahmud, S. M. Ikhtiar; Razib, Amirul Hasan; Rahman, Md. Rabab Raiyatur

2017-12-01

Majority of the crack propagation in ships and offshore structures are caused due to fatigue. Previously, it was known that fatigue strength of notched specimen is dependent on size, but recently it came to light that fatigue strength of some welded joints depends on the thickness. Much investigation is done on the fatigue growth of welded joints. Fatigue often results in fracture accidents, which starts from the sites of structural discontinuities because of the reason that they may induce local stress concentrations. Structural discontinuities include notches, holes, sharp corners, and weld defects. Weld defects include undercut, porosity, lack of fusion, slag inclusion, incomplete weld root penetration, and misalignments. In order to investigate the effects of plate thickness on fatigue strength, semi-elliptical side notches (U and V shaped) in plates are studied in the present research. First consider a simple problem of crack emanating from notches in plates where the solution of stress intensity factor is given by an empirical formula so that the thickness effect on fatigue strength can easily be investigated for a variety of geometrical parameters. The present study aims to investigate the transitional behaviour of thickness effect in plates on fatigue strength. In order to calculate the stress, finite element analysis is carried by using ANSYS.

Penetration Effects of the Compound Vortex in Gas Metal-Arc Welding

DTIC Science & Technology

1988-05-01

steel plate using constant current GMAW equipment and argon + 2;. oxygen shielding gas. After welding, the plates were cut, ground, polished and etched...49 14. Typical time plot of current used in pulsed GMAW ..... 51 15. The experimental apparatus ........................... 54 16. Plot...this phenomenon could be employed in some manner to yield high penetration welds with low average current. 2. Pulsed GMAW . KolodziejczaK [26] studied

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.

The effects of aluminum oxide on inertial welding of aluminum in space applications

NASA Astrophysics Data System (ADS)

Smith, Michael H.

1992-05-01

Inertial friction welding of 2219 aluminum alloy studs to 2219 aluminum alloy plates is investigated in air and in an argon atmosphere to determine the effects of an intact oxide layer on weld quality. Scratch-brushing of plates and studs was performed in an argon atmosphere to break up the oxide layer and prevent reformation prior to testing. Argon was used to simulate the near-oxygen free space environment. Weld quality was determined by a bend test and by measurement of the fraction of the weld surface area that was dimpled in appearance following fracture of the weld. The fundamental theories of friction and wear that are applicable to friction welding are reviewed. A brief survey of current welding methods that may have application in space is presented, as well as a discussion of their feasibility and limitations. Characteristics of the space station are discussed as well as their consequences on welding in space. A qualitative model of the process of inertial friction welding based on the theories of friction and observations of welds and weld fractures is developed and presented.

Metallurgical effects on titanium by laser welding on dental stone.

PubMed

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

2003-12-01

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

Effect of Pin Geometry on the Mechanical Strength of Friction-Stir-Welded Polypropylene Composite Plates

NASA Astrophysics Data System (ADS)

Kordestani, F.; Ashenai Ghasemi, F.; Arab, N. B. M.

2017-09-01

Friction stir welding (FSW) is a solid-state welding process, which has successfully been applied in aerospace and automotive industries for joining materials. The friction stir tool is the key element in the FSW process. In this study, the effect of four different tool pin geometries on the mechanical properties of two types of polypropylene composite plates, with 30% glass and carbon fiber, respectively, were investigated. For this purpose, four pins of different geometry, namely, a threaded-tapered pin, square pin, four-flute threaded pin, and threaded-tapered pin with a chamfer were made and used to carry out the butt welding of 5-mm-thick plates. The standard tensile and Izod impact tests were performed to evaluate the tensile strength and impact toughness of welded specimens. The results indicated that the threaded-tapered pin with a chamfer produced welds with a better surface appearance and higher tensile and impact strengths. The tests also showed that, with the threaded-tapered pin with a chamfer, the impact strength of the glass- and carbon-fiber composite welds were about 40 and 50%, respectively, of that of the base materials.

Optimization of robotic welding procedures for maintenance repair of hydraulic turbines

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

Lamarche, L.; Galopin, M.; Simoneau, R.

1996-12-31

A six axes super-compact robot is used for field repair of cavitation damages found on the discharge ring of hydraulic turbines. Optimization of overlay welding procedures to minimize surface distortion and reduce tearing forces on anchors in concrete, were studied through experimentation and FEM modelling. Planned experimentation has been used to develop optimum pulsed GMAW schedules of stainless steel overlays in 2G position. Best welding sequence was resolved through over lay welding of free plates. Each overlay consisted in one or two layers which were welded in the longitudinal and/or transverse direction of the rectangular plate. A bidirectional welding mode,more » a longitudinal layer followed by a transverse layer position and no cooling between the two layers, were found to be most effective in reducing distortion. The optimized 2G welding procedure was applied to a simulated field repair. Plate was anchored on a massive iron bracket with a set of instrumented bolts, to understand how normal tearing forces in anchors evolve. Preliminary results on FEM modelling of lateral force on anchors indicate good correlation with experiments, for an elementary design.« less

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

Clean Metal Finishing Alternatives

DTIC Science & Technology

2006-05-01

Cr, must heat treat for hardness 4 4 Trivalent chrome Trivalent plating chemistry Varying success, some must be brush plate 3 3 Alloy plating...metals. Hard coating deposition unproven. 3 N/A Weld coating Electrospark Deposition/ Alloying (ESD/ ESA) Microarc welding Localized repair of non...Alternatives to chromate conversion coatings Al TriChrome Pretreatment (TCP)* – AnoChem TCP, Aluminescent, TCP-HF Trivalent Cr3+ conversion with Zr

Room temperature crack growth rates and -20 deg F fracture toughness of welded 1 1/4 inch A-285 steel plate

NASA Technical Reports Server (NTRS)

Shannon, J. L., Jr.; Rzasnicki, W.

1977-01-01

Data are presented which were developed in support of a structural assessment of NASA-LEWIS' 10-foot by 10-foot supersonic wind tunnel, critical portions of which are fabricated from rolled and welded 1 1/4 inch thick A-285 steel plate. Test material was flame cut from the tunnel wall and included longitudinal and circumferential weld joints. Parent metal, welds, and weld heat affected zone were tested. Tensile strength and fracture toughness were determined at -20 F, the estimated lowest tunnel operating temperature. Crack growth rates were measured at room temperature, where growth rates in service are expected to be highest.

Micro-Welding of Copper Plate by Frequency Doubled Diode Pumped Pulsed Nd:YAG Laser

NASA Astrophysics Data System (ADS)

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

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

Laser Welding of Coated Press-hardened Steel 22MnB5

NASA Astrophysics Data System (ADS)

Siltanen, Jukka; Minkkinen, Ari; Järn, Sanna

The press-hardening process is widely used for steels that are used in the automotive industry. Using ultra-high-strength steels enables car manufacturers to build lighter, stronger, and safer vehicles at a reduced cost and generating lower CO2 emissions. In the study, laser welding properties of the coated hot stamped steel 22BMn5 were studied. A constant 900 °C temperature was used to heat the steel plates, and two different furnace times were used in the press-hardening, being 300 and 740 seconds. Some of the plates were shot blasted to see the influence of the partly removed oxide layer on the laser welding and quality. The welding set-up, welding, and testing of the weld specimens complied with the automotive testing code SEP 1220.

Crack-growth behavior in thick welded plates of Inconel 718 at room and cryogenic temperatures

NASA Technical Reports Server (NTRS)

Forman, R. G.

1974-01-01

Results of mechanical-properties and axial-load fatigue and fracture tests performed on thick welded plates of Inconel 718 superalloy are presented. The test objectives were to determine the tensile strength properties and the crack-growth behavior in electron-beam, plasma-arc, and gas tungsten are welds for plates 1.90 cm (0.75 in) thick. Base-metal specimens were also tested to determine the flaw-growth behavior. The tests were performed in room-temperature-air and liquid nitrogen environments. The experimental crack-growth-rate data are correlated with theoretical crack-growth-rate predictions for semielliptical surface flaws.

Process Model for Friction Stir Welding

NASA Technical Reports Server (NTRS)

Adams, Glynn

1996-01-01

Friction stir welding (FSW) is a relatively new process being applied for joining of metal alloys. The process was initially developed by The Welding Institute (TWI) in Cambridge, UK. The FSW process is being investigated at NASA/MSEC as a repair/initial weld procedure for fabrication of the super-light-weight aluminum-lithium shuttle external tank. The FSW investigations at MSFC were conducted on a horizontal mill to produce butt welds of flat plate material. The weldment plates are butted together and fixed to a backing plate on the mill bed. A pin tool is placed into the tool holder of the mill spindle and rotated at approximately 400 rpm. The pin tool is then plunged into the plates such that the center of the probe lies at, one end of the line of contact, between the plates and the shoulder of the pin tool penetrates the top surface of the weldment. The weld is produced by traversing the tool along the line of contact between the plates. A lead angle allows the leading edge of the shoulder to remain above the top surface of the plate. The work presented here is the first attempt at modeling a complex phenomenon. The mechanical aspects of conducting the weld process are easily defined and the process itself is controlled by relatively few input parameters. However, in the region of the weld, plasticizing and forging of the parent material occurs. These are difficult processes to model. The model presented here addresses only variations in the radial dimension outward from the pin tool axis. Examinations of the grain structure of the weld reveal that a considerable amount of material deformation also occurs in the direction parallel to the pin tool axis of rotation, through the material thickness. In addition, measurements of the axial load on the pin tool demonstrate that the forging affect of the pin tool shoulder is an important process phenomenon. Therefore, the model needs to be expanded to account for the deformations through the material thickness and the forging affect of the shoulder. The energy balance at the boundary of the plastic region with the environment required that energy flow away from the boundary in both radial directions. One resolution to this problem may be to introduce a time dependency into the process model, allowing the energy flow to oscillate across this boundary. Finally, experimental measurements are needed to verify the concepts used here and to aid in improving the model.

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

NASA Astrophysics Data System (ADS)

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

2014-12-01

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

Quasi-Rayleigh waves in butt-welded thick steel plate

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

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

2015-03-31

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

Considerations on repeated repairing of weldments in Inconel 718 alloy

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

Plasma Processes of Cutting and Welding

DTIC Science & Technology

1976-02-01

TIG process. 2.2.2 Keyhole Welding In plasma arc welding , the term...Cutting 3 3 4 4 4 2.2 Plasma Arc Welding 5 2.2.1 Needle Arc Welding 2.2.2 Keyhole Welding 5 6 3. Applications 8 93.1 Economics 4. Environmental Aspects of...Arc Lengths III. Needle Arc Welding Conditions IV. Keyhole Welding Conditions v. Chemical Analyses of Plates Used - vii - 1. 2. 3. 4. 5. 6. 7. 8.

Application of YAG Laser TIG Arc Hybrid Welding to Thin AZ31B Magnesium Alloy Sheet

NASA Astrophysics Data System (ADS)

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

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

Gas Metal Arc Welding Process Modeling and Prediction of Weld Microstructure in MIL A46100 Armor-Grade Martensitic Steel

DTIC Science & Technology

2013-06-01

acicular/Widmanstatten ferrite (a version of ferrite possessing an acicular/ lenticular - plate morphology which grows into the untransformed aus- tenite...boundary regions which have been transformed into allotriomorphic ferrite, as well as lenticular -shaped Widmanstatten plates advancing from the

49 CFR 179.200-7 - Materials.

Code of Federal Regulations, 2010 CFR

2010-10-01

... suitable for welding and comply with one of the following specifications (IBR, see § 171.7 of this... to testing. (A typical sensitizing treatment is 1 hour at 1250 F.) (e) Nickel plate: Nickel plate... must be suitable for fusion welding and comply with the following specification (IBR, see § 171.7 of...

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.

Investigation of Microstructure and Microhardness in Self-Reacting Friction Stir Welded AA2014-T6 and AA2219-T87

NASA Technical Reports Server (NTRS)

Horton, K. Renee; McGill, Preston; Barkey, Mark

2011-01-01

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. This work reports on the microstructure and microhardness of SR-FSW between two dissimilar aluminum alloys. Specifically, the study examines the cross section of the weld joint formed between an AA2014-T6 plate on the advancing side and an AA2219-T87 plate on the retreating side. The microstructural analysis shows an irregularly displaced weld seam from the advancing side past the thermo-mechanical affected zone (TMAZ) into the weld nugget region. There are sharp variations in the microhardness across the weld. These variations are described in the paper and mechanisms for their formation are discussed.

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

PubMed

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

2013-01-01

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

Study of the Performance of Stainless Steel A-TIG Welds

NASA Astrophysics Data System (ADS)

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

2008-04-01

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

Inert-Gas Diffuser For Plasma Or Arc Welding

NASA Technical Reports Server (NTRS)

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

1994-01-01

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

Welds in thermoplastic composite materials

NASA Astrophysics Data System (ADS)

Taylor, N. S.

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

A Study on the compensation margin on butt welding joint of Large Steel plates during Shipbuilding construction.

NASA Astrophysics Data System (ADS)

Kim, J.; Jeong, H.; Ji, M.; Jeong, K.; Yun, C.; Lee, J.; Chung, H.

2015-09-01

This paper examines the characteristics of butt welding joint shrinkage for shipbuilding and marine structures main plate. The shrinkage strain of butt welding joint which is caused by the process of heat input and cooling, results in the difference between dimensions of the actual parent metal and the dimensions of design. This, in turn, leads to poor quality in the production of ship blocks and reworking through period of correction brings about impediment on improvement of productivity. Through experiments on butt welding joint's shrinkage strain on large structures main plate, the deformation of welding residual stress in the form of I, Y, V was obtained. In addition, the results of experiments indicate that there is limited range of shrinkage in the range of 1 ∼ 2 mm in 11t ∼ 21.5t thickness and the effect of heat transfer of weld appears to be limited within 1000 mm based on one side of seam line so there was limited impact of weight of parent metal on the shrinkage. Finally, it has been learned that Shrinkage margin needs to be applied differently based on groove phenomenon in the design phase in order to minimize shrinkage.

Development of electromagnetic welding facility of flat plates for nuclear industry

NASA Astrophysics Data System (ADS)

Kumar, Rajesh; Sahoo, Subhanarayan; Sarkar, Biswanath; Shyam, Anurag

2017-04-01

Electromagnetic pulse welding (EMPW) process, one of high speed welding process uses electromagnetic force from discharged current through working coil, which develops a repulsive force between the induced current flowing parallel and in opposite direction. For achieving the successful weldment using this process the design of working coil is the most important factor due to high magnetic field on surface of work piece. In case of high quality flat plate welding factors such as impact velocity, angle of impact standoff distance, thickness of flyer and overlap length have to be chosen carefully. EMPW has wide applications in nuclear industry, automotive industry, aerospace, electrical industries. However formability and weldability still remain major issues. Due to ease in controlling the magnetic field enveloped inside tubes, the EMPW has been widely used for tube welding. In case of flat components control of magnetic field is difficult. Hence the application of EMPW gets restricted. The present work attempts to make a novel contribution by investigating the effect of process parameters on welding quality of flat plates. The work emphasizes the approaches and engineering calculations required to effectively use of actuator in EMPW of flat components.

Detection and assessment of flaws in friction stir welded metallic plates

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

Mechanical strength of laser-welded cobalt-chromium alloy.

PubMed

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

2004-05-15

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

Electroslag and electrogas welding

NASA Technical Reports Server (NTRS)

Campbell, H. C.

1972-01-01

These two new joining methods perform welding in the vertical position, and therein lies the secret of their impressive advantages in material handling, in weld preparation, in welding speed, in freedom from distortion, and in weld soundness. Once the work has been set in the proper vertical position for welding, no further plate handling is required. The molten filler metal is held in place by copper shoes or dams, and the weld is completed in one pass.

Finite element normal mode analysis of resistance welding jointed of dissimilar plate hat structure

NASA Astrophysics Data System (ADS)

Nazri, N. A.; Sani, M. S. M.

2017-10-01

Structural joints offer connection between structural element (beam, plate, solid etc.) in order to build a whole assembled structure. The complex behaviour of connecting elements plays a valuable role in characteristics of dynamic such as natural frequencies and mode shapes. In automotive structures, the trustworthiness arrangement of the structure extremely depends on joints. In this paper, top hat structure is modelled and designed with spot welding joint using dissimilar materials which is mild steel 1010 and stainless steel 304, using finite element software. Different types of connector elements such as rigid body element (RBE2), welding joint element (CWELD), and bar element (CBAR) are applied to represent real connection between two dissimilar plates. Normal mode analysis is simulated with different types of joining element in order to determine modal properties. Natural frequencies using RBE2, CBAR and CWELD are compared to equivalent rigid body method. Connection that gives the lowest percentage error among these three will be selected as the most reliable joining for resistance spot weld. From the analysis, it is shown that CWELD is better compared to others in term of weld joining among dissimilar plate materials. It is expected that joint modelling of finite element plays significant role in structural dynamics.

Optimization of process parameters of pulsed TIG welded maraging steel C300

NASA Astrophysics Data System (ADS)

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

2016-09-01

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

METHOD OF MAKING AND PLATE CONNECTION

DOEpatents

Patriarca, P.; Shubert, C.E.; Slaughter, G.M.

1963-02-26

This invention relates to a method of joining, by welding or brazing, a tube to a plate, particularly where the tube and the plate are of different thickness or have different thermal conductivities and are subject to high temperatures. In this method the tube is inserted in the core of a plate containing an annular groove in its back face concentric with the bore and in communication with the bore. One end of the tube is welded substantially flush with the front end of the plate. Brazing alloy is placed in the groove on the back face of the plate and heat is applied to the plate and tube to melt the brazing alloy to permit the alloy to flow into the bore and bond the tube to the plate. (AEC)

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.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Yb-fibre Laser Welding of 6 mm Duplex Stainless Steel 2205

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

Experimental investigations of tungsten inert gas assisted friction stir welding of pure copper plates

NASA Astrophysics Data System (ADS)

Constantin, M. A.; Boșneag, A.; Nitu, E.; Iordache, M.

2017-10-01

Welding copper and its alloys is usually difficult to join by conventional fusion welding processes because of high thermal diffusivity of the copper, alloying elements, necessity of using a shielding gas and a clean surface. To overcome this inconvenience, Friction Stir Welding (FSW), a solid state joining process that relies on frictional heating and plastic deformation, is used as a feasible welding process. In order to achieve an increased welding speed and a reduction in tool wear, this process is assisted by another one (WIG) which generates and adds heat to the process. The aim of this paper is to identify the influence of the additional heat on the process parameters and on the welding joint properties (distribution of the temperature, hardness and roughness). The research includes two experiments for the FSW process and one experiment for tungsten inert gas assisted FSW process. The outcomes of the investigation are compared and analysed for both welding variants. Adding a supplementary heat source, the plates are preheated and are obtain some advantages such as reduced forces used in process and FSW tool wear, faster and better plasticization of the material, increased welding speed and a proper weld quality.

The influence of laser pulse waveform on laser-TIG hybrid welding of AZ31B magnesium alloy

NASA Astrophysics Data System (ADS)

Song, Gang; Luo, Zhimin

2011-01-01

By dividing laser pulse duration into two parts, three kinds of laser waveforms are designed, including a high power density pulse (HPDP) laser in a short duration set at the beginning of the laser waveform. This paper aims to find out the laser pulse waveform and idiographic critical values of HPDP, which can affect the magnesium penetration in laser-tungsten inert gas (TIG) hybrid welding. Results show that when the laser pulse duration of HPDP is not more than 0.4 ms, the welding penetration values of lasers with HPDP are larger than otherwise. Also, the welding penetration values of laser with HPDP have increased by up to 26.1%. It has been found that with HPDP, the laser can form the keyhole more easily because the interaction between laser and the plate is changed, when the TIG arc preheats the plate. Besides, the laser with high power density and short duration strikes on the plates so heavily that the corresponding background power can penetrate into the bottom of the keyhole and maintain the keyhole open, which facilitates the final welding penetration.

Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes.

PubMed

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

2017-04-01

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

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.

Microstructure and Properties of 5083 Al/1060 Al/AZ31 Composite Plate Fabricated by Explosive Welding

NASA Astrophysics Data System (ADS)

Yang, Suyuan; Bao, Jiawei

2018-03-01

A 5083 Al/1060 Al/AZ31 composite plate was fabricated by explosive welding. The microstructure and properties of the composite plate were investigated after explosive welding. The results showed that all bonding interfaces were wavy interfaces. With an increasing distance from the detonation point, the wavelength and the amplitude also increased. The EDS results indicated that a 5-μm diffusion layer was observed at the 1060 Al/AZ31 layer, including the Mg2Al3 phase. Adiabatic shear bands and twin structures were observed in AZ31. The shear bond strength of the 5083 Al/1060 Al interface was 60 MPa, and the shear bond strength of the 1060 Al/AZ31 interface was 84 MPa.

Brittle crack arrestability of thick steel plate welds in large structure

NASA Astrophysics Data System (ADS)

An, Gyu Baek; Park, Joon Sik

2011-10-01

Recently, there has been such a critical issue in shipbuilding industry that much larger and stronger ships are required to develop oil and gas in the Arctic region. Attention has been paid to obtaining high strength, good toughness at low temperature, and good weldability. An experimental study was performed to evaluate the brittle crack arrest toughness value (Kca) and brittle crack arrest method of welded joints using EH40 grade steel with a thickness of 80 mm. The test specimens were made by both flux cored arc welding (FCAW) and combined welding (EGW+FCAW) processes. Temperature gradient ESSO test was performed to measure the Kca of the base metal. Also, a constant temperature (-10 °C) ESSO test was performed to establish a brittle crack arrest method using high toughness welding consumable with real structural specimens. The research aims in this study were to investigate the effect of joint design and welding consumable for the crack arrestability of thick steel plates using EH40 grade shipbuilding steel of straight block joint weld line with two kinds of welding processes.

Submerged arc welding of heavy plate

NASA Technical Reports Server (NTRS)

Wilson, R. A.

1972-01-01

The submerged arc process is particularly suitable for heavy plate welding because of its ability to combine very high deposit rates along with excellent quality. It does these things without the smoke and spatter often accompanying other processes. It is available today in several forms that are pointed to the fabricators of heavy sections with long, short or round about welds. Tandem arc full automatic equipment is particularly suitable for those long heavy welds where speed and deposit rate are of the first order. An attachment called long stick-out which makes use of the IR drop on long electrode extensions can be included on this equipment to increase deposition rates 50% or more.

Laser-Hybrid welding, an innovative technology to join automotive body parts

NASA Astrophysics Data System (ADS)

Sieben, Manuel; Brunnecker, Frank

The design of Tail lamps has been changed dramatically since cars built. At modern lamps, the lenses are absolutely transparent and allow a direct view onto the weld seam. Conventional welding technologies, such as vibration and hot plate welding cannot compete with this demand. Focused on this targeted application, LPKF Laser & Electronics AG has developed in cooperation with the Bavarian Laser Centre a unique Laser welding technology called hybrid welding.

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.

Studies on microstructure, mechanical and pitting corrosion behaviour of similar and dissimilar stainless steel gas tungsten arc welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

In the present study, an attempt has been made to weld dissimilar alloys of 5mm thick plates i.e., austenitic stainless steel (316L) and duplex stainless steel (2205) and compared with that of similar welds. Welds are made with conventional gas tungsten arc welding (GTAW) process with two different filler wires namely i.e., 309L and 2209. Welds were characterized using optical microscopy to observe the microstructural changes and correlate with mechanical properties using hardness, tensile and impact testing. Potentio-dynamic polarization studies were carried out to observe the pitting corrosion behaviour in different regions of the welds. Results of the present study established that change in filler wire composition resulted in microstructural variation in all the welds with different morphology of ferrite and austenite. Welds made with 2209 filler showed plate like widmanstatten austenite (WA) nucleated at grain boundaries. Compared to similar stainless steel welds inferior mechanical properties was observed in dissimilar stainless steel welds. Pitting corrosion resistance is observed to be low for dissimilar stainless steel welds when compared to similar stainless steel welds. Overall study showed that similar duplex stainless steel welds having favorable microstructure and resulted in better mechanical properties and corrosion resistance. Relatively dissimilar stainless steel welds made with 309L filler obtained optimum combination of mechanical properties and pitting corrosion resistance when compared to 2209 filler and is recommended for industrial practice.

EFFECTS OF COMPOSITION ON THE MECHANICAL PROPERTIES OF NI-CR-MO-CO FILLER METALS.

DTIC Science & Technology

STEEL, WELDING RODS), CHEMICAL ANALYSIS, CARBON ALLOYS , COBALT ALLOYS , CHROMIUM ALLOYS , MOLYBDENUM ALLOYS , NICKEL ALLOYS , MARAGING STEELS...ALUMINUM COMPOUNDS, TITANIUM , NONMETALS, SHIP HULLS, SHIP PLATES, SUBMARINE HULLS, WELDING , WELDS , MECHANICAL PROPERTIES, STATISTICAL ANALYSIS, MICROSTRUCTURE.

Welding of titanium and stainless steel using the composite insert

NASA Astrophysics Data System (ADS)

Cherepanov, A. N.; Mali, V. I.; Orishich, A. M.; Malikov, A. G.; Drozdov, V. O.; Malyutina, Y. N.

2016-11-01

The paper concerns the possibility of obtaining a lasting permanent joint of dissimilar metals: technically pure titanium and stainless steel using laser welding and an intermediate composite insert. The insert was a four-layer composition of plates of steel, copper, niobium, and titanium welded by explosion. The material layers used in the insert prevented the molten steel and titanium from mixing, which excluded the formation of brittle intermetallic compounds, such as FeTi and Fe2Ti. The optimization of explosion welding parameters provided a high quality of the four-layer composition and the absence of defects in the area of the joint of insert plates. The results of strength tests showed that values of the ultimate strength and yield of the permanent joint with the composite insert welded by explosion are comparable to the strength characteristics of titanium.

Microstructure and Mechanical Properties of Plasma Arc Brazed AISI 304L Stainless Steel and Galvanized Steel Plates

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Elucidation of Metallic Plume and Spatter Characteristics Based on SVM During High-Power Disk Laser Welding

NASA Astrophysics Data System (ADS)

Gao, Xiangdong; Liu, Guiqian

2015-01-01

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

Laser-based welding of 17-4 PH martensitic stainless steel in a tubular butt joint configuration with a built-in backing bar

NASA Astrophysics Data System (ADS)

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

2016-08-01

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

Ferrous friction stir weld physical simulation

NASA Astrophysics Data System (ADS)

Norton, Seth Jason

2006-04-01

Traditional fusion welding processes have several drawbacks associated with the melting and solidification of metal. Weld defects associated with the solidification of molten metal may act as initiation sites for cracks. Segregation of alloying elements during solidification may cause local changes in resistance to corrosion. The high amount of heat required to produce the molten metal in the weld can produce distortion from the intended position on cooling. The heat from the electric arc commonly used to melt metal in fusion welds may also produce metal fumes which are a potential health hazard. Friction stir welding is one application which has the potential to make full thickness welds in a single pass, while eliminating fume, reducing distortion, and eliminating solidification defects. Currently the friction stir welding process is used in the aerospace industry on aluminum alloys. Interest in the process by industries which rely on iron and its alloys for structural material is increasing. While friction stir welding has been shown to be feasible with iron alloys, the understanding of friction stir welding process effects on these materials is in its infancy. This project was aimed to better that understanding by developing a procedure for physical simulation of friction stir welding. Friction stir weld material tracer experiments utilizing stainless steel markers were conducted with plates of ingot iron and HSLA-65. Markers of 0.0625" diameter 308 stainless steel worked well for tracing the end position of material moved by the friction stir welding tool. The markers did not produce measurable increases in the loading of the tool in the direction of travel. Markers composed of 0.25" diameter 304 stainless steel did not perform as well as the smaller markers and produced increased loads on the friction stir welding tool. The smaller markers showed that material is moved in a curved path around the tool and deposited behind the tool. Material near the surface is moved a greater distance as it is acted upon by the tool shoulder. A friction stir weld was made on a plate of HSLA-65 which had 0.0625" Inconel sheathed thermocouples embedded in the tool path at seven positions. Thermocouples on the top of the plate acquired data at the desired position until encountering the shoulder, at which point they were sheared by the shoulder and stirred behind the tool. Thermocouples on the bottom of the plate were deformed a relatively small amount and acquired data throughout the welding process. Heating rates calculated from the slope of the acquired temperature data show that the peak heating rate (˜1100°C on top and ˜500°C on the bottom) occurs on both the top and bottom of the weld at temperatures between 350°C and 500°C. An increase in the heating rate occurring at elevated temperature was associated with the transformation from ferrite to austenite. Comparison of phase transformation data acquired in rapid heating in the GleebleRTM suggests that austenite transforms back to ferrite at higher temperatures in the presence of strain than in its absence. Peak temperatures on the top of the plate exceeded 1200°C and peak temperatures acquired on the bottom exceeded 1000°C. The heating rate method of data analysis was sensitive enough to pick up variations in the heating rate which occurred at the same frequency as the rotation rate of the tool. (Abstract shortened by UMI.)

Stress corrosion evaluation of HP 9Ni-4Co-0.30C steel plate welds

NASA Technical Reports Server (NTRS)

Torres, Pablo D.

1993-01-01

A stress corrosion cracking (SCC) investigation was conducted on HP 9Ni-4Co-0.30C steel plate welds (welded by using straight polarity plasma arc and HP 9Ni-4Co-0.20C weld wire) since this material is being considered for use in the Advanced Solid Rocket Motor (ASRM) program. Prior to the welding, the material was double tempered at 538 C (1,000 F). After welding, only part of the material was stress relieved at 510 C (950 F) for 3 h. Round tensile specimens obtained from nonstress-relieved material were tested in 100-percent relative humidity at 38 C (100 F), in 3.5-percent NaCl alternate immersion, and in 5-percent salt spray at 35 C (95 F). Specimens obtained from stress-relieved material were tested in alternate immersion. The stress levels were 50, 75, and 90 percent of the corresponding 0.2-percent yield strength (YS). All the nonstress-relieved specimens exposed to salt spray and alternate immersion failed. Stress-relieved specimens (exposed to alternate immersion) failed at 75 and 90 percent of YS. No failures occurred at 50 percent of YS in the stress-relieved specimens which indicates a beneficial effect of the stress relief on the SCC resistance of these welds. The stress relief also had a positive effect on the mechanical properties of the welds (the most important being an increase of 21 percent on the YS). Under the conditions of these tests, the straight polarity plasma are welded HP 9Ni4Co-0.30C steel plate was found highly susceptible to SCC in the nonstress-relieved condition. This susceptibility to SCC was reduced by stress relieving.

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

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

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

PubMed

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

2016-04-01

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

Building No. 392, interior overview with welding stalls and steel ...

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

Building No. 392, interior overview with welding stalls and steel plate floor, view facing west-southwest - U.S. Naval Base, Pearl Harbor, Marine Railway No. 1 Accessories House & Apprentice Welding School, Additions, Intersection of Avenue B & Sixth Street, Pearl City, Honolulu County, HI

Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

NASA Technical Reports Server (NTRS)

Horton, Karla Renee

2011-01-01

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures.

Numerical analysis on temperature field in single-wire flux-aided backing-submerged arc welding

NASA Astrophysics Data System (ADS)

Pu, Juan; Wu, Ming Fang; Pan, Haichao

2017-07-01

Single-wire flux-aided backing-submerged arc welding (FAB-SAW) technology has been widely used to weld thick steel plate due to its easy assembly and high heat input. The microstructure and property of welded joint are closely related to the thermal field of FAB-SAW process. In this research, the feature of thermal field for single-wire FAB-SAW was investigated. Based on the heat transfer mechanism, a three-dimensional transient model for thermal field was developed based on the influence of steel thickness, groove angle and ceramic backing. The temperature profile in single-wire FAB-SAW of D36 steel under different welding conditions was simulated by ANSYS. The characteristic of thermal field was analyzed and the influences of groove angle on temperature field for different plate thicknesses were discussed. The calculated geometries and dimensions of weld cross-section under different conditions show a good agreement with the experimental results. This newly built model can describe the thermal field accurately, which would be helpful to understanding the thermophysical mechanism of FAB-SAW and optimizing the welding process.

Friction Stir Welding of Curved Plates

NASA Technical Reports Server (NTRS)

Sanchez, Nestor

1999-01-01

Friction stir welding (FSW) is a remarkable technology for making butt and lap joints in aluminum alloys. The process operates by passing a rotating tool between two closely butted plates. This process generates heat and the heated material is stirred from both sides of the plates to generate a high quality weld. Application of this technique has a very broad field for NASA. In particular, NASA is interested in using this welding process to manufacture tanks and curved elements. Therefore, this research has been oriented to the study the FSW of curved plates. The study has covered a number of topics that are important in the model development and to uncover the physical process involve in the welding itself. The materials used for the experimental welds were as close to each other as we could possibly find, aluminum 5454-0 and 5456-0 with properties listed at http://matweb.com. The application of FSW to curved plates needs to consider the behavior that we observed in this study. There is going to be larger force in the normal direction (Fz) as the curvature of the plate increases. A particular model needs to be derived for each material and thickness. A more complete study should also include parameters such as spin rate, tool velocity, and power used. The force in the direction of motion (Fx) needs to be reconsidered to make sure of its variability with respect to other parameters such as velocity, thickness, etc. It seems like the curvature does not play a role in this case. Variations in temperature were found with respect to the curvature. However, these changes seem to be smaller than the effect on Fz. The temperatures were all below the melting point. We understand now that the process of FSW produces a three dimensional flow of material that takes place during the weld. This flow needs to be study in a more detailed way to see in which directions the flow of material is stronger. It could be possible to model the flow using a 2-dimensional model in the particular directions where the flow moves faster. More experimental information is required to enrich the knowledge about FSW, and from this point, derive useful mathematical formulas to optimize the process and the design of the machines that will perform it. More experiments and experimental equipment are required to uncover the mathematics of the process.

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.

Design and Fabrication of Quadrupole Ion Mass Spectrometer for Upper Atmosphere.

DTIC Science & Technology

1981-09-30

34 diameter con-flat flange were T.I.G. welded to the end of each of three bowls. All bowls were then electro- polished, cleaned and sent out to have...plated surface was .0001" to .0002" thick. After gold plating, the hemispheres were mated and T.I.G. welded to form a sphere with a con-flat flange at...Valve Rotatable Conflat to fit k" Swage Lock Weld Adaptors. 5 2 3/4" Conflat Flanges machined to fit Swage Lock unions. 12 10-24 x 2 " Brass Screws necket

Welding of HSLA-100 steel using ultra low carbon bainitic weld metal to eliminate preheating

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

Devletian, J.H.; Singh, D.; Wood, W.E.

1996-12-31

Advanced high strength steels such as the Navy`s HSLA-100 and HSLA-80 contain sufficiently low carbon levels to be weldable without preheating. Unfortunately, commercial filler metals specifically designed to weld these steels without costly preheating have not yet been developed. The objective of this paper is to show that the Navy`s advanced steels can be welded by gas metal-arc (GMAW) and gas tungsten-arc welding (GTAW) without preheating by using filler metal compositions that produce weld metal with an ultra-low carbon bainitic (ULCB) microstructure. Filler metals were fabricated from vacuum induction melted (VIM) ingots containing ultra-low levels of C, O and N.more » HSLA-100 plate and plate from the VIM ingots were welded by both GMAW and GTAW with Ar-5% CO{sub 2} shielding gas using welding conditions to achieve cooling times from 800 to 500 C (t{sub 8-5}) from 35 to 14 sec. Weld metal tensile, hardness and CVN impact toughness testing as well as microstructural studies using transmission electron microscopy were conducted. The ULCB weld metal was relatively insensitive to cooling rate, resulting in good strength and toughness values over a wide range of t{sub 8-5} cooling times. Filler metal compositions which met the mechanical property requirements for HSLA-100, HSLA-80 and HSLA-65 weld metal were developed.« less

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

Effects of argon gas flow rate on laser-welding.

PubMed

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

2012-01-01

The purpose of this study was to evaluate the effects of the rate of argon gas flow on joint strength in the laser-welding of cast metal plates and to measure the porosity. Two cast plates (Ti and Co-Cr alloy) of the same metal were abutted and welded together. The rates of argon gas flow were 0, 5 and 10 L/min for the Co-Cr alloy, and 5 and 10 L/min for the Ti. There was a significant difference in the ratio of porosity according to the rate of argon gas flow in the welded area. Argon shielding had no significant effect on the tensile strength of Co-Cr alloy. The 5 L/min specimens showed greater tensile strength than the 10 L/min specimens for Ti. Laser welding of the Co-Cr alloy was influenced very little by argon shielding. When the rate of argon gas flow was high, joint strength decreased for Ti.

Investigation on the Interface Morphologies of Explosive Welding of Inconel 625 to Steel A516 Plates

NASA Astrophysics Data System (ADS)

Mousavi, S. A. A. Akbari; Zareie, H. R.

2011-01-01

The purpose of this study is to produce composite plates by explosive cladding process. This is a process in which the controlled energy of explosives is used to create a metallic bond between two similar or dissimilar materials. The welding conditions were tailored through parallel geometry route with different operational parameters. In this investigation, a two-pronged study was adopted to establish the conditions required for producing successful solid state welding: (a) Analytical calculations to determine the weldability domain or welding window; (b) Metallurgical investigations of explosive welding experiments carried out under different explosive ratios to produce both wavy and straight interfaces. The analytical calculations confirm the experimental results. Optical microscopy studies show that a transition from a smooth to wavy interface occurs with an increase in explosive ratio. SEM studies show that the interface was outlined by characteristic sharp transition between two materials.

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.

Friction Stir Weld System for Welding and Weld Repair

NASA Technical Reports Server (NTRS)

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

2001-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

OPERATION SUNBEAM, SHOT SMALL BOY. Project Officer’s Report - Project 2.2, Measurement of Fast-Neutron Dose Rate as a Function of Time

DTIC Science & Technology

1985-09-01

Calibration 44 3.1.3 The SPIDER Calibration 45 3.1.*» Thermistor Temperature Detector Calibration. . 45 3.2 Amplifier Calibration 45 3.2.1...of a material with high conductivity and preferably high permeability. For the bunker construction, welded one-inch soft-steel plates were chosen for...Kovar flanges (metal- to-ceramic seal). The external plates are hel1arc- welded to the flanges. The external plate facing away from the incoming

1001619

NASA Image and Video Library

2010-09-15

SAMUEL SMITH (WELD TECHNICIAN, JACOBS ESTS GROUP/ALL POINTS) AND ANDRÉ PASEUR (WELD TECHNICIAN, JACOBS ESTS GROUP/ERC) DISPLAY TWO PROCESS DEMONSTRATION ARTICLES – A 9-FOOT BUTT WELD (FOREGROUND) AND A HEXAGON FABRICATED FROM FRICTION STIR WELDED PLATES (BACKGROUND) – THAT WERE FABRICATED FROM 6AL-4V TITANIUM (ELI) USING THERMAL STIR WELDING. THIS WORK WAS PERFORMED FOR A NASA TECHNOLOGY TRANSFER INDUSTRIAL PARTNER (KEYSTONE SYNERGETIC ENTERPRISES, INC.) IN SUPPORT OF A PROJECT FOR THE U.S. NAVY

Inert-gas welding and brazing enclosure fabricated from sheet plastic

NASA Technical Reports Server (NTRS)

Wisner, J. P.

1965-01-01

Custom-fabricated plastic bag maintains an inert-gas atmosphere for welding and brazing certain metals. The bag fits over part of the workpieces and the welding and brazing tools. It is also used for metal brazing and fusion plating which require an inert-gas atmosphere.

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.

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

NASA Astrophysics Data System (ADS)

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

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

Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

NASA Astrophysics Data System (ADS)

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

1999-10-01

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

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.

Measured Biaxial Residual Stress Maps in a Stainless Steel Weld

DOE PAGES

Olson, Mitchell D.; Hill, Michael R.; Patel, Vipul I.; ...

2015-09-16

Here, this paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a stainless steel weld. A long stainless steel (316L) plate with an eight-pass groove weld (308L filler) was used. The biaxial stress measurements follow a recently developed approach, comprising a combination of contour method and slitting measurements, with a computation to determine the effects of out-of-plane stress on a thin slice. The measured longitudinal stress is highly tensile in the weld- and heat-affected zone, with a maximum around 450 MPa, and compressive stress toward the transverse edges around ₋250more » MPa. The total transverse stress has a banded profile in the weld with highly tensile stress at the bottom of the plate (y = 0) of 400 MPa, rapidly changing to compressive stress (at y = 5 mm) of ₋200 MPa, then tensile stress at the weld root (y = 17 mm) and in the weld around 200 MPa, followed by compressive stress at the top of the weld at around ₋150 MPa. Finally, the results of the biaxial map compare well with the results of neutron diffraction measurements and output from a computational weld simulation.« less

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

Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

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

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

1999-10-01

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

Electrochemical Investigation of the Corrosion of Different Microstructural Phases of X65 Pipeline Steel under Saturated Carbon Dioxide Conditions

PubMed Central

Yang, Yuanfeng; Joshi, Gaurav R.; Akid, Robert

2015-01-01

The aim of this research was to investigate the influence of metallurgy on the corrosion behaviour of separate weld zone (WZ) and parent plate (PP) regions of X65 pipeline steel in a solution of deionised water saturated with CO2, at two different temperatures (55 °C and 80 °C) and at initial pH~4.0. In addition, a non-electrochemical immersion experiment was also performed at 80 °C in CO2, on a sample portion of X65 pipeline containing part of a weld section, together with adjacent heat affected zones (HAZ) and parent material. Electrochemical impedance spectroscopy (EIS) was used to evaluate the corrosion behaviour of the separate weld and parent plate samples. This study seeks to understand the significance of the different microstructures within the different zones of the welded X65 pipe in CO2 environments on corrosion performance; with particular attention given to the formation of surface scales; and their composition/significance. The results obtained from grazing incidence X-ray diffraction (GIXRD) measurements suggest that, post immersion, the parent plate substrate is scale free, with only features arising from ferrite (α-Fe) and cementite (Fe3C) apparent. In contrast, at 80 °C, GIXRD from the weld zone substrate, and weld zone/heat affected zone of the non-electrochemical sample indicates the presence of siderite (FeCO3) and chukanovite (Fe2CO3(OH)2) phases. Scanning Electron Microscopy (SEM) on this surface confirmed the presence of characteristic discrete cube-shaped crystallites of siderite together with plate-like clusters of chukanovite.

Ion plating seals microcracks or porous metal components

NASA Technical Reports Server (NTRS)

Spalvins, T.; Buckley, D. H.; Brainard, W. A.

1972-01-01

Description of ion plating process is given. Advantage of this process is that any plating metal or alloy can be selected, whereas, for conventional welding, material selection is limited by compatability.

1001624

NASA Image and Video Library

2010-09-15

SAMUEL SMITH (WELD TECHNICIAN, JACOBS ESTS GROUP/ALL POINTS) DISPLAYS A HEXAGON THAT WAS FABRICATED FROM FRICTION STIR WELDED PLATES OF 6AL-4V TITANIUM (ELI) USING THERMAL STIR WELDING. THIS WORK WAS PERFORMED FOR A NASA TECHNOLOGY TRANSFER INDUSTRIAL PARTNER (KEYSTONE SYNERGETIC ENTERPRISES, INC.) IN SUPPORT OF A PROJECT FOR THE U.S. NAVY

1001623

NASA Image and Video Library

2010-09-15

ANDRÉ PASEUR (WELD TECHNICIAN, JACOBS ESTS GROUP/ERC) DISPLAYS A HEXAGON THAT WAS FABRICATED FROM FRICTION STIR WELDED PLATES OF 6AL-4V TITANIUM (ELI) USING THERMAL STIR WELDING. THIS WORK WAS PERFORMED FOR A NASA TECHNOLOGY TRANSFER INDUSTRIAL PARTNER (KEYSTONE SYNERGETIC ENTERPRISES, INC.) IN SUPPORT OF A PROJECT FOR THE U.S. NAVY

NUCLEAR REACTOR FUEL ELEMENT ASSEMBLY

DOEpatents

Stengel, F.G.

1963-12-24

A method of fabricating nuclear reactor fuel element assemblies having a plurality of longitudinally extending flat fuel elements in spaced parallel relation to each other to form channels is presented. One side of a flat side plate is held contiguous to the ends of the elements and a welding means is passed along the other side of the platertransverse to the direction of the longitudinal extension of the elements. The setting and speed of travel of the welding means is set to cause penetration of the side plate with welds at bridge the gap in each channel between adjacent fuel elements with a weld-through bubble of predetermined size. The fabrication of a high strength, dependable fuel element is provided, and the reduction of distortion and high production costs are facilitated by this method. (AEC)

10-kW-class YAG laser application for heavy components

NASA Astrophysics Data System (ADS)

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

2000-02-01

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

Process stability during fiber laser-arc hybrid welding of thick steel plates

NASA Astrophysics Data System (ADS)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F. H.

2018-03-01

Thick steel plates are frequently used in shipbuilding, pipelines and other related heavy industries, and are usually joined by arc welding. Deep penetration laser-arc hybrid welding could increase productivity but has not been thoroughly investigated, and is therefore usually limited to applications with medium thickness (5-15 mm) sections. A major concern is process stability, especially when using modern welding consumables such as metal-cored wire and advanced welding equipment. High speed imaging allows direct observation of the process so that process behavior and phenomena can be studied. In this paper, 45 mm thick high strength steel was welded (butt joint double-sided) using the fiber laser-MAG hybrid process utilizing a metal-cored wire without pre-heating. Process stability was monitored under a wide range of welding parameters. It was found that the technique can be used successfully to weld thick sections with appropriate quality when the parameters are optimized. When comparing conventional pulsed and the more advanced cold metal transfer pulse (CMT+P) arc modes, it was found that both can provide high quality welds. CMT+P arc mode can provide more stable droplet transfer over a limited range of travel speeds. At higher travel speeds, an unstable metal transfer mechanism was observed. Comparing leading arc and trailing arc arrangements, the leading arc configuration can provide higher quality welds and more stable processing at longer inter-distances between the heat sources.

Effects of Heat Treatment on Interface Microstructure and Mechanical Properties of Explosively Welded Ck60/St37 Plates

NASA Astrophysics Data System (ADS)

Yazdani, Majid; Toroghinejad, Mohammad Reza; Hashemi, Seyyed Mohammad

2016-12-01

This study explores the effects of heat treatment on the microstructure and mechanical properties of explosively welded Ck60 steel/St37 steel. The objective is to find an economical way for manufacturing bimetallic plates that can be used in the rolling stand of hot rolling mill units. The explosive ratio and stand-off distance are set at 1.7 and 1.5 t ( t = flyer thickness), respectively. Since explosive welding is accompanied by such undesirable metallurgical effects as remarkable hardening, severe plastic deformation, and even formation of local melted zones near the interface, heat treatment is required to overcome or alleviate these adverse effects. For this purpose, the composites are subjected to heat treatment in a temperature range of 600-700 °C at a rate of 90 °C/h for 1 h. Results demonstrate well-bonded composite plates with a wavy interface. In the as-welded case, vortex zones are formed along the interface; however, they are transformed into fine grains upon heat treatment. Microhardness is also observed to be maximum near the interface in the welded case before it decreases with increasing temperature. Shear strength is the highest in the as-welded specimen, which later decreases as a result of heat treatment. Moreover, the energy absorbed by the heat-treated specimens is observed to increase with increasing temperature so that the lowest value of absorbed energy belongs to the as-welded specimen. Finally, fractography is carried out using the scanning electron microscope to examine the specimens subjected to shear and impact tests. As a result of heat treatment, fracture surfaces exhibit dimpled ruptures and fail in the mixed mode, while failure in the as-welded specimens predominantly occurs in the brittle mode.

Automatic welding systems for large ship hulls

NASA Astrophysics Data System (ADS)

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

2012-04-01

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

Numerical and Experimental Evaluation on the Residual Stresses of Welded Joints

NASA Astrophysics Data System (ADS)

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

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

Vibration analysis of resistance spot welding joint for dissimilar plate structure (mild steel 1010 and stainless steel 304)

NASA Astrophysics Data System (ADS)

Sani, M. S. M.; Nazri, N. A.; Alawi, D. A. J.

2017-09-01

Resistance spot welding (RSW) is a proficient joining method commonly used for sheet metal joining and become one of the oldest spot welding processes use in industry especially in the automotive. RSW involves the application of heat and pressure without neglecting time taken when joining two or more metal sheets at a localized area which is claimed as the most efficient welding process in metal fabrication. The purpose of this project is to perform model updating of RSW plate structure between mild steel 1010 and stainless steel 304. In order to do the updating, normal mode finite element analysis (FEA) and experimental modal analysis (EMA) have been carried out. Result shows that the discrepancies of natural frequency between FEA and EMA are below than 10 %. Sensitivity model updating is evaluated in order to make sure which parameters are influences in this structural dynamic modification. Young’s modulus and density both materials are indicate significant parameters to do model updating. As a conclusion, after perform model updating, total average error of dissimilar RSW plate is improved significantly.

Effects of various tool pin profiles on mechanical and metallurgical properties of friction stir welded joints of cryorolled AA2219 aluminium alloy

NASA Astrophysics Data System (ADS)

Kamal Babu, Karupannan; Panneerselvam, Kavan; Sathiya, Paulraj; Noorul Haq, Abdul Haq; Sundarrajan, Srinivasan; Mastanaiah, Potta; Srinivasa Murthy, Chunduri Venkata

2018-02-01

Friction stir welding (FSW) process was conducted on cryorolled (CR) AA2219 plate using different tool pin profiles such as cylindrical pin, threaded cylindrical pin, square pin and hexagonal pin profiles. The FSW was carried out with pairs of 6 mm thick CR aluminium plates with different tool pin profiles. The different tool pin profile weld portions' behaviors like mechanical (tensile strength, impact and hardness) and metallurgical characteristics were analyzed. The results of the mechanical analysis revealed that the joint made by the hexagonal pin tool had good strength compared to other pin profiles. This was due to the pulsating action and material flow of the tool resulting in dynamic recrystallization in the weld zone. This was confirmed by the ultra fine grain structure formation in Weld Nugget (WN) of hexagonal pin tool joint with a higher percentage of precipitate dissolution. The fractograph of the hexagonal tool pin weld portion confirmed the finer dimple structure morphology without having any interior defect compared to other tool pin profiles. The lowest weld joint strength was obtained from cylindrical pin profile weld joint due to insufficient material flow during welding. The Transmission Electron Microscope and EDX analysis showed the dissolution of the metastable θ″, θ' (Al2Cu) partial precipitates in the WN and proved the influence of metastable precipitates on enhancement of mechanical behavior of weld. The XRD results also confirmed the Al2Cu precipitation dissolution in the weld zone.

Weld Nugget Temperature Control in Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2014-01-01

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

Manufacturing and Performance Assessment of Stamped, Laser Welded, and Nitrided FeCrV Stainless Steel Bipolar Plates for Proton Exchange Membrane Fuel Cells

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

Brady, Michael P; Abdelhamid, Mahmoud; Dadheech, G

A manufacturing and single-cell fuel cell performance study of stamped, laser welded, and gas nitrided ferritic stainless steel foils in an advanced automotive bipolar plate assembly design was performed. Two developmental foil compositions were studied: Fee20Cre4V and Fee23Cre4V wt.%. Foils 0.1 mm thick were stamped and then laser welded together to create single bipolar plate assemblies with cooling channels. The plates were then surface treated by pre-oxidation and nitridation in N2e4H2 based gas mixtures using either a conventional furnace or a short-cycle quartz lamp infrared heating system. Single-cell fuel cell testing was performed at 80 C for 500 h atmore » 0.3 A/cm2 using 100% humidification and a 100%/40% humidification cycle that stresses the membrane and enhances release of the fluoride ion and promotes a more corrosive environment for the bipolar plates. Periodic high frequency resistance potential-current scans during the 500 h fuel cell test and posttest analysis of the membrane indicated no resistance increase of the plates and only trace levels of metal ion contamination.« less

Development of High Heat Input Welding Offshore Steel as Normalized Condition

NASA Astrophysics Data System (ADS)

Deng, Wei; Qin, Xiaomei

The heavy plate used for offshore structure is one of the important strategic products. In recent years, there is an increasing demand for heavy shipbuilding steel plate with excellent weldability in high heat input welding. During the thermal cycle, the microstructure of the heat affected zone (HAZ) of plates was damaged, and this markedly reduced toughness of HAZ. So, how to improve the toughness of HAZ has been a key subject in the fields of steel research. Oxide metallurgy is considered as an effective way to improve toughness of HAZ, because it could be used to retard grain growth by fine particles, which are stable at the high temperature.The high strength steel plate, which satisfies the low temperature specification, has been applied to offshore structure. Excellent properties of the plates and welded joints were obtained by oxide metallurgy technology, latest controlled rolling and accelerated cooling technology using Ultra-Fast Cooling (an on-line accelerated cooling system). The 355MPa-grade high strength steel plates with normalizing condition were obtained, and the steels have excellent weldability with heat input energy of 79 287kJ/cm, and the nil ductility transition (NDT) temperature was -70°C, which can satisfy the construction of offshore structure in cold regions.

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

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

Fu, B.

1994-12-31

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

Tungsten inert gas (TIG) welding of Ni-rich NiTi plates: functional behavior

NASA Astrophysics Data System (ADS)

Oliveira, J. P.; Barbosa, D.; Braz Fernandes, F. M.; Miranda, R. M.

2016-03-01

It is often reported that, to successfully join NiTi shape memory alloys, fusion-based processes with reduced thermal affected regions (as in laser welding) are required. This paper describes an experimental study performed on the tungsten inert gas (TIG) welding of 1.5 mm thick plates of Ni-rich NiTi. The functional behavior of the joints was assessed. The superelasticity was analyzed by cycling tests at maximum imposed strains of 4, 8 and 12% and for a total of 600 cycles, without rupture. The superelastic plateau was observed, in the stress-strain curves, 30 MPa below that of the base material. Shape-memory effect was evidenced by bending tests with full recovery of the initial shape of the welded joints. In parallel, uniaxial tensile tests of the joints showed a tensile strength of 700 MPa and an elongation to rupture of 20%. The elongation is the highest reported for fusion-welding of NiTi, including laser welding. These results can be of great interest for the wide-spread inclusion of NiTi in complex shaped components requiring welding, since TIG is not an expensive process and is simple to operate and implement in industrial environments.

46 CFR 59.10-20 - Patches in shells and tube sheets.

Code of Federal Regulations, 2010 CFR

2010-10-01

... BOILERS, PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service... inside the drum or shell and sealed against leakage by welding. Such plates shall have a diameter of at... wasted portion with a new section. The ligaments between the tube holes may be joined by means of welding...

Manual tube-to-tubesheet welding torch

DOEpatents

Kiefer, Joseph H.; Smith, Danny J.

1982-01-01

A welding torch made of a high temperature plastic which fits over a tube intermediate the ends thereof for welding the juncture between the tube and the back side of a tube plate and has a ballooned end in which an electrode, filler wire guide, fiber optic bundle, and blanketing gas duct are disposed.

Fillet Weld Stress Using Finite Element Methods

NASA Technical Reports Server (NTRS)

Lehnhoff, T. F.; Green, G. W.

1985-01-01

Average elastic Von Mises equivalent stresses were calculated along the throat of a single lap fillet weld. The average elastic stresses were compared to initial yield and to plastic instability conditions to modify conventional design formulas is presented. The factor is a linear function of the thicknesses of the parent plates attached by the fillet weld.

46 CFR 59.10-20 - Patches in shells and tube sheets.

Code of Federal Regulations, 2012 CFR

2012-10-01

... BOILERS, PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service... inside the drum or shell and sealed against leakage by welding. Such plates shall have a diameter of at... wasted portion with a new section. The ligaments between the tube holes may be joined by means of welding...

46 CFR 59.10-20 - Patches in shells and tube sheets.

Code of Federal Regulations, 2011 CFR

2011-10-01

... BOILERS, PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service... inside the drum or shell and sealed against leakage by welding. Such plates shall have a diameter of at... wasted portion with a new section. The ligaments between the tube holes may be joined by means of welding...

46 CFR 59.10-20 - Patches in shells and tube sheets.

Code of Federal Regulations, 2014 CFR

2014-10-01

... BOILERS, PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service... inside the drum or shell and sealed against leakage by welding. Such plates shall have a diameter of at... wasted portion with a new section. The ligaments between the tube holes may be joined by means of welding...

46 CFR 59.10-20 - Patches in shells and tube sheets.

Code of Federal Regulations, 2013 CFR

2013-10-01

... BOILERS, PRESSURE VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service... inside the drum or shell and sealed against leakage by welding. Such plates shall have a diameter of at... wasted portion with a new section. The ligaments between the tube holes may be joined by means of welding...

Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

DOE PAGES

Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; ...

2015-09-08

This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stirmore » zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.« less

Properties of the welded joints of manganese steel made by low-frequency pulsed arc welding

NASA Astrophysics Data System (ADS)

Saraev, Yu. N.; Bezborodov, V. P.; Gladovskii, S. V.; Golikov, N. I.

2017-04-01

The structure, the mechanical properties, the impact toughness, and the fracture mechanisms of the welded joints made of steel 09G2S plates by direct current welding and pulsed arc welding with a modulated arc current in the frequency range 0.25-5.0 Hz are studied. The application of low-frequency pulsed arc welding allowed us to form welded joints with a fine-grained structure in the weld metal and the heat-affected zone and to achieve a higher impact toughness and a longer cyclic fatigue life as compared to the welded joints fabricated by direct current welding. The achieved effect manifests itself over the entire testing range from 20 to-60°C.

Effect of Welding Process on Microstructure, Mechanical and Pitting Corrosion Behaviour of 2205 Duplex Stainless Steel Welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Thermal Stir Welding Development at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2008-01-01

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Latest MIG, TIG arc-YAG laser hybrid welding systems for various welding products

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, Shuho; Watanabe, Masao

2003-03-01

Laser welding is capable of high-efficiency low-strain welding, and so its applications are started to various products. We have also put the high-power YAG laser of up to 10 kW to practical welding use for various products. On the other hand the weakest point of this laser welding is considered to be strict in the welding gap aiming allowance. In order to solve this problem, we have developed hybrid welding of TIG, MIG arc and YAG laser, taking the most advantages of both the laser and arc welding. Since the electrode is coaxial to the optical axis of the YAG laser in this process, it can be applied to welding of various objects. In the coaxial MIG, TIG-YAG welding, in order to make irradiation positions of the YAG laser beams having been guided in a wire or an electrode focused to the same position, the beam transmitted in fibers is separated to form a space between the separated beams, in which the laser is guided. With this method the beam-irradiating area can be brought near or to the arc-generating point. This enables welding of all directions even for the member of a three-dimensional shape. This time we carried out welding for various materials and have made their welding of up to 1 mm or more in welding groove gap possible. We have realized high-speed 1-pass butt welding of 4m/min in welding speed with the laser power of 3 kW for an aluminum alloy plate of approximately 4 mm thick. For a mild steel plate also we have realized butt welding of 1m/min with 5 kW for 6 mm thick. Further, in welding of stainless steel we have shown its welding possibility, by stabilizing the arc with the YAG laser in the welding atmosphere of pure argon, and shown that this welding is effective in high-efficiency welding of various materials. Here we will report the fundamental welding performances and applications to various objects for the coaxial MIG, TIG-YAG welding we have developed.

Pressure-welded flange assembly provides leaktight seal at reduced bolt loads

NASA Technical Reports Server (NTRS)

Martenson, A. J.

1966-01-01

Vibration resistant flange-connector assembly provides a leaktight seal under reduced bolt loads. The assembly consists of ductile metal plates that are pressure welded between dies mounted in recessed flanges.

Microstructural Characterization of the Heat-Affected Zones in Grade 92 Steel Welds: Double-Pass and Multipass Welds

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Actively controlled vibration welding system and method

DOEpatents

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

2013-04-02

A vibration welding system includes a controller, welding horn, an active material element, and anvil assembly. The assembly may include an anvil body connected to a back plate and support member. The element, e.g., a piezoelectric stack or shape memory alloy, is positioned with respect to the assembly. The horn vibrates in a desirable first direction to form a weld on a work piece. The element controls any vibrations in a second direction by applying calibrated response to the anvil body in the second direction. A method for controlling undesirable vibrations in the system includes positioning the element with respect to the anvil assembly, connecting the anvil body to the support member through the back plate, vibrating the horn in a desirable first direction, and transmitting an input signal to the element to control vibration in an undesirable second direction.

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

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

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

2014-08-01

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

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.

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

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

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

2014-02-18

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

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

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

Energy Losses Estimation During Pulsed-Laser Seam Welding

NASA Astrophysics Data System (ADS)

Sebestova, Hana; Havelkova, Martina; Chmelickova, Hana

2014-06-01

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

WELDING APPARATUS

DOEpatents

Correy, T.B.; DeWitt, D.E.; Nelson, I.V.

1963-04-23

This patent covers an arrangement for replacing air in a welding chamber with an inert gas. This operation usually is time-consuming because of the tendency of the inert gas to mix with the air being removed from the welding chamber. The chamber is open at the bottom and has at its top a cover and a porous plate a little below the cover. The inert gas is admitted to the chamber through two screened openings in the cover. On passing through the porous plate, the gas acts as a piston extending across the chamber and moving downwardly to expel the air through the lower open end of the chamber, with a minimum of mixing with the air being expelled. (AEC)

On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

NASA Astrophysics Data System (ADS)

Jimenez-Mena, N.; Jacques, P. J.; Drezet, J. M.; Simar, A.

2018-07-01

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz-Drezet-Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.

On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

NASA Astrophysics Data System (ADS)

Jimenez-Mena, N.; Jacques, P. J.; Drezet, J. M.; Simar, A.

2018-04-01

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz-Drezet-Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.

Plating Patches On Heat-Exchanger Jackets

NASA Technical Reports Server (NTRS)

Loureiro, Henry; Kubik, Frank

1989-01-01

Permanent repairs made without welding. Technique used to repair nickel-alloy nozzle jacket of Space Shuttle main engine. Applicable to other metal heat-exchanger jackets with similar configurations. Does not require welding, brazing, soldering, or other operations involving high temperatures and consequent damage to surrounding areas. Portion of jacket around damaged area removed by grinding and polishing out to edges adjacent to tube/jacket braze bonds. Spaces between tubes filled with wax preventing contamination of spaces during subsequent plating.

46 CFR 57.06-1 - Production test plate requirements.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 2 2010-10-01 2010-10-01 false Production test plate requirements. 57.06-1 Section 57.06-1 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING WELDING AND BRAZING Production Tests § 57.06-1 Production test plate requirements. (a) Production test plates shall be...

46 CFR 57.06-1 - Production test plate requirements.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 2 2011-10-01 2011-10-01 false Production test plate requirements. 57.06-1 Section 57.06-1 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING WELDING AND BRAZING Production Tests § 57.06-1 Production test plate requirements. (a) Production test plates shall be...

46 CFR 57.06-1 - Production test plate requirements.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 46 Shipping 2 2013-10-01 2013-10-01 false Production test plate requirements. 57.06-1 Section 57.06-1 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING WELDING AND BRAZING Production Tests § 57.06-1 Production test plate requirements. (a) Production test plates shall be...

46 CFR 57.06-1 - Production test plate requirements.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 46 Shipping 2 2012-10-01 2012-10-01 false Production test plate requirements. 57.06-1 Section 57.06-1 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING WELDING AND BRAZING Production Tests § 57.06-1 Production test plate requirements. (a) Production test plates shall be...

46 CFR 57.06-1 - Production test plate requirements.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 46 Shipping 2 2014-10-01 2014-10-01 false Production test plate requirements. 57.06-1 Section 57.06-1 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING WELDING AND BRAZING Production Tests § 57.06-1 Production test plate requirements. (a) Production test plates shall be...

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

Hybrid/Tandem Laser-Arc Welding of Thick Low Carbon Martensitic Stainless Steel Plates =

NASA Astrophysics Data System (ADS)

Mirakhorli, Fatemeh

High efficiency and long-term life of hydraulic turbines and their assemblies are of utmost importance for the hydropower industry. Usually, hydroelectric turbine components are made of thick-walled low carbon martensitic stainless steels. The assembly of large hydroelectric turbine components has been a great challenge. The use of conventional welding processes involves typical large groove design and multi-pass welding to fill the groove which exposes the weld to a high heat input creating relatively large fusion zone and heat affected zone. The newly-developed hybrid/tandem laser-arc welding technique is believed to offer a highly competitive solution to improve the overall hydro-turbine performance by combining the high energy density and fast welding speed of the laser welding technology with the good gap bridging and feeding ability of the gas metal arc welding process to increase the productivity and reduce the consumable material. The main objective of this research work is to understand different challenges appearing during hybrid laser-arc welding (HLAW) of thick gauge assemblies of low carbon 13%Cr- 4%Ni martensitic stainless steel and find a practical solution by adapting and optimizing this relatively new welding process in order to reduce the number of welding passes necessary to fill the groove gap. The joint integrity was evaluated in terms of microstructure, defects and mechanical properties in both as-welded and post-welded conditions. A special focus was given to the hybrid and tandem laser-arc welding technique for the root pass. Based on the thickness of the low carbon martensitic stainless steel plates, this work is mainly focused on the following two tasks: • Single pass hybrid laser-arc welding of 10-mm thick low carbon martensitic stainless steel. • Multi-pass hybrid/tandem laser-arc welding of 25-mm thick martensitic stainless steel.

Laser-Assisted Stir Welding of 25-mm-Thick HSLA-65 Plate

NASA Astrophysics Data System (ADS)

Williamson, Keith M.

2002-12-01

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

Alloying Elements Transition Into the Weld Metal When Using an Inventor Power Source

NASA Astrophysics Data System (ADS)

Mamadaliev, R. A.; Kuskov, V. N.; Popova, A. A.; Valuev, D. V.

2016-04-01

The temperature distribution over the surface of the welded 12Kh18N10T steel plates using the inventor power source ARC-200 has been calculated. In order to imitate multipass welding when conducting the thermal analysis the initial temperature was changed from 298K up to 798K in 100K increments. It has been determined that alloying elements transition into the weld metal depends on temperature. Using an inventor power source facilitates a uniform distribution of alloying elements along the length and height of the weld seam.

The Effect of Welding Energy on the Microstructural and Mechanical Properties of Ultrasonic-Welded Copper Joints

PubMed Central

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-01-01

The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed. PMID:28772553

The Effect of Welding Energy on the Microstructural and Mechanical Properties of Ultrasonic-Welded Copper Joints.

PubMed

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-02-16

The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed.

75 FR 8746 - Certain Steel Grating From China

Federal Register 2010, 2011, 2012, 2013, 2014

2010-02-25

... sheet or thin plate steel that has been slit and expanded, and does not involve welding or joining of..., that has been pierced and cold formed, and does not involve welding or joining of multiple pieces of...

FIXED END OF MIDDLE SPAN. WESTERN SIDE SHOWING WELDING OF ...

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

FIXED END OF MIDDLE SPAN. WESTERN SIDE SHOWING WELDING OF TOP PLATE ADDED TO STRENGTHEN THE BRIDGE. - Spile Bridge Road Bridge, Spanning Black Lake Outlie at Spile Bridge Road, Oswegatchie, St. Lawrence County, NY

8. DETAIL VIEW OF CONNECTION AT CENTER OF BRIDGE. WELDED ...

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

8. DETAIL VIEW OF CONNECTION AT CENTER OF BRIDGE. WELDED PLATE AND I-BARS ARE 20TH CENTURY REVISIONS. - Bucks County Bridge No. 313, Spanning Delaware Canal at Letchworth Avenue, Yardley, Bucks County, PA

Elastic And Plastic Deformations In Butt Welds

NASA Technical Reports Server (NTRS)

Verderaime, V.

1992-01-01

Report presents study of mathematical modeling of stresses and strains, reaching beyond limits of elasticity, in bars and plates. Study oriented toward development of capability to predict stresses and resulting elastic and plastic strains in butt welds.

Reflexion measurements for inverse characterization of steel diffusion bond mechanical properties

NASA Astrophysics Data System (ADS)

Le Bourdais, Florian; Cachon, Lionel; Rigal, Emmanuel

2017-02-01

The present work describes a non-destructive testing method aimed at securing high manufacturing quality of the innovative compact heat exchanger developed under the framework of the CEA R&D program dedicated to the Advanced Sodium Technological Reactor for Industrial Demonstration (ASTRID). The heat exchanger assembly procedure currently proposed involves high temperature and high pressure diffusion welding of stainless steel plates. The aim of the non-destructive method presented herein is to characterize the quality of the welds obtained through this assembly process. Based on a low-frequency model developed by Baik and Thompson [1], pulse-echo normal incidence measurements are calibrated according to a specific procedure and allow the determination of the welding interface stiffness using a nonlinear fitting procedure in the frequency domain. Performing the characterization of plates after diffusion welding using this method allows a useful assessment of the material state as a function of the diffusion bonding process.

Understanding the solidification and microstructure evolution during CSC-MIG welding of Fe–Cr–B-based alloy

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

Sorour, A.A., E-mail: ahmad.sorour@mail.mcgill.ca; Chromik, R.R., E-mail: richard.chromik@mcgill.ca; Gauvin, R., E-mail: raynald.gauvin@mcgill.ca

2013-12-15

The present is a study of the solidification and microstructure of Fe–28.2%Cr–3.8%B–1.5%Si–1.5%Mn (wt.%) alloy deposited onto a 1020 plain carbon steel substrate using the controlled short-circuit metal inert gas welding process. The as-solidified alloy was a metal matrix composite with a hypereutectic microstructure. Thermodynamic calculation based on the Scheil–Gulliver model showed that a primary (Cr,Fe){sub 2}B phase formed first during solidification, followed by an eutectic formation of the (Cr,Fe){sub 2}B phase and a body-centered cubic Fe-based solid solution matrix, which contained Cr, Mn and Si. Microstructure analysis confirmed the formation of these phases and showed that the shape of themore » (Cr,Fe){sub 2}B phase was irregular plate. As the welding heat input increased, the weld dilution increased and thus the volume fraction of the (Cr,Fe){sub 2}B plates decreased while other microstructural characteristics were similar. - Highlights: • We deposit Fe–Cr–B-based alloy onto plain carbon steel using the CSC-MIG process. • We model the solidification behavior using thermodynamic calculation. • As deposited alloy consists of (Cr,Fe){sub 2}B plates embedded in Fe-based matrix. • We study the effect of the welding heat input on the microstructure.« less

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

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

2011-06-01

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

Tungsten Inert Gas and Friction Stir Welding Characteristics of 4-mm-Thick 2219-T87 Plates at Room Temperature and -196 °C

NASA Astrophysics Data System (ADS)

Lei, Xuefeng; Deng, Ying; Yin, Zhimin; Xu, Guofu

2014-06-01

2219-T87 aluminum alloy is widely used for fabricating liquid rocket propellant storage tank, due to its admirable cryogenic property. Welding is the dominant joining method in the manufacturing process of aerospace components. In this study, the tungsten inert gas welding and friction stir welding (FSW) characteristics of 4-mm-thick 2219-T87 alloy plate at room temperature (25 °C) and deep cryogenic temperature (-196 °C) were investigated by property measurements and microscopy methods. The studied 2219 base alloy exhibits a low strength plane anisotropy and excellent room temperature and cryogenic mechanical properties. The ultimate tensile strength values of TIG and FSW welding joints can reach 265 and 353 MPa at room temperature, and 342 and 438 MPa at -196 °C, respectively. The base metal consists of elongated deformed grains and many nano-scaled θ (Al2Cu) aging precipitates. Fusion zone and heat-affected zone (HAZ) of the TIG joint are characterized by coarsening dendritic grains and equiaxed recrystallized grains, respectively. The FSW-welded joint consists of the weld nugget zone, thermo-mechanically affected zone (TMAZ), and HAZ. In the weld nugget zone, a micro-scaled sub-grain structure is the main microstructure characteristic. The TMAZ and HAZ are both characterized by coarsened aging precipitates and elongated deformed grains. The excellent FSW welding properties are attributed to the preservation of the working structures and homogenous chemical compositions.

Intraoral laser welding: ultrastructural and mechanical analysis to compare laboratory laser and dental laser.

PubMed

Fornaini, Carlo; Passaretti, Francesca; Villa, Elena; Rocca, Jean-Paul; Merigo, Elisabetta; Vescovi, Paolo; Meleti, Marco; Manfredi, Maddalena; Nammour, Samir

2011-07-01

The Nd:YAG laser has been used since 1970 in dental laboratories to weld metals on dental prostheses. Recently in several clinical cases, we have suggested that the Nd:YAG laser device commonly utilized in the dental office could be used to repair broken fixed, removable and orthodontic prostheses and to weld metals directly in the mouth. The aim of this work was to evaluate, using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and dynamic mechanical analysis (DMA), the quality of the weld and its mechanical strength, comparing a device normally used in dental laboratory and a device normally used in the dental office for oral surgery, the same as that described for intraoral welding. Metal plates of a Co-Cr-Mo dental alloy and steel orthodontic wires were subjected to four welding procedures: welding without filler metal using the laboratory laser, welding with filler metal using the laboratory laser, welding without filler metal using the office laser, and welding with filler metal using the office laser. The welded materials were then analysed by SEM, EDS and DMA. SEM analysis did not show significant differences between the samples although the plates welded using the office laser without filler metal showed a greater number of fissures than the other samples. EDS microanalysis of the welding zone showed a homogeneous composition of the metals. Mechanical tests showed similar elastic behaviours of the samples, with minimal differences between the samples welded with the two devices. No wire broke even under the maximum force applied by the analyser. This study seems to demonstrate that the welds produced using the office Nd:YAG laser device and the laboratory Nd:YAG laser device, as analysed by SEM, EDS and DMA, showed minimal and nonsignificant differences, although these findings need to be confirmed using a greater number of samples.

A simple 2-d thermal model for GMA welds

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

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

1996-12-31

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

Cassette less SOFC stack and method of assembly

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

Meinhardt, Kerry D

2014-11-18

A cassette less SOFC assembly and a method for creating such an assembly. The SOFC stack is characterized by an electrically isolated stack current path which allows welded interconnection between frame portions of the stack. In one embodiment electrically isolating a current path comprises the step of sealing a interconnect plate to a interconnect plate frame with an insulating seal. This enables the current path portion to be isolated from the structural frame an enables the cell frame to be welded together.

Extension of E7024 Electrode Applications in Shipbuilding

DTIC Science & Technology

1980-08-01

E7028, or ABS Grades 2, 2Y electrodes. A class of E7024 electrodes meeting elongation and Charpy V-notch requirements equivalent to ABS Grades 2 and...that adequate weld quality is maintained. The ABS limitations on E7024 electrodes are associated with the absence of a Charpy impact requirement and...fillet welds 1/2” base plate was used were made with each brand of E7024 electrodes; for tension tests; 1“ plate was used for Charpy . tests to provide

Modification of the Gurney Equation for Explosive Bonding by Slanted Elevation Angle

DTIC Science & Technology

2014-04-01

researching high temperature fatigue behaviour and modelling of ferritic pressure vessel steel , for which he was awarded the degree at the University of...weld metal solidification cracking in steels and stainless steels . He has also undertaken extensive work on improving the weld zone toughness of high... steel (2.0) 15 2.4 16 300 x300 1: S defines ‘Superaustenitic’. The flyer plate was placed on the top of the bottom plate for each test with

Bead on Plate Temper Pass Study: Thermal and Microhardness Study

DTIC Science & Technology

2009-09-01

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

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

NASA Technical Reports Server (NTRS)

Rietz, Ward W., Jr.

2008-01-01

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

78 FR 9676 - Clad Steel Plate From Japan: Continuation of Antidumping Duty Order

Federal Register 2010, 2011, 2012, 2013, 2014

2013-02-11

... hot-rolling of the cladding metal to ensure efficient welding to the basic metal; any other method of... welding (e.g., electrocladding), in which the cladding metal (nickel, chromium, etc.) is applied to the...

Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

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

Charpy V-notch properties and microstructures of narrow gap ferritic welds of a quenched and tempered steel plate

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

Powell, G.L.F.; Herfurth, G.

1998-11-01

Multipass welds of quenched and tempered 50-mm-thick steel plate have been deposited by a single wire narrow gap process using both gas metal arc welding (GMAW) and submerged arc welding (SAW). Of the five welds, two reported much lower Charpy V-notch (CVN) values when tested at {minus} 20 C. The CVN toughness did not correlate with either the welding process or whether the power source was pulsed or nonpulsed. The only difference in the ferritic microstructure between the two welds of low Charpy values and the three of high values was the percentage of acicular ferrite. There was no effectmore » of the percentage of as-deposited reheated zones intersected by the Charpy notch or the microhardness of the intercellular-dendritic regions. In all welds, austenite was the microconstituent between the ferrite laths. The percentage of acicular ferrite correlated with the presence of MnO, TiO{sub 2}, {gamma} Al{sub 2}O{sub 3}, or MnO. Al{sub 2}O{sub 3} as the predominant crystalline compound in the oxide inclusions. In turn, the crystalline compound depended on the aluminum-to-titanium ratio in both the weld deposits and the oxide inclusions. In addition to the presence of less acicular ferrite, the two welds that showed lower Charpy values also reported more oxide inclusions greater than 1 {micro}m in diameter. The combination of more oxide inclusions greater than 1 {micro}m and less acicular ferrite is considered to be the explanation for the lower Charpy values.« less

The effects of laser welding parameters on the microstructure of ferritic and duplex stainless steels welds

NASA Astrophysics Data System (ADS)

Pekkarinen, J.; Kujanpää, V.

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

Laser penetration spike welding: a welding tool enabling novel process and design opportunities

NASA Astrophysics Data System (ADS)

Dijken, Durandus K.; Hoving, Willem; De Hosson, J. Th. M.

2002-06-01

A novel method for laser welding for sheet metal. is presented. This laser spike welding method is capable of bridging large gaps between sheet metal plates. Novel constructions can be designed and manufactured. Examples are light weight metal epoxy multi-layers and constructions having additional strength with respect to rigidity and impact resistance. Its capability to bridge large gaps allows higher dimensional tolerances in production. The required laser systems are commercially available and are easily implemented in existing production lines. The lasers are highly reliable, the resulting spike welds are quickly realized and the cost price per weld is very low.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Laser Powder Welding of a Ti52Al46.8Cr1Si0.2Titanium Aluminide Alloy at Elevated Temperature

NASA Astrophysics Data System (ADS)

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

2011-04-01

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

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

PubMed

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

2004-04-01

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

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.

Investigation of Hot Cracking Behavior in Transverse Mechanically Arc Oscillated Autogenous AA2014 T6 TIG Welds

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

2012-09-01

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

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

NASA Astrophysics Data System (ADS)

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

2016-09-01

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

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

NASA Astrophysics Data System (ADS)

Yang, Lei; Ume, I. Charles

2014-02-01

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

Investigation of the vapour-plasma plume in the welding of titanium by high-power ytterbium fibre laser radiation

NASA Astrophysics Data System (ADS)

Bykovskiy, D. P.; Petrovskii, V. N.; Uspenskiy, S. A.

2015-03-01

The vapour-plasma plume produced in the welding of 6-mm thick VT-23 titanium alloy plates by ytterbium fibre laser radiation of up to 10 kW power is studied in the protective Ar gas medium. High-speed video filming of the vapour-plasma plume is used to visualise the processes occurring during laser welding. The coefficient of inverse bremsstrahlung by the welding plasma plume is calculated from the data of the spectrometric study.

Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using Multiple Constraints

DTIC Science & Technology

2015-08-12

Naval Research Laboratory Washington, DC 20375-5320 NRL/MR/6390--15-9621 Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using...b. ABSTRACT c. THIS PAGE 18. NUMBER OF PAGES 17. LIMITATION OF ABSTRACT Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using...plate structures. The results of the case studies provide parametric representations of weld temperature histories that can be adopted as input data to

Experimental Study and Fractal Analysis on the Anisotropic Performance of Explosively Welded Interfaces of 304 Stainless Steel/245 Carbon Steel

NASA Astrophysics Data System (ADS)

Fu, Yanshu; Qiu, Yaohui; Li, Yulong

2018-03-01

The mechanical anisotropy of an explosive welding composite plate made of 304 stainless steel/245 steel was studied through shear experiments performed on explosively welded wavy interfaces along several orientation angles. The results indicated that the strength and the fracture energy of samples significantly varied with the orientation angles. The fracture surfaces of all samples were observed using a scanning electron microscope and through three-dimensional structure microscopy. The periodic features of all the fracture surfaces were clearly shown in different fracture modes. The fractal dimension of the fracture surfaces was calculated based on the fractal geometry by the box-counting method in MATLAB. The cohesive element model was used to analyze the fracture energy according to the physical dependence of the fractal dimension on thermodynamic entropy and interface separation energy. The fracture energy was an exponential function of the fractal dimension value, which was in good agreement with the experimental results. All results were validated for effective use in the application of anisotropy analysis to the welded interface and structural optimization of explosively welded composite plates.

Experimental Study and Fractal Analysis on the Anisotropic Performance of Explosively Welded Interfaces of 304 Stainless Steel/245 Carbon Steel

NASA Astrophysics Data System (ADS)

Fu, Yanshu; Qiu, Yaohui; Li, Yulong

2018-05-01

The mechanical anisotropy of an explosive welding composite plate made of 304 stainless steel/245 steel was studied through shear experiments performed on explosively welded wavy interfaces along several orientation angles. The results indicated that the strength and the fracture energy of samples significantly varied with the orientation angles. The fracture surfaces of all samples were observed using a scanning electron microscope and through three-dimensional structure microscopy. The periodic features of all the fracture surfaces were clearly shown in different fracture modes. The fractal dimension of the fracture surfaces was calculated based on the fractal geometry by the box-counting method in MATLAB. The cohesive element model was used to analyze the fracture energy according to the physical dependence of the fractal dimension on thermodynamic entropy and interface separation energy. The fracture energy was an exponential function of the fractal dimension value, which was in good agreement with the experimental results. All results were validated for effective use in the application of anisotropy analysis to the welded interface and structural optimization of explosively welded composite plates.

Weld pool oscillation during GTA welding of mild steel

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

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

1993-08-01

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

Friction pull plug welding: chamfered heat sink pull plug design

NASA Technical Reports Server (NTRS)

Coletta, Edmond R. (Inventor); Cantrell, Mark A. (Inventor)

2002-01-01

Friction Pull Plug Welding (FPPW) is a solid state repair process for defects up to one inch in length, only requiring single sided tooling (OSL) for usage on flight hardware. Experimental data has shown that the mass of plug heat sink remaining above the top of the plate surface after a weld is completed (the plug heat sink) affects the bonding at the plug top. A minimized heat sink ensures complete bonding of the plug to the plate at the plug top. However, with a minimal heat sink three major problems can arise, the entire plug could be pulled through the plate hole, the central portion of the plug could be separated along grain boundaries, or the plug top hat can be separated from the body. The Chamfered Heat Sink Pull Plug Design allows for complete bonding along the ISL interface through an outside diameter minimal mass heat sink, while maintaining enough central mass in the plug to prevent plug pull through, central separation, and plug top hat separation.

49 CFR 179.220-7 - Materials.

Code of Federal Regulations, 2010 CFR

2010-10-01

...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... and with the indicated minimum tensile strength and elongation in the welded condition. (b) Carbon steel plate: The maximum allowable carbon content must be 0.31 percent when the individual specification...

9. DETAIL VIEW OF BOTTOM CHORD/FLOOR BEAM/IBAR PIN CONNECTION. WELDED ...

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

9. DETAIL VIEW OF BOTTOM CHORD/FLOOR BEAM/I-BAR PIN CONNECTION. WELDED PLATE AT PIN CONNECTION IS 20TH CENTURY REVISION. - Bucks County Bridge No. 313, Spanning Delaware Canal at Letchworth Avenue, Yardley, Bucks County, PA

Extended electrode technique. [gas metal arc welding of metal plates

NASA Technical Reports Server (NTRS)

Schaper, V. D.; Pollack, A.

1972-01-01

The extended electrode technique is a unique welding process which utilizes manual gas-metal-arc (GMAW) semi-automatic equipment and close, square butt joints to effectively produce a weld. The technique takes advantage of the resistance heating of the electode extension to effect the root pass. Weldments as large as 72-X30-X2-inch have been fabricated with this technique under normal shipyard welding conditions. Mechanical properties and explosion bulge tests indicate that satisfactory results are obtained with this process. Potential savings of approximately 50 percent can be achieved in flat welding and repair of heavy structural steel members.

Advanced Metalworking Solutions For Naval Systems That Go In Harm’s Way

DTIC Science & Technology

2015-01-01

destroyers USS Momsen (DDG 92) and USS Preble (DDG 88) are underway in formation. U.S. Navy photo Front cover: Ingalls Shipbuilding welding photo...applies a variety of innovative welding technologies to address the challenges associated with joining weapon system components. Joining Technologies...friction stir welding process to manufacture edge-cooled naval electronic cold plate assemblies. The modular, high- performance, and scalable

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Formed Domes

NASA Technical Reports Server (NTRS)

Stewart, Thomas J.; Torres, Pablo D.; Caratus, Andrei A.; Curreri, Peter A.

2010-01-01

Simulated service testing (SST) development was required to help qualify a new 2195 aluminum lithium (Al-Li) alloy spin forming dome fabrication process for the National Aeronautics and Space Administration (NASA) Exploration Development Technology Program. The application for the technology is to produce high strength low weight tank components for NASA s next generation launch vehicles. Since plate material is not currently manufactured large enough to fabricate these domes, two plates are joined by means of friction stir welding. The plates are then pre-contour machined to near final thicknesses allowing for a thicker weld land and anticipating the level of stretch induced by the spin forming process. The welded plates are then placed in a spin forming tool and hot stretched using a trace method producing incremental contours. Finally the dome receives a room temperature contour stretch to final dimensions, heat treatment, quenching, and artificial aging to emulate a T-8 condition of temper. Stress corrosion cracking (SCC) tests were also performed by alternate immersion in a sodium chloride (NaCl) solution using the typical double beam assembly and with 4-point loaded specimens and use of bent-beam stress-corrosion test specimens under alternate immersion conditions. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K(sub ISCC)) which to our knowledge has not been determined previously for Al-Li 2195 alloy. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication

Welding processes and ocular hazards and protection.

PubMed

Pabley, A S; Keeney, A H

1981-07-01

There are approximately 60 different forms of welding, but only six of these are commonly used. Shielded metal-arc or stick welding, gas metal-arc welding, and oxyacetylene welding are the most frequently used. All produce ultraviolet, visible, and infrared radiation at damaging levels. Conventional glass welding shields contain ultraviolet, visible, and infrared absorbers. Infrared absorbers, however, cause heating and secondary re-radiation. New polycarbonate lenses offer greater impact resistance, and have less tendency to welding spatter. Early abrasion-resistant and reflective coatings on plastics were ineffective. Thin layers of gold with proprietary coatings provide cool reflection and surface resistance. Thermal monitoring of welding indicated that these new shields reduce temperature rises above the ambient by 150% to 175% compared to green glass filter plates without interfering with the welder's vision.

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

Effect of FSW welding speed on microstructure and microhardness of Al-0.84Mg-0.69Si-0.76Fe alloy at moderate rotational tool velocity

NASA Astrophysics Data System (ADS)

Chand, Suresh; Vineetha, S.; Madhusudhan, D.; Sai Krishna, CH; Kusuma Devi, G.; Bhawani; Hemarao, K.; Ganesh Naidu, G.

2018-03-01

The plate of 7.0 mm thickness was double side welded using friction stir welding is investigated. The rotational velocity of friction stir welding tool is used 1400 rpm. The influence of welding speed on the microstructure and microhardness values of Al-0.84Mg-0.69Si-0.76Fe aluminum alloy is presented. Two welding speeds 25 mm/min and 31.5 mm/min are used. The microhardness values of friction stir weld are measured at various locations from the weld interface. The microhardness values in stir zone of weld are found larger than lower welding speed at constant rotational velocity of 1400 rpm of friction stir welding tool. The similar effects on microhardness values are found in the thermo-mechanically affected zone and heat affected zone. The fine microstructure is observed at 31.5 mm/min welding speed compared to the 25 mm/min welding speed at 1400 rpm.

Significance of the Resonance Condition for Controlling the Seam Position in Laser-assisted TIG Welding

NASA Astrophysics Data System (ADS)

Emde, B.; Huse, M.; Hermsdorf, J.; Kaierle, S.; Wesling, V.; Overmeyer, L.; Kozakov, R.; Uhrlandt, D.

As an energy-preserving variant of laser hybrid welding, laser-assisted arc welding uses laser powers of less than 1 kW. Recent studies have shown that the electrical conductivity of a TIG welding arc changes within the arc in case of a resonant interaction between laser radiation and argon atoms. This paper presents investigations on how to control the position of the arc root on the workpiece by means of the resonant interaction. Furthermore, the influence on the welding result is demonstrated. The welding tests were carried out on a cooled copper plate and steel samples with resonant and non-resonant laser radiation. Moreover, an analysis of the weld seam is presented.

Measurement of Laser Weld Temperatures for 3D Model Input

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

Dagel, Daryl; Grossetete, Grant; Maccallum, Danny O.

Laser welding is a key joining process used extensively in the manufacture and assembly of critical components for several weapons systems. Sandia National Laboratories advances the understanding of the laser welding process through coupled experimentation and modeling. This report summarizes the experimental portion of the research program, which focused on measuring temperatures and thermal history of laser welds on steel plates. To increase confidence in measurement accuracy, researchers utilized multiple complementary techniques to acquire temperatures during laser welding. This data serves as input to and validation of 3D laser welding models aimed at predicting microstructure and the formation of defectsmore » and their impact on weld-joint reliability, a crucial step in rapid prototyping of weapons components.« less

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.

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.

Simplified welding distortion analysis for fillet welding using composite shell elements

NASA Astrophysics Data System (ADS)

Kim, Mingyu; Kang, Minseok; Chung, Hyun

2015-09-01

This paper presents the simplified welding distortion analysis method to predict the welding deformation of both plate and stiffener in fillet welds. Currently, the methods based on equivalent thermal strain like Strain as Direct Boundary (SDB) has been widely used due to effective prediction of welding deformation. Regarding the fillet welding, however, those methods cannot represent deformation of both members at once since the temperature degree of freedom is shared at the intersection nodes in both members. In this paper, we propose new approach to simulate deformation of both members. The method can simulate fillet weld deformations by employing composite shell element and using different thermal expansion coefficients according to thickness direction with fixed temperature at intersection nodes. For verification purpose, we compare of result from experiments, 3D thermo elastic plastic analysis, SDB method and proposed method. Compared of experiments results, the proposed method can effectively predict welding deformation for fillet welds.

Sensoring fusion data from the optic and acoustic emissions of electric arcs in the GMAW-S process for welding quality assessment.

PubMed

Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

2012-01-01

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

Tailored Welding Technique for High Strength Al-Cu Alloy for Higher Mechanical Properties

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

AA2014 aluminum alloy, with 4.5% Cu as major alloying element, offers highest strength and hardness values in T6 temper and finds extensive use in aircraft primary structures. However, this alloy is difficult to weld by fusion welding because the dendritic structure formed can affect weld properties seriously. Among the welding processes, AC-TIG technique is largely used for welding. As welded yield strength was in the range of 190-195 MPa, using conventional TIG technique. Welding metallurgy of AA2014 was critically reviewed and factors responsible for lower properties were identified. Square-wave AC TIG with Transverse mechanical arc oscillation (TMAO) was postulated to improve the weld strength. A systematic experimentation using 4 mm thick plates produced YS in the range of 230-240 MPa, has been achieved. Through characterization including optical and SEM/EDX was conducted to validate the metallurgical phenomena attributable to improvement in weld properties.

77 FR 31834 - Clad Steel Plate from Japan: Final Results of the Expedited Third Sunset Review of the...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-05-30

... rolling; simple hot-rolling of the cladding metal to ensure efficient welding to the basic metal; any... process to ensure welding (e.g., electrocladding), in which the cladding metal (nickel, chromium, etc.) is...

Assessment of delta ferrite in multipass TIG welds of 40 mm thick SS 316L: A comparative study of ferrite number (FN) prediction and measurements

NASA Astrophysics Data System (ADS)

Buddu, Ramesh Kumar; Raole, P. M.; Sarkar, B.

2017-04-01

Austenitic stainless steels are widely used in the fabrication of fusion reactor major systems like vacuum vessel, divertor, cryostat and other structural components development. Multipass welding is used for the development of thick plates for the structural components fabrication. Due to the repeated weld thermal cycles, the microstructure adversely alters owing to the presence of complex phases like austenite, ferrite and delta ferrite and subsequently influences the mechanical properties like tensile and impact toughness of joints. The present paper reports the detail analysis of delta ferrite phase in welded region of 40 mm thick SS316L plates welded by special design multipass narrow groove TIG welding process under three different heat input conditions. The correlation of delta ferrite microstructure of different type structures acicular and vermicular is observed. The chemical composition of weld samples was used to predict the Ferrite Number (FN), which is representative form of delta ferrite in welds, with Schaeffler’s, WRC-1992 diagram and DeLong techniques by calculating the Creq and Nieq ratios and compared with experimental data of FN from Feritescope measurements. The low heat input conditions (1.67 kJ/mm) have produced higher FN (7.28), medium heat input (1.72 kJ/mm) shown FN (7.04) where as high heat input (1.87 kJ/mm) conditions has shown FN (6.68) decreasing trend and FN data is compared with the prediction methods.

Thermal Fatigue Study on the Divertor Plate Materials

NASA Astrophysics Data System (ADS)

Wu, Ji-hong; Zhang, Fu; Xu, Zeng-yu; Yan, Jian-cheng

2002-10-01

Thermal fatigue property of the divertor plate is one of the key issues that governs the lifetime of the divertor plate. Taking tungsten as surface material, a small-mock-up divertor plate was made by hot isostatic press welding (HIP). A thermal cycling experiment for divertor mock-up was carried out in the vacuum, where a high-heat-flux electronic gun was used as the thermal source. A cyclic heat flux of 9 MW/m2 was loaded onto the mock-up, a heating duration of 20 s was selected, the cooling water flow rate was 80 ml/s. After 1000 cycles, the surface and the W/Cu joint of the mock-up did not show any damage. The SEM was used to analyze the microstructure of the welding joint, where no cracks were found also.

Structure and Microhardness of Cu-Ta Joints Produced by Explosive Welding

PubMed Central

Maliutina, Iu. N.; Mali, V. I.; Bataev, I. A.; Bataev, A. A.; Esikov, M. A.; Smirnov, A. I.; Skorokhod, K. A.

2013-01-01

The structure and microhardness of Cu-Ta joints produced by explosive welding were studied. It was found that, during explosive welding, an intermediate layer 20⋯40 μm thick with a finely dispersed heterophase structure, formed between the welded copper and tantalum plates. The structure of the layer was studied by scanning and transmission electron microscopy. Microvolumes with tantalum particles distributed in a copper matrix and microvolumes of copper particles in a tantalum matrix were detected. The tantalum particles in copper have a size of 5⋯500 nm, with a predominance of 5⋯50 nm particles. A mechanism for the formation of the finely dispersed heterophase structure in explosive welding is proposed. The microhardness of interlayers with the heterophase structure reaches 280 HV, which far exceeds the microhardness of copper (~130 HV) and tantalum (~160 HV). Many twins of deformation origin were found in the structure of the copper plate. The effect of heating temperature in the range from 100 to 900°C on the microhardness of copper, tantalum, and the Cu-Ta welded joint was studied. Upon heating to 900°C, the microhardness of the intermediate layer decreases from 280 to 150 HV. The reduction in the strength properties of the weld material is mainly due to structural transformations in copper. PMID:24453818

Effect of friction stir welding on microstructure and corrosion behavior of LF6 aluminum alloy

NASA Astrophysics Data System (ADS)

Ghauri, Faizan Ali; Farooq, A.; Ahmad, A.; Deen, K. M.

2017-03-01

The LF6 aluminum alloy plates were joined by friction stir welding method. The tool rotational (1180 rpm) and transverse speed (0.56 mm s-1) were kept constant during welding of 4 mm thick plates. The microstructural features, hardness and tensile properties of the welded samples were determined to evaluate the structural integrity in comparison with the base metal. The electrochemical behavior of base metal (BM), thermo-mechanically affected zone (TMAZ) and weld nugget zone (WNZ) was also investigated by potentiodynamic polarization and electrochemical impedance spectroscopy in 3.5% NaCl solution. The microstructural study revealed significant grain refinement and agglomeration of β (Mg2Al3) intermetallic precipitates in the WNZ. The relatively higher hardness and a decrease in the ductility (3%) also assured the formation of precipitates β precipitates in the WNZ welded samples. The fracture surface of welded sample also revealed the existence of β precipitates within the elongated dimples which may be considered as the crack initiation sites. The relatively lower corrosion rate (23.68 mpy) and higher charge transfer resistance (403 Ω cm2) of BM compared to WNZ could be associated with the galvanic dissolution of Al-matrix through competitive charge transfer and relaxation (adsorption/desorption of intermediate species) processes specifically at the vicinity of the β precipitates.

Friction pull plug welding: top hat plug design

NASA Technical Reports Server (NTRS)

Coletta, Edmond R. (Inventor); Cantrell, Mark A. (Inventor)

2001-01-01

Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug `top` a small `hat` section is added to the pull plug for added frictional heating and pressure.

Friction pull plug welding: top hat plug design

NASA Technical Reports Server (NTRS)

Coletta, Edmond R. (Inventor); Cantrell, Mark A. (Inventor)

2002-01-01

Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug `top` a small `hat` section is added to the pull plug for added frictional heating and pressure.

Characterization of lap joints laser beam welding of thin AA 2024 sheets with Yb:YAG disk-laser

NASA Astrophysics Data System (ADS)

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

2012-06-01

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

Heat exchanger tube mounts

DOEpatents

Wolowodiuk, W.; Anelli, J.; Dawson, B.E.

1974-01-01

A heat exchanger in which tubes are secured to a tube sheet by internal bore welding is described. The tubes may be moved into place in preparation for welding with comparatively little trouble. A number of segmented tube support plates are provided which allow a considerable portion of each of the tubes to be moved laterally after the end thereof has been positioned in preparation for internal bore welding to the tube sheet. (auth)

Influence of FSW pin tool geometry on plastic flow of AA7075 T651

NASA Astrophysics Data System (ADS)

Lertora, Enrico; Mandolfino, Chiara; Gambaro, Carla

2016-10-01

In this paper the behaviour of the plastic flow during Friction Stir Welding of AA7075 T651 plates, realized with different shaped tools, has been investigated. In particular, the influence of the shape of three tools was studied using copper strips placed along the welds. After welding, radiography and metallurgical analysis were used in order to investigate the marker movement and its fragmentation.

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

NASA Technical Reports Server (NTRS)

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

2001-01-01

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

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.

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

NASA Astrophysics Data System (ADS)

Mazar Atabaki, Mehdi

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

High-power Laser Welding of Thick Steel-aluminum Dissimilar Joints

NASA Astrophysics Data System (ADS)

Lahdo, Rabi; Springer, André; Pfeifer, Ronny; Kaierle, Stefan; Overmeyer, Ludger

According to the Intergovernmental Panel on Climate Change (IPCC), a worldwide reduction of CO2-emissions is indispensable to avoid global warming. Besides the automotive sector, lightweight construction is also of high interest for the maritime industry in order to minimize CO2-emissions. Using aluminum, the weight of ships can be reduced, ensuring lower fuel consumption. Therefore, hybrid joints of steel and aluminum are of great interest to the maritime industry. In order to provide an efficient lap joining process, high-power laser welding of thick steel plates (S355, t = 5 mm) and aluminum plates (EN AW-6082, t = 8 mm) is investigated. As the weld seam quality greatly depends on the amount of intermetallic phases within the joint, optimized process parameters and control are crucial. Using high-power laser welding, a tensile strength of 10 kN was achieved. Based on metallographic analysis, hardness tests, and tensile tests the potential of this joining method is presented.

Proceedings of the IREAPS Technical Symposium (9th) Held in San Diego, California on September 14-16, 1982. Volume 1 (The National Shipbuilding Research Program)

DTIC Science & Technology

1982-01-01

templates. Bends plate to radius of forming cylinder. One sided butt welds up through 5/8" using magnet bed for alignment. Automatically fits and welds...up to nine stiffeners per panel. Exit Butt Weld One sided butt welds stiffened bottom panels to Tank Top Fitting Area each other using magnet bed for...be over-emphasized! Benefits derived from the model are somewhat like magnetism . Model usage is inversely proportional to the square of the distance

Investigation of the vapour-plasma plume in the welding of titanium by high-power ytterbium fibre laser radiation

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

Bykovskiy, D P; Petrovskii, V N; Uspenskiy, S A

2015-03-31

The vapour-plasma plume produced in the welding of 6-mm thick VT-23 titanium alloy plates by ytterbium fibre laser radiation of up to 10 kW power is studied in the protective Ar gas medium. High-speed video filming of the vapour-plasma plume is used to visualise the processes occurring during laser welding. The coefficient of inverse bremsstrahlung by the welding plasma plume is calculated from the data of the spectrometric study. (interaction of laser radiation with matter)

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

NASA Astrophysics Data System (ADS)

Güler, Hande

2014-10-01

Aluminum and alloys are widely used in the automotive industry due to the light weight, good formability, and malleability. Spot welding is the most commonly used joining method of these materials, but the high current requirements and the inconsistent quality of the final welds make this process unsuitable. An alternative welding technique, the friction-stir spot welding process, can also be successfully used in joining of aluminum and alloys. In this study, 1-mm-thick AA5754 Al-alloy plates in the H-111 temper conditions were joined by friction-stir spot welding using two different weld parameters such as tool rotational speed and dwell time. Mechanical properties of the joints were obtained with extensive hardness measurements and tensile shear tests. The effect of these parameters on the failure modes of welded joints was also determined.

Intraoral Laser Welding (ILW): ultrastructural and mechanical analysis

NASA Astrophysics Data System (ADS)

Fornaini, Carlo; Passaretti, Francesca; Villa, Elena; Nammour, Samir

2010-05-01

Nd:YAG, currently used since 1970 in dental laboratories to weld metals on dental prostheses has some limits such great dimensions, high costs and fixed delivery system. Recently it was proposed the possibility to use the Nd:YAG laser device commonly utilised in dental office, to repair broken fixed, removable and orthodontic prostheses and to weld metals directly into the mouth. The aim of this work is to value, through SEM (Scanning Electron Microscope), EDS (Energy Dispersive X-Ray Spectroscopy) and DMA (Dynamic Mechanical Analysis), quality and mechanical strength of the welding process comparing a device normally used in dental lab and a device normally used in dental office for oral surgery. Sixteen CoCrMo metal plates and twenty steel orthodontic wires were divided in four groups: one was welded without metal apposition by laboratory laser, one was welded with metal apposition by laboratory laser, one was welded without metal apposition by office laser and one was welded with metal apposition by office laser. The welding process was analysed by SEM, EDS and DMA to compare the differences between the different samples. By SEM analysis it was seen that the plates welded by office laser without apposition metal showed a greater number of fissurations compared with the other samples. By EDS analysis it was seen a homogeneous composition of the metals in all the samples. The mechanical tests showed a similar elastic behaviour of the samples, with minimal differences between the two devices. No wire broke even under the maximum strength by the Analyser. This study seems to demonstrate that the welding process by office Nd:YAG laser device and the welding process by laboratory Nd:YAG laser device, analysed by SEM, EDS and DMA, showed minimal and not significant differences even if these data will be confirmed by a greater number of samples.

Simulation on friction taper plug welding of AA6063-20Gr metal matrix composite

NASA Astrophysics Data System (ADS)

Hynes, N. Rajesh Jesudoss; Nithin, Abeyram M.

2016-05-01

Friction taper plug welding a variant of friction welding is useful in welding of similar and dissimilar materials. It could be used for joining of composites to metals in sophisticated aerospace applications. In the present work numerical simulation of friction taper plug welding process is carried out using finite element based software. Graphite reinforced AA6063 is modelled using the software ANSYS 15.0 and temperature distribution is predicted. Effect of friction time on temperature distribution is numerically investigated. When the friction time is increased to 30 seconds, the tapered part of plug gets detached and fills the hole in the AA6063 plate perfectly.

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

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

NASA Astrophysics Data System (ADS)

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

1997-08-01

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

Practical method of diffusion-welding steel plate in air

NASA Technical Reports Server (NTRS)

Holko, K. H.; Moore, T. J.

1971-01-01

Method is ideal for critical service requirements where parent metal properties are equaled in notch toughness, stress rupture and other characteristics. Welding technique variations may be used on a variety of materials, such as carbon steels, alloy steels, stainless steels, ceramics, and reactive and refractory materials.

Development of a lemon cutting machine.

PubMed

Hrishikesh Tavanandi, A; Deepak, S; Venkateshmurthy, K; Raghavarao, K S M S

2014-12-01

Cutting of lemon and other similar fruits is conventionally done manually by sharp knife, which is labor intensive and often un-hygienic. In the present work, a device has been designed and developed for cutting of lemon hygienically into four pieces of similar shape based on stationery cutters and rotating centralizing/locating slit plate concept. Machine has a unique knife assembly consisting of two bird wing shaped knives, joined by welding perpendicularly to a vertical knife, so that the lemon can be cut into four pieces in a single sweep. Six numbers of rotating centralizing/locating slit plates are welded on to the side plates and the plates carry a groove on its inner face, to enable the wing shaped knife to complete the horizontal cut. The rotating slit plates, having centralizing angle of 90°, are rotated by an electric geared motor. The prototype machine has capacity of over 5,000 lemons/h with a power consumption of 0.11 kW.

Prediction of the Vickers Microhardness and Ultimate Tensile Strength of AA5754 H111 Friction Stir Welding Butt Joints Using Artificial Neural Network.

PubMed

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

2016-11-10

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

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

DOE PAGES

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

2014-01-01

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

Behaviour of several fatigue prone bridge details

NASA Astrophysics Data System (ADS)

Kubiš, Petr; Ryjáček, Pavel

2017-09-01

Three fatigue welded bridge joints analysed in this work are the alternative details of the bottom flange connection. This construction detail is mainly used for the erection connection for steel and composite bridges. If applied in the place, where live load is significant, the fatigue becomes the main design criterion. The detail category is thus very important factor. The aim of this paper is to analyse the possibilities of the improving the behaviour of this detail, by various methods. First solution is to modify the shape of the cope hole to the elliptic shape. Second option is to use the “Olemutz” fully welded detail. This detail is often used in bridge designing despite there is no exact information about the fatigue category, and doubts of the performance exists. “Olemutz” is a long web plate slit that is filled by the double bevel weld after the execution of the bottom flange weld. The last detail is the elliptic cope hole filled by the plate-cap welded into an empty hole. The geometry is the same, as in the first case. The conclusion of the numerical analysis and the pilot fatigue experiments is discussed with several practical recommendations for designing.

The potential of a GAS can with payload G-169

NASA Technical Reports Server (NTRS)

Tamir, David

1988-01-01

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

Thermo-mechanical modeling of the gas-tungsten-arc (GTA) welding process

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

Duncan, D.B.

1980-01-18

A fundamental study of gas-tungsten-arc (GTA) welding was undertaken. This was initiated with a review of the GTA welding process which lead to the decision to focus experimental and analytical efforts on stationary welds on a pure material. Pure nickel was selected for the test material. Temperature, strain, and distortion measurements were made during the formation of spot welds on circular plates. Transient thermal data were obtained with thermocouples, a radiation pyrometer, and from motion pictures. Local strain was observed qualitatively from Moire interference fringe patterns. Distortion during welding was measured with displacement gages and residual distortion with a profilometer.more » Experimental measurements are compared with predictions of thermal and mechanical finite element codes.« less

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.

Detection and assessment of flaws in friction stir welded joints using ultrasonic guided waves: experimental and finite element analysis

NASA Astrophysics Data System (ADS)

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

2018-02-01

Ultrasonic guided waves (GWs), e.g. Lamb waves, have been proven effective in the detection of defects such as corrosion, cracking, delamination, and debonding in both composite and metallic structures. They are a significant tool employed in structural health monitoring. In this study, the ability of ultrasonic GWs to assess the quality of friction stir welding (FSW) was investigated. Four friction stir welded AZ31B magnesium plates processed with different welding parameters and a non-welded plate were used. The fundamental symmetric (S0) Lamb wave mode was excited using piezoelectric wafers (PZTs). Further, the S0 mode was separated using the "Improved complete ensemble empirical mode decomposition with adaptive noise (Improved CEEMDAN)" technique. A damage index (DI) was defined based on the variation in the amplitude of the captured wave signals in order to detect the presence and asses the severity of damage resulting from the welding process. As well, computed tomography (CT) scanning was used as a non-destructive testing (NDT) technique to assess the actual weld quality and validate predictions based on the GW approach. The findings were further confirmed using finite element analysis (FEA). To model the actual damage profile in the welds, "Mimics" software was used for the 3D reconstruction of the CT scans. The built 3D models were later used for evaluation of damage volume and for FEA. The damage volumes were correlated to the damage indices computed from both experimental and numerical data. The proposed approach showed high sensitivity of the S0 mode to internal flaws within the friction stir welded joints. This methodology has great potential as a future classification method of FSW quality.

A Bottom-Up Optimization Approach for Friction Stir Welding Parameters of Dissimilar AA2024-T351 and AA7075-T651 Alloys

NASA Astrophysics Data System (ADS)

Anil Kumar, K. S.; Murigendrappa, S. M.; Kumar, Hemantha

2017-07-01

In the present study, optimum friction stir weld parameters such as plunge depth, tool rotation speed and traverse speed for butt weld of dissimilar aluminum alloy plates, typically 2024-T351 and 7075-T651, are investigated using a bottom-up approach. In the approach, optimum FSW parameters are achieved by varying any one parameter for every trial while remaining parameters are kept constant. The specimens are extracted from the friction stir-welded plates for studying the tensile, hardness and microstructure properties. Optimum friction stir weld individual parameters are selected based on the highest ultimate tensile strength of the friction stir-welded butt joint specimens produced by varying in each case one parameter and keeping the other two constant. The microstructure samples were investigated for presence of defects, grain refinement at the weld nugget (WN), bonding between the two materials and interface of WN, TMAZ (thermomechanically affected zone) of both advancing and retreating sides of the dissimilar joints using optical microscopy and scanning electron microscopy analyses. In the experimental investigations, the optimum FSW parameters such as plunge depth, 6.2 mm, rotation speed, 650 rpm and traverse speed of 150 mm/min result in ultimate tensile strength, 435 MPa, yield strength, 290 MPa, weld joint efficiency, 92% and maximum elongation, 13%. The microstructure of optimized sample in the WN region revealed alternate lamellae material flow pattern with better metallurgical properties, defect free and very fine equiaxed grain size of about 3-5 µm.

New weldable high strength aluminum alloy developed for cryogenic service

NASA Technical Reports Server (NTRS)

1966-01-01

Wrought aluminum alloy has improved low temperature notch toughness and weldability. This alloy can be mill-fabricated to plate and sheet without difficulty. Post-weld aging improves weld ductility and strength properties. A typical treatment is 8 hours at 225 deg F plus 16 hours at 300 deg F.

Alternate Design of ITER Cryostat Skirt Support System

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

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

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Sensoring Fusion Data from the Optic and Acoustic Emissions of Electric Arcs in the GMAW-S Process for Welding Quality Assessment

PubMed Central

Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

2012-01-01

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

Creep Deformation, Rupture Analysis, Heat Treatment and Residual Stress Measurement of Monolithic and Welded Grade 91 Steel for Power Plant Components

NASA Astrophysics Data System (ADS)

Shrestha, Triratna

Modified 9Cr-1 Mo (Grade 91) steel is currently considered as a candidate material for reactor pressure vessels (RPVs) and reactor internals for the Very High Temperature Reactor (VHTR), and in fossil-fuel fired power plants at higher temperatures and stresses. The tensile creep behavior of Grade 91 steel was studied in the temperature range of 600°C to 750°C and stresses between 35 MPa and 350 MPa. Heat treatment of Grade 91 steel was studied by normalizing and tempering the steel at various temperatures and times. Moreover, Thermo-Ca1c(TM) calculation was used to predict the precipitate stability and their evolution, and construct carbon isopleths of Grade 91 steel. Residual stress distribution across gas tungsten arc welds (GTAW) in Grade 91 steel was measured by the time-of-flight neutron diffraction using the Spectrometer for Materials Research at Temperature and Stress (SMARTS) diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory, Los Alamos, NM, USA. Analysis of creep results yielded stress exponents of ˜9-11 in the higher stress regime and ˜1 in the lower stress regime. The creep behavior of Grade 91 steel was described by the modified Bird-Mukherjee-Dorn relation. The rate-controlling creep deformation mechanism in the high stress regime was identified as the edge dislocation climb with a stress exponent of n = 5. On the other hand, the deformation mechanism in the Newtonian viscous creep regime (n = 1) was identified as the Nabarro-Herring creep. Creep rupture data were analyzed in terms of Monkman-Grant relation and Larson-Miller parameter. Creep damage tolerance factor and stress exponent were used to identify the cause of creep damage. The fracture surface morphology of the ruptured specimens was studied by scanning electron microscopy to elucidate the failure mechanisms. Fracture mechanism map for Grade 91 steel was developed based on the available material parameters and experimental observations. The microstructural evolution of heat treated steel was correlated with the differential scanning calorimetric study. The combination of microstructural studies with optical microscopy, scanning and transmission electron microscopy, microhardness profiles, and calorimetric plots helped in the understanding of the evolution of microstructure and precipitates in Grade 91 steel. The residual stresses were determined at the mid-thickness of the plate, 4.35 mm and 2.35 mm below the surface of the as-welded and post-weld heat treated plate. The residual stresses of the as-welded plate were compared with the post-weld heat treated plate. The post-weld heat treatment significantly reduced the residual stress in the base metal, heat affected zone, and the weld zone. Vickers microhardness profiles of the as-welded, and post-weld heat treated specimens were also determined and correlated with the observed residual stress profile and microstructure.

Analysis and design of friction stir welding tool

NASA Astrophysics Data System (ADS)

Jagadeesha, C. B.

2016-12-01

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

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.

Control of microstructure in soldered, brazed, welded, plated, cast or vapor deposited manufactured components

DOEpatents

Ripley, Edward B.; Hallman, Russell L.

2015-11-10

Disclosed are methods and systems for controlling of the microstructures of a soldered, brazed, welded, plated, cast, or vapor deposited manufactured component. The systems typically use relatively weak magnetic fields of either constant or varying flux to affect material properties within a manufactured component, typically without modifying the alloy, or changing the chemical composition of materials or altering the time, temperature, or transformation parameters of a manufacturing process. Such systems and processes may be used with components consisting of only materials that are conventionally characterized as be uninfluenced by magnetic forces.

The numerical simulation of Lamb wave propagation in laser welding of stainless steel

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Fabrication of experimental three-meter space telescope primary and secondary mirror support structure

NASA Technical Reports Server (NTRS)

Mishler, H. W.

1974-01-01

The fabrication of prototype titanium alloy primary and secondary mirror support structures for a proposed experimental three-meter space telescope is discussed. The structure was fabricated entirely of Ti-6Al-4V tubing and plate. Fabrication included the development of procedures including welding, forming, and machining. Most of the structures was fabricated by gas-shielding tungsten-arc (GTA) welding with several major components fabricated by high frequency resistance (HFR) welding.

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

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Gleeson, Sean T.

2014-03-01

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

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.

Vibration stress relief of DH 36 rectangle welded plates

NASA Astrophysics Data System (ADS)

Li, Shuqi; Fang, Hongyuan

2018-03-01

Vibration stress relief (VSR) is widely used in reducing residual stress in welded structures. However, the effectiveness of this method is still instable in some circumstance. In this study, a covert negative treatment phenomenon was investigated, i.e. natural frequency of welded structures decreased after VSR but residual stress in one direction increased. When the alteration of natural frequency after VSR is significant, the residual stresses in both the longitudinal and transversal directions shall decrease. Otherwise, residual stresses may increase on one direction. Thus, sufficient power shall be applied to the welded structures to avoid negative results.

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.

Seismic Stability of St. Stephen Hydropower Plant, South Carolina

DTIC Science & Technology

2006-11-01

looking from the fish-lift side ....................................... 9 Figure 1-9. Upstream T- beam connection : shim plates welded to embedded wall (an...Figure 1-10. Downstream T- beam connection : T- beam bearing plate rests on Neoprene pad, bolt through plate with slotted holes (an ideal roller condition...37 Figure 4-1. Beam - column model of the erection bay

CALUTRON FACE PLATE

DOEpatents

Brobeck, W.M.

1959-08-25

The construction of a removable cover plate for a calutron tank is described. The plate is fabricated of a rectangular frame member to which is welded a bowed or dished plate of thin steel, reinforced with transverse stiffening ribs. When the tank is placed between the poles of a magnet, the plate may be pivoted away from the tank and magnet and is adapted to support the ion separation mechanism secured to its inner side as well as the vacuum load within the tank.

The effect of laser pulse tailored welding of Inconel 718

NASA Technical Reports Server (NTRS)

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

1990-01-01

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

Experimental Investigation and Optimization of TIG Welding Parameters on Aluminum 6061 Alloy Using Firefly Algorithm

NASA Astrophysics Data System (ADS)

Kumar, Rishi; Mevada, N. Ramesh; Rathore, Santosh; Agarwal, Nitin; Rajput, Vinod; Sinh Barad, AjayPal

2017-08-01

To improve Welding quality of aluminum (Al) plate, the TIG Welding system has been prepared, by which Welding current, Shielding gas flow rate and Current polarity can be controlled during Welding process. In the present work, an attempt has been made to study the effect of Welding current, current polarity, and shielding gas flow rate on the tensile strength of the weld joint. Based on the number of parameters and their levels, the Response Surface Methodology technique has been selected as the Design of Experiment. For understanding the influence of input parameters on Ultimate tensile strength of weldment, ANOVA analysis has been carried out. Also to describe and optimize TIG Welding using a new metaheuristic Nature - inspired algorithm which is called as Firefly algorithm which was developed by Dr. Xin-She Yang at Cambridge University in 2007. A general formulation of firefly algorithm is presented together with an analytical, mathematical modeling to optimize the TIG Welding process by a single equivalent objective function.

A density-adaptive SPH method with kernel gradient correction for modeling explosive welding

NASA Astrophysics Data System (ADS)

Liu, M. B.; Zhang, Z. L.; Feng, D. L.

2017-09-01

Explosive welding involves processes like the detonation of explosive, impact of metal structures and strong fluid-structure interaction, while the whole process of explosive welding has not been well modeled before. In this paper, a novel smoothed particle hydrodynamics (SPH) model is developed to simulate explosive welding. In the SPH model, a kernel gradient correction algorithm is used to achieve better computational accuracy. A density adapting technique which can effectively treat large density ratio is also proposed. The developed SPH model is firstly validated by simulating a benchmark problem of one-dimensional TNT detonation and an impact welding problem. The SPH model is then successfully applied to simulate the whole process of explosive welding. It is demonstrated that the presented SPH method can capture typical physics in explosive welding including explosion wave, welding surface morphology, jet flow and acceleration of the flyer plate. The welding angle obtained from the SPH simulation agrees well with that from a kinematic analysis.

Investigation of Laser Welding of Ti Alloys for Cognitive Process Parameters Selection.

PubMed

Caiazzo, Fabrizia; Caggiano, Alessandra

2018-04-20

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

Investigation of Laser Welding of Ti Alloys for Cognitive Process Parameters Selection

PubMed Central

2018-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

NASA welding assessment program

NASA Technical Reports Server (NTRS)

Patterson, R. E.

1985-01-01

A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

Weldability of AA 5052 H32 aluminium alloy by TIG welding and FSW process - A comparative study

NASA Astrophysics Data System (ADS)

Shanavas, S.; Raja Dhas, J. Edwin

2017-10-01

Aluminium 5xxx series alloys are the strongest non-heat treatable aluminium alloy. Its application found in automotive components and body structures due to its good formability, good strength, high corrosion resistance, and weight savings. In the present work, the influence of Tungsten Inert Gas (TIG) welding parameters on the quality of weld on AA 5052 H32 aluminium alloy plates were analyzed and the mechanical characterization of the joint so produced was compared with Friction stir (FS) welded joint. The selected input variable parameters are welding current and inert gas flow rate. Other parameters such as welding speed and arc voltage were kept constant throughout the study, based on the response from several trial runs conducted. The quality of the weld is measured in terms of ultimate tensile strength. A double side V-butt joints were fabricated by double pass on one side to ensure maximum strength of TIG welded joints. Macro and microstructural examination were conducted for both welding process.

Microstructures and mechanical properties of bonding layers between low carbon steel and alloy 625 processed by gas tungsten arc welding

NASA Astrophysics Data System (ADS)

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

2017-11-01

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

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

PubMed Central

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

2013-01-01

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

Influence of the welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW-2219-T87

NASA Astrophysics Data System (ADS)

Bachmann, A.; Krutzlinger, M.; Zaeh, M. F.

2018-06-01

Friction Stir Welding (FSW) is an innovative joining technique, which has proven to produce high quality joints in high strength aluminum alloys. Consequently, it is commonly used to manufacture lightweight aerospace structures with stringent requirements. For these structures, it is necessary to ensure a high ultimate tensile strength (UTS). Various studies have reported that the UTS is significantly influenced by the welding parameters. Samples welded with different parameter sets showed a considerably different UTS, despite being free from detectable welding defects (e.g. tunnel defect, voids, or lack of penetration). Based on the observations in the literature, a hypothesis was posed. The welding temperature along with the welding speed determine the UTS of the weld. This study aims to prove this hypothesis experimentally by using temperature-controlled FSW to join plates of EN AW-2219-T87 in butt joint configuration. The welded samples were examined using visual inspection, metallography, X-ray imaging, and uniaxial tensile tests. Finally, a statistical analysis was conducted. Hereby, the hypothesis was confirmed.

Modified Welding Technique of a Hypo-Eutectic Al-Cu Alloy for Higher Mechanical Properties

NASA Astrophysics Data System (ADS)

Ghosh, B. R.; Gupta, R. K.; Biju, S.; Sinha, P. P.

GTAW process is used for welding of pressure vessels made of hypo-eutectic Al-Cu alloy AA2219 containing 6.3% Cu. As welded Yield strength of the alloy was found to be in the range of 140-150 MPa, using conventional single pass GTAW technique on both AC and DCSP modes. Interestingly, it was also found that weld-strength decreased with increase in thickness of the weld coupons. Welding metallurgy of AA2219 Al alloy was critically reviewed and factors responsible for lower properties were identified. Multipass GTAW on DCSP mode was postulated to improve the weld strength of this alloy. A systematic experimentation using 12 mm thick plates was carried out and YS of 200 MPa has been achieved in the as welded condition. Thorough characterization including optical and electron microscopy was conducted to validate the metallurgical phenomena attributable to improvement in weld strength. This paper presents the conceptual understanding of welding metallurgy of AA2219 alloy and validation by experiments, which could lead to better weld properties using multipass GTAW on DCSP mode.

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

PubMed

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

2013-12-18

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

46 CFR 54.05-16 - Production toughness testing.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 2 2010-10-01 2010-10-01 false Production toughness testing. 54.05-16 Section 54.05-16... Toughness Tests § 54.05-16 Production toughness testing. (a) For vessels of welded construction, production... welding procedures shall be the same as used in the fabrication of the vessel. From each test plate, one...

49 CFR 179.400-5 - Materials.

Code of Federal Regulations, 2010 CFR

2010-10-01

... Specification for Cryogenic Liquid Tank Car Tanks and Seamless Steel Tanks (Classes DOT-113 and 107A) § 179.400... condition prior to fabrication, forming and fusion welding; (2) Suitable for use at the temperature of the...) Conducted at the tank design service temperature or colder; and (4) Performed on test plate welds and...

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

NASA Astrophysics Data System (ADS)

Yun, Seok-Chul; Kim, Jae-Woong

2010-12-01

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

Optimization of the A-TIG welding for stainless steels

NASA Astrophysics Data System (ADS)

Jurica, M.; Kožuh, Z.; Garašić, I.; Bušić, M.

2018-03-01

The paper presents the influence of the activation flux and shielding gas on tungsten inert gas (A-TIG) welding of the stainless steel. In introduction part, duplex stainless steel was analysed. The A-TIG process was explained and the possibility of welding stainless steels using the A-TIG process to maximize productivity and the cost-effectiveness of welded structures was presented. In the experimental part duplex, 7 mm thick stainless steel has been welded in butt joint. The influence of activation flux chemical composition upon the weld penetration has been investigated prior the welding. The welding process was performed by a robot with TIG equipment. With selected A-TIG welding technology preparation of plates and consumption of filler material (containing Cr, Ni and Mn) have been avoided. Specimens sectioned from the produced welds have been subjected to tensile strength test, macrostructure analysis and corrosion resistance analysis. The results have confirmed that this type of stainless steel can be welded without edge preparation and addition of filler material containing critical raw materials as Cr, Ni and Mn when the following welding parameters are set: current 200 A, welding speed 9,1 cm/min, heat input 1,2 kJ/mm and specific activation flux is used.

Encapsulated fuel unit and method of forming same

DOEpatents

Groh, Edward F.; Cassidy, Dale A.; Lewandowski, Edward F.

1985-01-01

This invention teaches an encapsulated fuel unit for a nuclear reactor, such as for an enriched uranium fuel plate of thin cross section of the order of 1/64 or 1/8 of an inch and otherwise of rectangular shape 1-2 inches wide and 2-4 inches long. The case is formed from (a) two similar channel-shaped half sections extended lengthwise of the elongated plate and having side edges butted and welded together to define an open ended tube-like structure and from (b) porous end caps welded across the open ends of the tube-like structure. The half sections are preferably of stainless steel between 0.002 and 0.01 of an inch thick, and are beam welded together over and within machined and hardened tool steel chill blocks. The porous end caps preferably are of T-316-L stainless steel having pores of approximately 3-10 microns size.

Improved encapsulated fuel unit and method of forming same

DOEpatents

Groh, E.F.; Cassidy, D.A.; Lewandowski, E.

1982-09-07

This invention teaches an encapsulated fuel unit for a nuclear reactor, such as for an enriched uranium fuel plate of thin cross section of the order of 1/64 or 1/8 of an inch and otherwise of rectangular shape 1 to 2 inches wide and 2 to 4 inches long. The case is formed from (a) two similar channel-shaped half sections extended lengthwise of the elongated plate and having side edges butted and welded together to define an open ended tube-like structure and from (b) porous end caps welded across the open ends of the tube-like structure. The half sections are preferably of stainless steel between 0.002 and 0.01 of an inch thick, and are beam welded together over and within machined and hardened tool steel chill blocks. The porous end caps preferably are of T-316-L stainless steel having pores of approximately 3 to 10 microns size.

Finite Element and Analytical Analysis of Cracks in Thick Stiffened Plates Repaired with a Single Sided Composite Patch

DTIC Science & Technology

2014-06-01

DC,Tech. Rep. CG-D-05–00, 2000. [16] S. Kou, Welding Metallurgy , 2nd edition, Hoboken: Wiley Interscience, 2003. [17] C. Poe, “Stress intensity...continuous aluminum superstructure welded to the deck. The shape of the superstructure created numerous stress concentration areas. Of the greatest concern...study as it will help provide a conservative estimate. In marine applications almost all stiffening members are attached by welding . Unlike a

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

This paper presents the influence of the effect of ultrasound on the wave formation and plastic deformation in the metals welded by ultrasound-assisted explosive welding. It has been established that the influence of high-frequency acoustic waves on the metal leads to a reduction of the dynamic yield stress, which in turn leads to changes in the properties of the surface layers of metal and in the conditions of bonding between the collided plates upon explosive welding. It has been shown that the changes in the length and amplitude of waves that arise in the weld joint upon the explosive welding with the simultaneous action of ultrasonic vibrations is connected with a decrease in the magnitude of the deforming pulse and time of action of the compressive stresses that exceed the dynamic yield stress behind the point of contact.

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.

Microstructure and Mechanical Characterization of Friction-Stir-Welded Dual-Phase Brass

NASA Astrophysics Data System (ADS)

Ramesh, R.; Dinaharan, I.; Akinlabi, E. T.; Murugan, N.

2018-03-01

Friction stir welding (FSW) is an ideal process to join brass to avoid the evaporation of zinc. In the present investigation, 6-mm-thick dual-phase brass plates were joined efficiently using FSW at various tool rotational speeds. The microstructures were studied using optical microscopy, electron backscattered diffraction and transmission electron microscopy. The optical micrographs revealed the evolution of various zones across the joint line. The microstructure of the heat-affected zone was similar to that of base metal. The weld zone exhibited finer grains due to dynamic recrystallization. The recrystallization was inhomogeneous and the inhomogeneity reduced with increased tool rotational speed. The dual phase was preserved in the weld zone due to the retention of zinc. The severe plastic deformation created a lot of dislocations in the weld zone. The weld zone was strengthened after welding. The role of tool rotational speed on the joint strength is further reported.

Control of Structure in Conventional Friction Stir Welds through a Kinematic Theory of Metal Flow

NASA Technical Reports Server (NTRS)

Rubisoff, H.A.; Schneider, J.A.; Nunes, A.C.

2009-01-01

In friction stir welding (FSW), a rotating pin is translated along a weld seam so as to stir the sides of the seam together. Metal is prevented from flowing up the pin, which would result in plowing/cutting instead of welding, by a shoulder on the pin. In conventional FSW, the weld metal rests on an "anvil", which supports the heavy "plunge" load on the tool. In this study, both embedded tungsten wires along and copper plating on the faying surfaces were used to trace the flow of AA2219 weld metal around the C-FSW tool. The effect of tool rotational speed, travel speed, plunge load, and pin thread pitch on the resulting weld metal flow was evaluated. Plan, longitudinal, and transverse section x-ray radiographs were examined to trace the metal flow paths. The results are interpreted in terms of a kinematic theory of metal flow in FSW.

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

Effects of gap width on droplet transfer behavior in ultra-narrow gap laser welding of high strength aluminum alloys

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Prediction of the Vickers Microhardness and Ultimate Tensile Strength of AA5754 H111 Friction Stir Welding Butt Joints Using Artificial Neural Network

PubMed Central

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

2016-01-01

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

ME8373 Spring 2015 ICME Proposal ICME Analysis of Fatigue Crack Growth Through a Weld in SA-516 Grade 70 Plate

NASA Technical Reports Server (NTRS)

Woods, Jody L.

2015-01-01

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

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

NASA Technical Reports Server (NTRS)

Graff, Karl; Short, Matt

2013-01-01

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

Background Paper on Aerospace & Missile Needs

DTIC Science & Technology

2006-05-01

Micro- welding based coatings Trivalent chromium plated coatings Nano-composite Ni-P and Co-P based plated coatings Thermal diffusion coatings Plasma...working in conjunction with Advanced Surfaces and Processes, Inc. to determine the applicability of another type of ESD process. Trivalent Chromium ...Plating: Trivalent chromium is considered to be much less toxic than hexavalent chromium . Consequently, trivalent chromium coatings are being

Fusion welding studies using laser on Ti-SS dissimilar combination

NASA Astrophysics Data System (ADS)

Shanmugarajan, B.; Padmanabham, G.

2012-11-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

Effect of Gas Tungsten Arc Welding Parameters on Hydrogen-Assisted Cracking of Type 321 Stainless Steel

NASA Astrophysics Data System (ADS)

Rozenak, Paul; Unigovski, Yaakov; Shneck, Roni

2016-05-01

The susceptibility of AISI type 321 stainless steel welded by the gas tungsten arc welding (GTAW) process to hydrogen-assisted cracking (HAC) was studied in a tensile test combined with in situ cathodic charging. Specimen charging causes a decrease in ductility of both the as-received and welded specimens. The mechanical properties of welds depend on welding parameters. For example, the ultimate tensile strength and ductility increase with growing shielding gas (argon) rate. More severe decrease in the ductility was obtained after post-weld heat treatment (PWHT). In welded steels, in addition to discontinuous grain boundary carbides (M23C6) and dense distribution of metal carbides MC ((Ti, Nb)C) precipitated in the matrix, the appearance of delta-ferrite phase was observed. The fracture of sensitized specimens was predominantly intergranular, whereas the as-welded specimens exhibited mainly transgranular regions. High-dislocation density regions and stacking faults were found in delta-ferrite formed after welding. Besides, thin stacking fault plates and epsilon-martensite were found in the austenitic matrix after the cathodic charging.

Numerical simulation of the laser welding process for the prediction of temperature distribution on welded aluminium aircraft components

NASA Astrophysics Data System (ADS)

Tsirkas, S. A.

2018-03-01

The present investigation is focused to the modelling of the temperature field in aluminium aircraft components welded by a CO2 laser. A three-dimensional finite element model has been developed to simulate the laser welding process and predict the temperature distribution in T-joint laser welded plates with fillet material. The simulation of the laser beam welding process was performed using a nonlinear heat transfer analysis, based on a keyhole formation model analysis. The model employs the technique of element ;birth and death; in order to simulate the weld fillet. Various phenomena associated with welding like temperature dependent material properties and heat losses through convection and radiation were accounted for in the model. The materials considered were 6056-T78 and 6013-T4 aluminium alloys, commonly used for aircraft components. The temperature distribution during laser welding process has been calculated numerically and validated by experimental measurements on different locations of the welded structure. The numerical results are in good agreement with the experimental measurements.

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

NASA Technical Reports Server (NTRS)

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

1972-01-01

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

Complete Status Report Documenting Development of Friction Stir Welding for Joining Thin Wall Tubing of ODS Alloys

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

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

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

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

Low Cost Wireless Fatigue Crack Monitoring System Using RFID Arrays

DOT National Transportation Integrated Search

2018-03-23

The use of welded steel cover plates had been a common design practice to increase beam section capacity in regions ofhigh torsion for decades. Many steel girder bridges with cover plates are still in service. Steel girder bridges are subject to cycl...

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

NASA Astrophysics Data System (ADS)

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

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

Modeling aluminum-lithium alloy welding characteristics

NASA Technical Reports Server (NTRS)

Bernstein, Edward L.

1996-01-01

The purpose of this project was to develop a finite element model of the heat-affected zone in the vicinity of a weld line on a plate in order to determine an accurate plastic strain history. The resulting plastic strain increments calculated by the finite element program were then to be used to calculate the measure of damage D. It was hoped to determine the effects of varying welding parameters, such as beam power, efficiency, and weld speed, and the effect of different material properties on the occurrence of microfissuring. The results were to be compared first to the previous analysis of Inconel 718, and then extended to aluminum 2195.

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.

Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

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

1995-01-01

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

46 CFR 54.05-15 - Weldment toughness tests-procedure qualifications.

Code of Federal Regulations, 2012 CFR

2012-10-01

... the weld metal. (2) Three specimens with the notch centered on the fusion line between parent plate and weld. (The fusion line may be identified by etching the specimen with a mild reagent.) (3) Three specimens with the notch centered in the heat affected zone, 1 mm from the fusion line. (4) Same as...

46 CFR 54.05-15 - Weldment toughness tests-procedure qualifications.

Code of Federal Regulations, 2011 CFR

2011-10-01

... the weld metal. (2) Three specimens with the notch centered on the fusion line between parent plate and weld. (The fusion line may be identified by etching the specimen with a mild reagent.) (3) Three specimens with the notch centered in the heat affected zone, 1 mm from the fusion line. (4) Same as...

46 CFR 54.05-15 - Weldment toughness tests-procedure qualifications.

Code of Federal Regulations, 2013 CFR

2013-10-01

... the weld metal. (2) Three specimens with the notch centered on the fusion line between parent plate and weld. (The fusion line may be identified by etching the specimen with a mild reagent.) (3) Three specimens with the notch centered in the heat affected zone, 1 mm from the fusion line. (4) Same as...

46 CFR 54.05-15 - Weldment toughness tests-procedure qualifications.

Code of Federal Regulations, 2014 CFR

2014-10-01

... the weld metal. (2) Three specimens with the notch centered on the fusion line between parent plate and weld. (The fusion line may be identified by etching the specimen with a mild reagent.) (3) Three specimens with the notch centered in the heat affected zone, 1 mm from the fusion line. (4) Same as...

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.

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

DOEpatents

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

2010-07-27

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

Theoretical prediction of welding distortion in large and complex structures

NASA Astrophysics Data System (ADS)

Deng, De-An

2010-06-01

Welding technology is widely used to assemble large thin plate structures such as ships, automobiles, and passenger trains because of its high productivity. However, it is impossible to avoid welding-induced distortion during the assembly process. Welding distortion not only reduces the fabrication accuracy of a weldment, but also decreases the productivity due to correction work. If welding distortion can be predicted using a practical method beforehand, the prediction will be useful for taking appropriate measures to control the dimensional accuracy to an acceptable limit. In this study, a two-step computational approach, which is a combination of a thermoelastic-plastic finite element method (FEM) and an elastic finite element with consideration for large deformation, is developed to estimate welding distortion for large and complex welded structures. Welding distortions in several representative large complex structures, which are often used in shipbuilding, are simulated using the proposed method. By comparing the predictions and the measurements, the effectiveness of the two-step computational approach is verified.

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

Comparisons between TiO2- and SiO2-flux assisted TIG welding processes.

PubMed

Tseng, Kuang-Hung; Chen, Kuan-Lung

2012-08-01

This study investigates the effects of flux compounds on the weld shape, ferrite content, and hardness profile in the tungsten inert gas (TIG) welding of 6 mm-thick austenitic 316 L stainless steel plates, using TiO2 and SiO2 powders as the activated fluxes. The metallurgical characterizations of weld metal produced with the oxide powders were evaluated using ferritoscope, optical microscopy, and Vickers microhardness test. Under the same welding parameters, the penetration capability of TIG welding with TiO2 and SiO2 fluxes was approximately 240% and 292%, respectively. A plasma column made with SiO2 flux exhibited greater constriction than that made with TiO2 flux. In addition, an anode root made with SiO2 flux exhibited more condensation than that made with TiO2 flux. Results indicate that energy density of SiO2-flux assisted TIG welding is higher than that of TiO2-flux assisted TIG welding.

Stresses in Circular Plates with Rigid Elements

NASA Astrophysics Data System (ADS)

Velikanov, N. L.; Koryagin, S. I.; Sharkov, O. V.

2018-05-01

Calculations of residual stress fields are carried out by numerical and static methods, using the flat cross-section hypothesis. The failure of metal when exposed to residual stresses is, in most cases, brittle. The presence in the engineering structures of rigid elements often leads to the crack initiation and structure failure. This is due to the fact that rigid elements under the influence of external stresses are stress concentrators. In addition, if these elements are fixed by welding, the residual welding stresses can lead to an increase in stress concentration and, ultimately, to failure. The development of design schemes for such structures is a very urgent task for complex technical systems. To determine the stresses in a circular plate with a welded circular rigid insert under the influence of an external load, one can use the solution of the plane stress problem for annular plates in polar coordinates. The polar coordinates of the points are the polar radius and the polar angle, and the stress state is determined by normal radial stresses, tangential and shearing stresses. The use of the above mentioned design schemes, formulas, will allow more accurate determination of residual stresses in annular welded structures. This will help to establish the most likely directions of failure and take measures at the stages of designing, manufacturing and repairing engineering structures to prevent these failures. However, it must be taken into account that the external load, the presence of insulation can lead to a change in the residual stress field.

Computer modeling of the stress-strain state of welded construction

NASA Astrophysics Data System (ADS)

Nurguzhin, Marat; Danenova, Gulmira; Akhmetzhanov, Talgat

2017-11-01

At the present time the maintenance of the welded construction serviceability over normative service life is provided by the maintenance system on the basis of the guiding documents according to the concept of "fail safe". However, technology factors relating to welding such as high residual stresses and significant plastic strains are not considered in the guiding documents. The design procedure of the stressed-strained state of welded constructions is suggested in the paper. The procedure investigates welded constructions during welding and the external load using the program ANSYS. In this paper, the model of influence of the residual stress strain state on the factor of stress intensity is proposed. The calculation method of the residual stressed-strained state (SSS) taking into account the phase transition is developed by the authors. Melting and hardening of a plate material during heating and cooling is considered. The thermomechanical problem of heating a plate by a stationary heat source is solved. The setup of the heating spot center on distance (190 mm) from the crack top in a direction of its propagation leads to the fact that the value of total factor of stress intensity will considerably decrease under action of the specified residual compressing stresses. It can lower the speed of the crack propagation to zero. The suggested method of survivability maintenance can be applied during operation with the purpose of increasing the service life of metal constructions up to running repair of technological machines.

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.

49 CFR 179.200-7 - Materials.

Code of Federal Regulations, 2011 CFR

2011-10-01

...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... 30 1 Maximum stresses to be used in calculations. 2 High alloy steel materials used to fabricate tank... specifications with the indicated minimum tensile strength and elongation in the welded condition. (b) Carbon...

49 CFR 179.200-7 - Materials.

Code of Federal Regulations, 2013 CFR

2013-10-01

...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... 30 1 Maximum stresses to be used in calculations. 2 High alloy steel materials used to fabricate tank... specifications with the indicated minimum tensile strength and elongation in the welded condition. (b) Carbon...

49 CFR 179.200-7 - Materials.

Code of Federal Regulations, 2014 CFR

2014-10-01

...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... 30 1 Maximum stresses to be used in calculations. 2 High alloy steel materials used to fabricate tank... specifications with the indicated minimum tensile strength and elongation in the welded condition. (b) Carbon...

49 CFR 179.200-7 - Materials.

Code of Federal Regulations, 2012 CFR

2012-10-01

...) High alloy steel plate: High alloy steel plate must comply with one of the following specifications... 30 1 Maximum stresses to be used in calculations. 2 High alloy steel materials used to fabricate tank... specifications with the indicated minimum tensile strength and elongation in the welded condition. (b) Carbon...

Computational Modeling of Microstructural-Evolution in AISI 1005 Steel During Gas Metal Arc Butt Welding

DTIC Science & Technology

2013-05-01

of ferrite possessing an acicular/ lenticular -plate morphology which grows into the untrans- formed austenite from the austenite/austenite grain...ferrite and lenticular -shaped Wid- manstatten plates advancing from the allotriomorphic ferrite/ austenite interfaces toward the grain centers is depicted

49 CFR 178.338-18 - Marking.

Code of Federal Regulations, 2014 CFR

2014-10-01

... Containers for Motor Vehicle Transportation § 178.338-18 Marking. (a) General. Each cargo tank certified... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left side near the front, in a place accessible for inspection. If the specification plate is attached...

49 CFR 178.338-18 - Marking.

Code of Federal Regulations, 2012 CFR

2012-10-01

... Containers for Motor Vehicle Transportation § 178.338-18 Marking. (a) General. Each cargo tank certified... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left side near the front, in a place accessible for inspection. If the specification plate is attached...

49 CFR 178.338-18 - Marking.

Code of Federal Regulations, 2011 CFR

2011-10-01

... Containers for Motor Vehicle Transportation § 178.338-18 Marking. (a) General. Each cargo tank certified... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left side near the front, in a place accessible for inspection. If the specification plate is attached...

49 CFR 178.338-18 - Marking.

Code of Federal Regulations, 2013 CFR

2013-10-01

... Containers for Motor Vehicle Transportation § 178.338-18 Marking. (a) General. Each cargo tank certified... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left side near the front, in a place accessible for inspection. If the specification plate is attached...

Investigation on the Effect of Sub-Zero Treatment on Micro-Hardness and Microstructure of GTAW Welded Al-Si-Mg-Mn Alloy

NASA Astrophysics Data System (ADS)

Devanathan, R.; Yuvarajan, D.; Christopher Selvam, D.; Venkatamuni, T.

2018-02-01

In this work, the effect of sub-zero treatment on the mechanical properties of an Al-Si-Mg-Mn alloy welded by GTAW (gas tungsten arc welding) leads to significant softening in the welded region. The latter is due to melting and resolidification in the welded region, which have resulted in decomposition of the strengthening precipitates. The experiments were performed on GTAW welded plates of 6 mm thickness by varying the heat inputs, namely, of 370, 317.1, 277.5, 246.4, and 222 J/mm, and sub-zero treatment time periods. The Sub-Zero treatment was performed at-45°C using dry ice; hardness and microstructure investigations were performed in the welded region of the Al‒Si-Mg-Mn alloy that was studied in two different conditions, namely, as-welded and in that formed after post weld sub-zero treatment with artificial aging. It was found that the post weld Sub-Zero treatment followed by artificial aging had led to realization of significantly higher hardness values in the welded region due to the recurrence of the precipitation sequence.

Bond Strength of Gold Alloys Laser Welded to Cobalt-Chromium Alloy

PubMed Central

Watanabe, Ikuya; Wallace, Cameron

2008-01-01

The objective of this study was to investigate the joint properties between cast gold alloys and Co-Cr alloy laser-welded by Nd:YAG laser. Cast plates were fabricated from three types of gold alloys (Type IV, Type II and low-gold) and a Co-Cr alloy. Each gold alloy was laser-welded to Co-Cr using a dental laser-welding machine. Homogeneously-welded and non-welded control specimens were also prepared. Tensile testing was conducted and data were statistically analyzed using ANOVA. The homogeneously-welded groups showed inferior fracture load compared to corresponding control groups, except for Co-Cr. In the specimens welded heterogeneously to Co-Cr, Type IV was the greatest, followed by low-gold and Type II. There was no statistical difference (P<0.05) in fracture load between Type II control and that welded to Co-Cr. Higher elongations were obtained for Type II in all conditions, whereas the lowest elongation occurred for low-gold welded to Co-Cr. This study indicated that, of the three gold alloys tested, the Type IV gold alloy was the most suitable alloy for laser-welding to Co-Cr. PMID:19088892

Nuclear reactor control room construction

DOEpatents

Lamuro, R.C.; Orr, R.

1993-11-16

A control room for a nuclear plant is disclosed. In the control room, objects labelled 12, 20, 22, 26, 30 in the drawing are no less than four inches from walls labelled 10.2. A ceiling contains cooling fins that extend downwards toward the floor from metal plates. A concrete slab is poured over the plates. Studs are welded to the plates and are encased in the concrete. 6 figures.

Nuclear reactor control room construction

DOEpatents

Lamuro, Robert C.; Orr, Richard

1993-01-01

A control room 10 for a nuclear plant is disclosed. In the control room, objects 12, 20, 22, 26, 30 are no less than four inches from walls 10.2. A ceiling 32 contains cooling fins 35 that extend downwards toward the floor from metal plates 34. A concrete slab 33 is poured over the plates. Studs 36 are welded to the plates and are encased in the concrete.

PROCESS FOR MAKING NEUTRON-ABSORBING BODIES

DOEpatents

Schippereit, G.H.; Lang, R.M.

1961-11-14

A process for making a control element for a nuclear reactor and the control element prepared by the process are described. Equally spaced, conically shaped depressions are formed in one face of a metal plate, spheres of boron of uniform size are placed in the depressions, another plate is welded on top of this place covering the depressions, and the joined plates are rolled to the desired thickness. (AEC)

Determination of a temperature sensor location for monitoring weld pool size in GMAW

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

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

1994-11-01

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

Development of method to remove weld scallop and ceramic backing material of wedge type and its application

NASA Astrophysics Data System (ADS)

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

2015-06-01

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

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.

Microstructures and Mechanical Properties of Friction Tapered Stud Overlap Welding for X65 Pipeline Steel Under Wet Conditions

NASA Astrophysics Data System (ADS)

Xu, Y. C.; Jing, H. Y.; Han, Y. D.; Xu, L. Y.

2017-08-01

This paper exhibits a novel in situ remediation technique named friction tapered stud overlap welding (FTSOW) to repair a through crack in structures and components in extremely harsh environments. Furthermore, this paper presents variations in process data, including rotational speed, stud displacement, welding force, and torque for a typical FTSOW weld. In the present study, the effects of welding parameters on the microstructures and mechanical properties of the welding joints were investigated. Inapposite welding parameters consisted of low rotational speeds and welding forces, and when utilized, they increased the occurrence of a lack of bonding and unfilled defects within the weld. The microstructures with a welding zone and heat-affected zone mainly consisted of upper bainite. The hardness value was highest in the welding zone and lowest in the base material. During the pull-out tests, all the welds failed in the stud. Moreover, the defect-free welds broke at the interface of the lap plate and substrate during the cruciform uniaxial tensile test. The best tensile test results at different depths and shear tests were 721.6 MPa and 581.9 MPa, respectively. The favorable Charpy impact-absorbed energy was 68.64 J at 0 °C. The Charpy impact tests revealed a brittle fracture characteristic with a large area of cleavage.

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

NASA Astrophysics Data System (ADS)

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

2017-11-01

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

Filler Wire Development for 2195 Aluminum-Lithium. Pt. 2

NASA Technical Reports Server (NTRS)

Bjorkman, Gerald W.; Cho, Alex

1998-01-01

The objective of the research was to determine the susceptibility of submitted welded 2195 plate in an AI (Alternate Immersion) environment. Forty-day AI exposure was completed on 8 welded 2195 stress corrosion samples. No stress corrosion cracking (SCC) was found on any of the samples tested. All 8 samples experienced exfoliation corrosion attack in the heat-affected zone (HAZ) adjacent to the weld. All samples were examined metallographically and showed varying degrees of intergranular corrosion (IG). The filler metal on all samples showed moderate to heavy pitting.

Establishment of a Continuous Wave Laser Welding Process

DTIC Science & Technology

1976-10-01

gas channel . A stiff bridge clamp with threaded force points was used on half inch plate welds to iron out waviness in the test coupons. Several...34 back up channel * 10.5kW on work 11-17 ^^^^^^^ ■ u u mi u.üiijüuiiiii IK««,,.! umm j,- u.jipiHi^iMii.ijii.ijiji j! J u„„, On each of four days...welded at 40 ipm using maximum available power on the surface (12.6 KV7 for the F/7 optical system) . Contours improved but porosity formed in the

Recent progress on gas tungsten arc welding of vanadium alloys

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

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

1997-04-01

This is a progress report on a continuing research project to acquire a fundamental understanding of the metallurgical processes in the welding of vanadium alloys. It also has the goal of developing techniques for welding structural vanadium alloys. The alloy V-4Cr-4Ti is used as a representative alloy of the group; it is also the prime candidate vanadium alloy for the U.S. Fusion Program at the present time. However, other alloys of this class were used in the research as necessary. The present work focuses on recent findings of hydrogen embrittlement found in vanadium alloy welds. It was concluded that themore » atmosphere in the inert gas glove box was insufficient for welding 6mm thick vanadium alloy plates.« less

Effect of pressure and shielding gas on the microstructure of hyperbaric metal cored GMAW welds down to 111 bar

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

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

1995-12-31

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

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.

49 CFR 178.337-17 - Marking.

Code of Federal Regulations, 2011 CFR

2011-10-01

... Containers for Motor Vehicle Transportation § 178.337-17 Marking. (a) General. Each cargo tank certified... inspection. If the specification plate is attached to the chassis rail, then the cargo tank serial number... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left...

49 CFR 178.337-17 - Marking.

Code of Federal Regulations, 2010 CFR

2010-10-01

... Specifications for Containers for Motor Vehicle Transportation § 178.337-17 Marking. (a) General. Each cargo tank... inspection. If the specification plate is attached to the chassis rail, then the cargo tank serial number... specification plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the...

49 CFR 178.337-17 - Marking.

Code of Federal Regulations, 2012 CFR

2012-10-01

... Containers for Motor Vehicle Transportation § 178.337-17 Marking. (a) General. Each cargo tank certified... inspection. If the specification plate is attached to the chassis rail, then the cargo tank serial number... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left...

49 CFR 178.337-17 - Marking.

Code of Federal Regulations, 2013 CFR

2013-10-01

... Containers for Motor Vehicle Transportation § 178.337-17 Marking. (a) General. Each cargo tank certified... inspection. If the specification plate is attached to the chassis rail, then the cargo tank serial number... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left...

49 CFR 178.337-17 - Marking.

Code of Federal Regulations, 2014 CFR

2014-10-01

... Containers for Motor Vehicle Transportation § 178.337-17 Marking. (a) General. Each cargo tank certified... inspection. If the specification plate is attached to the chassis rail, then the cargo tank serial number... plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left...

49 CFR 178.338-18 - Marking.

Code of Federal Regulations, 2010 CFR

2010-10-01

... Specifications for Containers for Motor Vehicle Transportation § 178.338-18 Marking. (a) General. Each cargo tank... specification plate permanently attached to the cargo tank by brazing, welding, or other suitable means on the left side near the front, in a place accessible for inspection. If the specification plate is attached...

49 CFR 178.337-4 - Joints.

Code of Federal Regulations, 2014 CFR

2014-10-01

... must be considered as essential variables: Number of passes; thickness of plate; heat input per pass... not be used. The number of passes, thickness of plate, and heat input per pass may not vary more than... machine heat processes, provided such surfaces are remelted in the subsequent welding process. Where there...

49 CFR 178.337-4 - Joints.

Code of Federal Regulations, 2013 CFR

2013-10-01

... must be considered as essential variables: Number of passes; thickness of plate; heat input per pass... not be used. The number of passes, thickness of plate, and heat input per pass may not vary more than... machine heat processes, provided such surfaces are remelted in the subsequent welding process. Where there...

49 CFR 178.337-4 - Joints.

Code of Federal Regulations, 2012 CFR

2012-10-01

... must be considered as essential variables: Number of passes; thickness of plate; heat input per pass... not be used. The number of passes, thickness of plate, and heat input per pass may not vary more than... machine heat processes, provided such surfaces are remelted in the subsequent welding process. Where there...

49 CFR 178.337-4 - Joints.

Code of Federal Regulations, 2011 CFR

2011-10-01

... must be considered as essential variables: Number of passes; thickness of plate; heat input per pass... not be used. The number of passes, thickness of plate, and heat input per pass may not vary more than... machine heat processes, provided such surfaces are remelted in the subsequent welding process. Where there...

Chromate Dissociation from Primer Paint in Simulated Lung Fluid.

DTIC Science & Technology

2000-03-01

not done properly. Chromium is found naturally in the earth’s crust; trivalent chromium is a necessary dietary mineral. Other oxidative states such...exposures to chromium can include welding , leather tanning, electroplating, textile manufacturing, photoengraving, copier servicing and paints/pigments...production, production of chromates and chromate pigments, leather tanning, chromium plating and welding . Unfortunately, no detailed health studies have

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.

Causal Factors of Weld Porosity in Gas Tungsten Arc Welding of Powder-Metallurgy-Produced Titanium Alloys

NASA Astrophysics Data System (ADS)

Muth, T. R.; Yamamoto, Y.; Frederick, D. A.; Contescu, C. I.; Chen, W.; Lim, Y. C.; Peter, W. H.; Feng, Z.

2013-05-01

An investigation was undertaken using gas tungsten arc (GTA) welding on consolidated powder metallurgy (PM) titanium (Ti) plate to identify the causal factors behind observed porosity in fusion welding. Tramp element compounds of sodium and magnesium, residual from the metallothermic reduction of titanium chloride used to produce the titanium, were remnant in the starting powder and were identified as gas-forming species. PM-titanium made from revert scrap, where sodium and magnesium were absent, showed fusion weld porosity, although to a lesser degree. We show that porosity was attributable to hydrogen from adsorbed water on the surface of the powders prior to consolidation. The removal and minimization of both adsorbed water on the surface of titanium powder and the residues from the reduction process prior to consolidation of titanium powders are critical for achieving equivalent fusion welding success similar to that seen in wrought titanium produced via the Kroll process.

Method of controlling the side wall thickness of a turbine nozzle segment for improved cooling

DOEpatents

Burdgick, Steven Sebastian

2002-01-01

A gas turbine nozzle segment has outer and inner bands and a vane extending therebetween. Each band has a side wall, a cover and an impingement plate between the cover and nozzle wall defining two cavities on opposite sides of the impingement plate. Cooling steam is supplied to one cavity for flow through apertures of the impingement plate to cool the nozzle wall. The side wall of the band has an inturned flange defining with the nozzle wall an undercut region. The outer surface of the side wall is provided with a step prior to welding the cover to the side wall. A thermal barrier coating is applied in the step and, after the cover is welded to the side wall, the side wall is finally machined to a controlled thickness removing all, some or none of the coating.

A comparison of field-dependent rheological properties between spherical and plate-like carbonyl iron particles-based magneto-rheological fluids

NASA Astrophysics Data System (ADS)

Tan Shilan, Salihah; Amri Mazlan, Saiful; Ido, Yasushi; Hajalilou, Abdollah; Jeyadevan, Balachandran; Choi, Seung-Bok; Azhani Yunus, Nurul

2016-09-01

This work proposes different sizes of the plate-like particles from conventional spherical carbonyl iron (CI) particles by adjusting milling time in the ball mill process. The ball mill process to make the plate-like particles is called a solid-state powder processing technique which involves repeated welding, fracturing and re-welding of powder particles in a high-energy ball mill. The effect of ball milling process on the magnetic behavior of CI particles is firstly investigated by vibrating sample magnetometer. It is found form this investigation that the plate-like particles have higher saturation magnetization (about 8%) than that of the spherical particles. Subsequently, for the investigation on the sedimentation behavior the cylindrical measurement technique is used. It is observed from this measurement that the plate-like particles show slower sedimentation rate compared to the spherical particles indicating higher stability of the MR fluid. The field-dependent rheological properties of MR fluids based on the plate-like particles are then investigated with respect to the milling time which is directly connected to the size of the plate-like particles. In addition, the field-dependent rheological properties such as the yield stress are evaluated and compared between the plate-like particles based MR fluids and the spherical particles based MR fluid. It is found that the yield shear stress of the plate-like particles based MR fluid is increased up to 270% compared to the spherical particles based MR fluid.

Optical sensing in laser machining

NASA Astrophysics Data System (ADS)

Smurov, Igor; Doubenskaia, Maria

2009-05-01

Optical monitoring of temperature evolution and temperature distribution in laser machining provides important information to optimise and to control technological process under study. The multi-wavelength pyrometer is used to measure brightness temperature under the pulsed action of Nd:YAG laser on stainless steel substrates. Specially developed "notch" filters (10-6 transparency at 1.06 μm wavelength) are applied to avoid the influence of laser radiation on temperature measurements. The true temperature is restored based on the method of multi-colour pyrometry. Temperature monitoring of the thin-walled gilded kovar boxes is applied to detect deviation of the welding seam from its optimum position. The pyrometers are used to control CO2-laser welding of steel and Ti plates: misalignment of the welded plates, variation of the welding geometry, internal defects, deviation of the laser beam trajectory from the junction, etc. The temperature profiles along and across the welding axis are measured by the 2D pyrometer. When using multi-component powder blends in laser cladding, for example metal matrix composite with ceramic reinforcement, one needs to control temperature of the melt to avoid thermal decomposition of certain compounds (as WC) and to assure melting of the base metal (as Co). Infra-red camera FLIR Phoenix RDAS provides detailed information on distribution of brightness temperature in laser cladding zone. CCD-camera based diagnostic system is used to measure particles-in-flight velocity and size distribution.

Effect of Microstructure on Stress Corrosion Cracking Behaviour of High Nitrogen Stainless Steel Gas Tungsten Arc Welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

Present work is aimed to improve stress corrosion cracking resistance of high nitrogen steel and its welds. An attempt to weld high nitrogen steel of 5 mm thick plate using gas tungsten arc welding (GTAW) with three high strength age hardenable fillers i.e., 11-10 PH filler, PH 13- 8Mo and maraging grade of MDN 250 filler is made. Welds were characterized by optical microscopy and scanning electron microscopy. Vickers hardness testing of the welds was carried out to study the mechanical behaviour of welds. Potentio-dynamic polarization studies were done to determine pitting corrosion resistance in aerated 3.5% NaCl solution. Stress corrosion cracking (SCC) testing was carried out using constant load type machine with applied stress of 50% yield strength and in 45% MgCl2 solution boiling at 155°C. The results of the present investigation established that improvement in resistance to stress corrosion cracking was observed for PH 13- 8Mo GTA welds when compared to 11-10 PH and MDN 250 GTA welds. However, All GTA welds failed in the weld interface region. This may be attributed to relatively lower pitting potential in weld interface which acts as active site and the initiation source of pitting.

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.

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.

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

Paillard, Pascal

Two try-out campaigns of friction stir welding (FSW) were performed with different friction parameters to join S690QL high yield strength steel. The welds were investigated at macroscopic and microscopic scales using optical and electronic microscopy and microhardness mapping. Welds of the second campaign exhibit microstructures and mechanical properties in accordance with requirements for service use. Microtexture measurements were carried out in different zones of welds by electron backscattered diffraction (EBSD). It is shown that that texture of the bottom of the weld is similar to that of the base metal, suggesting a diffusion bonding mechanism. Finally, the mechanical properties (tensilemore » strength, resilience, bending) were established on the most promising welds. It is shown that it is possible to weld this high yield strength steel using FSW process with satisfactory geometric, microstructural and mechanical properties. - Highlights: •1000 mm ∗ 400 mm ∗ 8 mm S690QL steel plates are joined by friction stir welding (FSW). •Maximum hardness is reduced by optimization of process parameters. •Various microstructures are formed but no martensite after process optimization. •Texture is modified in mechanically affected zones of the weld. •Texture in the bottom of the weld is preserved, suggesting diffusion bonding.« less

Comparative Studies on microstructure, mechanical and corrosion behaviour of DMR 249A Steel and its welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

DMR249A Medium strength (low carbon) Low-alloy steels are used as structural components in naval applications due to its low cost and high availability. An attempt has been made to weld the DMR 249A steel plates of 8mm thickness using shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW). Welds were characterized for metallography to carry out the microstructural changes, mechanical properties were evaluated using vickers hardness tester and universal testing machine. Potentio-dynamic polarization tests were carried out to determine the pitting corrosion behaviour. Constant load type Stress corrosion cracking (SCC) testing was done to observe the cracking tendency of the joints in a 3.5%NaCl solution. Results of the present study established that SMA welds resulted in formation of relatively higher amount of martensite in ferrite matrix when compared to gas tungsten arc welding (GTAW). It is attributed to faster cooling rates achieved due to high thermal efficiency. Improved mechanical properties were observed for the SMA welds and are due to higher amount of martensite. Pitting corrosion and stress corrosion cracking resistance of SMA welds were poor when compared to GTA welds.

Arc Welding of Mg Alloys: Oxide Films, Irregular Weld Shape and Liquation Cracking

NASA Astrophysics Data System (ADS)

Chai, Xiao

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

Research on the microstructure and properties of laser-MIG hybrid welded joint of Invar alloy

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Friction Stir Welding of GR-Cop 84 for Combustion Chamber Liners

NASA Technical Reports Server (NTRS)

Russell, Carolyn K.; Carter, Robert; Ellis, David L.; Goudy, Richard

2004-01-01

GRCop-84 is a copper-chromium-niobium alloy developed by the Glenn Research Center for liquid rocket engine combustion chamber liners. GRCop-84 exhibits superior properties over conventional copper-base alloys in a liquid hydrogen-oxygen operating environment. The Next Generation Launch Technology program has funded a program to demonstrate scale-up production capabilities of GR-Cop 84 to levels suitable for main combustion chamber production for the prototype rocket engine. This paper describes a novel method of manufacturing the main combustion chamber liner. The process consists of several steps: extrude the GR-Cop 84 powder into billets, roll the billets into plates, bump form the plates into cylinder halves and friction stir weld the halves into a cylinder. The cylinder is then metal spun formed to near net liner dimensions followed by finish machining to the final configuration. This paper describes the friction stir weld process development including tooling and non-destructive inspection techniques, culminating in the successful production of a liner preform completed through spin forming.

Effect of Friction Stir Process Parameters on the Mechanical and Thermal Behavior of 5754-H111 Aluminum Plates.

PubMed

Serio, Livia Maria; Palumbo, Davide; De Filippis, Luigi Alberto Ciro; Galietti, Umberto; Ludovico, Antonio Domenico

2016-02-23

A study of the Friction Stir Welding (FSW) process was carried out in order to evaluate the influence of process parameters on the mechanical properties of aluminum plates (AA5754-H111). The process was monitored during each test by means of infrared cameras in order to correlate temperature information with eventual changes of the mechanical properties of joints. In particular, two process parameters were considered for tests: the welding tool rotation speed and the welding tool traverse speed. The quality of joints was evaluated by means of destructive and non-destructive tests. In this regard, the presence of defects and the ultimate tensile strength (UTS) were investigated for each combination of the process parameters. A statistical analysis was carried out to assess the correlation between the thermal behavior of joints and the process parameters, also proving the capability of Infrared Thermography for on-line monitoring of the quality of joints.

Effect of Friction Stir Process Parameters on the Mechanical and Thermal Behavior of 5754-H111 Aluminum Plates

PubMed Central

Serio, Livia Maria; Palumbo, Davide; De Filippis, Luigi Alberto Ciro; Galietti, Umberto; Ludovico, Antonio Domenico

2016-01-01

A study of the Friction Stir Welding (FSW) process was carried out in order to evaluate the influence of process parameters on the mechanical properties of aluminum plates (AA5754-H111). The process was monitored during each test by means of infrared cameras in order to correlate temperature information with eventual changes of the mechanical properties of joints. In particular, two process parameters were considered for tests: the welding tool rotation speed and the welding tool traverse speed. The quality of joints was evaluated by means of destructive and non-destructive tests. In this regard, the presence of defects and the ultimate tensile strength (UTS) were investigated for each combination of the process parameters. A statistical analysis was carried out to assess the correlation between the thermal behavior of joints and the process parameters, also proving the capability of Infrared Thermography for on-line monitoring of the quality of joints. PMID:28773246

Diffusion-Welded Microchannel Heat Exchanger for Industrial Processes

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

Piyush Sabharwall; Denis E. Clark; Michael V. Glazoff

The goal of next generation reactors is to increase energy ef?ciency in the production of electricity and provide high-temperature heat for industrial processes. The ef?cient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for ef?ciency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more ef?cientmore » industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required ?ow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design speci?cations for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.« less

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

NASA Astrophysics Data System (ADS)

Winarto, Winarto; Riastuti, Rini; Kumeidi, Nur

2018-03-01

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

Diffractive beam shaping for enhanced laser polymer welding

NASA Astrophysics Data System (ADS)

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

2015-03-01

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

Deformation During Friction Stir Welding

NASA Technical Reports Server (NTRS)

White, Henry J.

2002-01-01

Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

Thermographic Analysis of Stress Distribution in Welded Joints

NASA Astrophysics Data System (ADS)

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

2010-06-01

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

Experimental Investigation of Tensile Test on Connection of Cold-formed Cut-curved Steel Section

NASA Astrophysics Data System (ADS)

Sani, Mohd Syahrul Hisyam Mohd; Muftah, Fadhluhartini; Rahman, Nurul Farraheeda Abdul; Fakri Muda, Mohd

2017-08-01

Cold-formed steel (CFS) is widely used as structural and non-structural components such as roof trusses and purlin. A CFS channel section with double intermediate web stiffener and lipped is chosen based on the broader usage in roof truss construction. CFS section is cut to form cold-formed pre-cut-curved steel section and lastly strengthened by several types of method or likely known as connection to establish the cold-formed cut-curved steel (CFCCS) section. CFCCS is proposed to be used as a top chord section in the roof truss system. The CFCCS is to resist the buckling phenomena of the roof truss structure and reduced the compression effect on the top chord. The tensile test connection of CFCCS section, especially at the flange element with eight types of connection by welding, plate with self-drilling screw and combination is investigated. The flange element is the weakest part that must be solved first other than the web element because they are being cut totally, 100% of their length for curving process. The testing is done using a universal testing machine for a tensile load. From the experiment, specimen with full welding has shown as a good result with an ultimate load of 13.37 kN and reported having 35.41% when compared with normal specimen without any of connection methods. Furthermore, the experimental result is distinguished by using Eurocode 3. The failure of a full welding specimen is due to breaking at the welding location. Additionally, all specimens with either full weld or spot weld or combination failed due to breaking on weld connection, but specimen with flange plate and self-drilling screw failed due to tilting and bearing. Finally, the full welding specimen is chosen as a good connection to perform the strengthening method of CFCCS section.

Advanced Fast Curing Adhesives for Adverse Conditions

DTIC Science & Technology

2007-07-01

experimentation. The catalyst is composed of 50% phthalate esters and 50% trivalent organic chromium complexes (15). 2.3 Aluminum Lap Plates...adhesives (2). Tape adhesives never provide weld - strength bonds and often have low tackiness when used underwater. Ultraviolet and visible light curable...diisocyanate and diphenylmethane-4, 4 diisocyanate (MDI) (12). The low viscosity ethyl cyanoacrylate Scotch- Weld CA40 was obtained from 3M of St

A simplified model for TIG-dressing numerical simulation

NASA Astrophysics Data System (ADS)

Ferro, P.; Berto, F.; James, M. N.

2017-04-01

Irrespective of the mechanical properties of the alloy to be welded, the fatigue strength of welded joints is primarily controlled by the stress concentration associated with the weld toe or weld root. In order to reduce the effects of such notch defects in welds, which are influenced by tensile properties of the alloy, post-weld improvement techniques have been developed. The two most commonly used techniques are weld toe grinding and TIG dressing, which are intended to both remove toe defects such as non-metallic intrusions and to re-profile the weld toe region to give a lower stress concentration. In the case of TIG dressing the weld toe is re-melted to provide a smoother transition between the plate and the weld crown and to beneficially modify the residual stress redistribution. Assessing the changes to weld stress state arising from TIG-dressing is most easily accomplished through a complex numerical simulation that requires coupled thermo-fluid dynamics and solid mechanics. However, this can be expensive in terms of computational cost and time needed to reach a solution. The present paper therefore proposes a simplified numerical model that overcomes such drawbacks and which simulates the remelted toe region by means of the activation and deactivation of elements in the numerical model.

Nuclear reactor I

DOEpatents

Ference, Edward W.; Houtman, John L.; Waldby, Robert N.

1977-01-01

A nuclear reactor, particularly a liquid-metal breeder reactor whose upper internals include provision for channeling the liquid metal flowing from the core-component assemblies to the outlet plenum in vertical paths in direction generally along the direction of the respective assemblies. The metal is channeled by chimneys, each secured to, and extending from, a grid through whose openings the metal emitted by a plurality of core-component assemblies encompassed by the grid flows. To reduce the stresses resulting from structural interaction, or the transmissive of thermal strains due to large temperature differences in the liquid metal emitted from neighboring core-component assemblies, throughout the chimneys and the other components of the upper internals, the grids and the chimneys are supported from the heat plate and the core barrel by support columns (double portal support) which are secured to the head plate at the top and to a member, which supports the grids and is keyed to the core barrel, at the bottom. In addition to being restrained from lateral flow by the chimneys, the liquid metal is also restrained from flowing laterally by a peripheral seal around the top of the core. This seal limits the flow rate of liquid metal, which may be sharply cooled during a scram, to the outlet nozzles. The chimneys and the grids are formed of a highly-refractory, high corrosion-resistant nickel-chromium-iron alloy which can withstand the stresses produced by temperature differences in the liquid metal. The chimneys are supported by pairs of plates, each pair held together by hollow stubs coaxial with, and encircling, the chimneys. The plates and stubs are a welded structure but, in the interest of economy, are composed of stainless steel which is not weld compatible with the refractory metal. The chimneys and stubs are secured together by shells of another nickel-chromium-iron alloy which is weld compatible with, and is welded to, the stubs and has about the same coefficient of expansion as the highly-refractory, high corrosion-resistant alloy.

46 CFR 54.05-15 - Weldment toughness tests-procedure qualifications.

Code of Federal Regulations, 2010 CFR

2010-10-01

...) Plate for which Charpy V-notch impact testing is required in the parent material and for which V-notch minima are specified shall similarly have welding procedures qualified for toughness by Charpy V-notch testing. For these tests, the test plates shall be oriented with their final rolling direction parallel to...

49 CFR 179.300-6 - Thickness of plates.

Code of Federal Regulations, 2010 CFR

2010-10-01

....037 Where: d = inside diameter in inches; E = 1.0 welded joint efficiency; P = minimum required bursting pressure in psig; S = minimum tensile strength of plate material in p.s.i. as prescribed in § 179... −d 2) where: d = inside diameter in inches; D = outside diameter in inches; p = tank test pressure in...

Inverse Thermal Analysis of Titanium GTA Welds Using Multiple Constraints

NASA Astrophysics Data System (ADS)

Lambrakos, S. G.; Shabaev, A.; Huang, L.

2015-06-01

Inverse thermal analysis of titanium gas-tungsten-arc welds using multiple constraint conditions is presented. This analysis employs a methodology that is in terms of numerical-analytical basis functions for inverse thermal analysis of steady-state energy deposition in plate structures. The results of this type of analysis provide parametric representations of weld temperature histories that can be adopted as input data to various types of computational procedures, such as those for prediction of solid-state phase transformations. In addition, these temperature histories can be used to construct parametric function representations for inverse thermal analysis of welds corresponding to other process parameters or welding processes whose process conditions are within similar regimes. The present study applies an inverse thermal analysis procedure that provides for the inclusion of constraint conditions associated with both solidification and phase transformation boundaries.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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.

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.

19 CFR 10.530 - Definitions.

Code of Federal Regulations, 2010 CFR

2010-04-01

... of the following processes: Welding, flame spraying, surface machining, knurling, plating, sleeving...” means a person who grows, raises, mines, harvests, fishes, traps, hunts, manufactures, processes...

Friction stir welding of Zr-based bulk metallic glass

NASA Astrophysics Data System (ADS)

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

2009-05-01

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

The Effect of Filler Wire and Flux Compositions on the Microstructure and Properties of Microalloyed Steel Weld Metal.

DTIC Science & Technology

1984-08-01

obtained from subsize (5.0 x 10.0 x 55.0 mm) Charpy V-Notch specimens, subsize (7.6 x 7.6 x 55.0 mm)-Izod specimens, and subsize (5.0 x 9.5 x 101.6 mm...47 15. Schematic of a submerged arc weld showing the dimensions and orientation of subsize Charpy V-Notch specimens... Subsize (5.0 x 10.0 x 55.0 mm) Charpy impact values P of two submerged arc welds performed on quenched and tempered C-Mn-Mo-Nb plate as a function of

Development of the Corporal: The Embryo of the Army Missile Program, Volume II: Supporting Data. Documents 1 through 31

DTIC Science & Technology

1961-04-01

heads, were used. Flights E-4 through E-6 utilized forged cylinders of SAE 4140 , machined to 0.25- inch wall thickness with machined skirts. The heads...cylindrical portion of the air tank in E-1 was welded of SAE 4130 steel plates 0.50 inch thick. The heads were 0.375 inch thick, whereas the internal...Edward S. Forman, and Weld Arnold. The early phases of the research were financed by a fund of $1,000 from Mr. Weld Arnold. "The first activities of

Microfissuring of Inconel 718

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

1983-01-01

A tentative mathematical computer model of the microfissuring process during electron beam welding of Inconel 718 has been constructed. Predictions of the model are compatible with microfissuring tests on eight 0.25-in. thick test plates. The model takes into account weld power and speed, weld loss (efficiency), parameters and material characteristics. Besides the usual material characteristics (thermal and strength properties), a temperature and grain size dependent critical fracture strain is required by the model. The model is based upon fundamental physical theory (i.e., it is not a mere data interpolation system), and can be extended to other metals by suitable parameter changes.

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

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

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

1994-12-31

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

Acceptance criteria for welds in ASTM A106 grade B steel pipe and plate

NASA Technical Reports Server (NTRS)

Hudson, C. M.; Wright, D. B., Jr.; Leis, B. N.

1986-01-01

Based on the RECERT Program findings, NASA-Langley funded a fatigue study of code-unacceptable welds. Usage curves were developed which were based on the structural integrity of the welds. The details of this study are presented in NASA CR-178114. The information presented is a condensation and reinterpretation of the information in NASA CR-178114. This condensation and reinterpretation generated usage curves for welds having: (1) indications 0.20 -inch deep by 0.40-inch long, and (2) indications 0.195-inch deep by 8.4-inches long. These curves were developed using the procedures used in formulating the design curves in Section VIII, Division 2 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code.

Hybrid Laser-Arc Welding of 10-mm-Thick Cast Martensitic Stainless Steel CA6NM: As-Welded Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

Metallurgical and mechanical properties of laser welded high strength low alloy steel

PubMed Central

Oyyaravelu, Ramachandran; Kuppan, Palaniyandi; Arivazhagan, Natarajan

2016-01-01

The study aimed at investigating the microstructure and mechanical properties of Neodymium-Doped Yttrium Aluminum Garnet (Nd:YAG) laser welded high strength low alloy (HSLA) SA516 grade 70 boiler steel. The weld joint for a 4 mm thick plate was successfully produced using minimum laser power of 2 kW by employing a single pass without any weld preheat treatment. The micrographs revealed the presence of martensite phase in the weld fusion zone which could be due to faster cooling rate of the laser weldment. A good correlation was found between the microstructural features of the weld joints and their mechanical properties. The highest hardness was found to be in the fusion zone of cap region due to formation of martensite and also enrichment of carbon. The hardness results also showed a narrow soft zone at the heat affected zone (HAZ) adjacent to the weld interface, which has no effect on the weld tensile strength. The yield strength and ultimate tensile strength of the welded joints were 338 MPa and 549 MPa, respectively, which were higher than the candidate metal. These tensile results suggested that the laser welding process had improved the weld strength even without any weld preheat treatment and also the fractography of the tensile fractured samples showed the ductile mode of failure. PMID:27222751

Detection of micro gap weld joint by using magneto-optical imaging and Kalman filtering compensated with RBF neural network

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

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

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.

Development of Real Time Ultrasonic Imaging

DTIC Science & Technology

1999-01-01

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

75 FR 23236 - Antidumping or Countervailing Duty Order, Finding, or Suspended Investigation; Opportunity To...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-05-03

.../10 India: Silicomanganese, A-533-823 5/1/09-4/30/10 Welded Carbon Steel Pipe and Tubes, A-533-502.../30/10 Republic of Korea: Polyester Staple Fiber, A-580-839 5/1/09-4/30/10 Stainless Steel Plate in.../10 805 Taiwan: Certain Circular Welded Carbon Steel Pipe and 5/1/09-4/30/10 Tubes, A-583-008...

Development of High Heat Input Welding High Strength Steel Plate for Oil Storage Tank in Xinyu Steel Company

NASA Astrophysics Data System (ADS)

Zhao, Hemin; Dong, Fujun; Liu, Xiaolin; Xiong, Xiong

This essay introduces the developed high-heat input welding quenched and tempered pressure vessel steel 12MnNiVR for oil storage tank by Xinyu Steel, which passed the review by the Boiler and Pressure Vessel Standards Technical Committee in 2009. The review comments that compared to the domestic and foreign similar steel standard, the key technical index of enterprise standard were in advanced level. After the heat input of 100kJ/cm electro-gas welding, welded points were still with excellent low temperature toughness at -20°C. The steel plate may be constructed for oil storage tank, which has been permitted by thickness range from 10 to 40mm, and design temperature among -20°C-100°C. It studied microstructure genetic effects mechanical properties of the steel. Many production practices indicated that the mechanical properties of products and the steel by stress relief heat treatment of steel were excellent, with pretreatment of hot metal, converter refining, external refining, protective casting, TMCP and heat treatment process measurements. The stability of performance and matured technology of Xinyu Steel support the products could completely service the demand of steel constructed for 10-15 million cubic meters large oil storage tank.

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.

High performance computation of residual stress and distortion in laser welded 301L stainless sheets

DOE PAGES

Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong; ...

2017-07-11

Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

High performance computation of residual stress and distortion in laser welded 301L stainless sheets

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

Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong

Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

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.

Neutron diffraction studies of laser welding residual stresses

NASA Astrophysics Data System (ADS)

Petrov, Peter I.; Bokuchava, Gizo D.; Papushkin, Igor V.; Genchev, Gancho; Doynov, Nikolay; Michailov, Vesselin G.; Ormanova, Maria A.

2016-01-01

The residual stress and microstrain distribution induced by laser beam welding of the low-alloyed C45 steel plate was investigated using high-resolution time-of-flight (TOF) neutron diffraction. The neutron diffraction experiments were performed on FSD diffractometer at the IBR-2 pulsed reactor in FLNP JINR (Dubna, Russia). The experiments have shown that the residual stress distribution across weld seam exhibit typical alternating sign character as it was observed in our previous studies. The residual stress level is varying in the range from -60 MPa to 450 MPa. At the same time, the microstrain level exhibits sharp maxima at weld seam position with maximal level of 4.8·10-3. The obtained experimental results are in good agreement with FEM calculations according to the STAAZ model. The provided numerical model validated with measured data enables to study the influence of different conditions and process parameters on the development of residual welding stresses.

Diffusion welding of Cassegrainian concentrator cell stack assemblies. M.S. Thesis Final Report, Jun. 1983 - Sep. 1985

NASA Technical Reports Server (NTRS)

Gangl, K. J.

1985-01-01

Development of a procedure to join the components of the Cassegrainian concentrator photovoltaic cell stack assembly was studied. Diffusion welding was selected as the most promising process, and was concentrated on exclusively. All faying surfaces were coated with silver to promote welding. The first phase of the study consisted of developing the relationship between process parameters and joint strength using silver plated steel samples and an isostatic pressure system. In the second phase, mockups of the cell stack assembly were welded in a hot isostatic press. Excellent joint strength was achieved with parameters of 350 C and 10 ksi, but the delicate GaAs component could not survive the welding cycle without cracking. The tendency towards cracking was found to be affected by both temperature and pressure. Further work will be required in the future to solve this problem.

Physical Nature of the Processes in Structure Forming, Phase and Chemical Composition of pipe Permanent Joints when MMA Welding

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Spectroscopic studies of GTA welding plasmas. Temperature calculation and dilution measurement

NASA Astrophysics Data System (ADS)

Lacroix, D.; Boudot, C.; Jeandel, G.

1999-10-01

A spectroscopic study of the GTAW plasma-plume created during the welding of stainless steel and other materials (iron, nickel and chromium) has been carried out. The spectra of these plasmas have been studied for several welding parameters. Temperature calculations are based on the observation of relative intensities and shapes of the emission peaks. We assume that the plasma is in local thermal equilibrium. The temperature is calculated with the Boltzmann plot method from twelve iron emission lines (in the range 368 385 nm): it varies between 9650 and 12 100 K. Dilution experiments have been carried out. We checked the mixing of metals: during welding of two different metallic plates and during welding with an Inconel wire. Dilution is monitored following the intensity of some characteristic emission lines (chromium and nickel). Comparison of spectroscopic results and metallographic ones is made.

Signal analysis of voltage noise in welding arcs. [gas tungsten arc welding

NASA Technical Reports Server (NTRS)

Elis, E.; Eagar, T. W.

1982-01-01

Gas tungsten arc welds were made on low alloy steel plates to which intentional defects (discontinuities) were imposed. Disruption of shielding gas, welding over surface films, and tack welds produce changes in what is otherwise a relatively uniform voltage signal. The arc voltage was 15 volts + or - 2 volts with 300 mV ripple noise from the power supply. Changes in this steady noise voltage varied from 50 mV to less than one millivolt depending on the severity and the type of change experienced. In some instances the changes were easily detected by analysis of the signal in real time, while in other cases the signal had to transformed to the frequency domain in order to detect the changes. Discontinuities as small as 1.5 mm in length were detected. The ultimate sensitivity and reproducibility of the technique is still being investigated.

Welding current and melting rate in GMAW of aluminium

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

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

1996-12-31

Studies on GMAW of aluminium and its alloy 5083, revealed that the welding current and melting rate were affected by any change in wire feed rate, arc voltage, nozzle to plate distance, welding speed and torch angle. Empirical models have been presented to determine accurately the welding current and melting rate for any set of these parameters. These results can be utilized for determining accurately the heat input into the workpiece from which reliable predictions can be made about the mechanical and the metallurgical properties of a welded joint. The analysis of the model also helps in providing a vitalmore » information about the static V-I characteristics of the welding power source. The models were developed using a two-level fractional factorial design. The adequacy of the model was tested by the use of analysis of variance technique and the significance of the coefficients was tested by the student`s t test. The estimated and observed values of the welding current and melting rate have been shown on a scatter diagram and the interaction effects of different parameters involved have been presented in graphical forms.« less

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.

Complete Status Report Documenting Weld Development for Thin Wall Tubing of ODS Ferritic Alloys

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

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

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

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

NASA Astrophysics Data System (ADS)

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

2012-02-01

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

Experimental Investigation on Laser Impact Welding of Fe-Based Amorphous Alloys to Crystalline Copper

PubMed Central

Wang, Xiao; Luo, Yapeng; Huang, Tao; Liu, Huixia

2017-01-01

Recently, amorphous alloys have attracted many researchers’ attention for amorphous structures and excellent properties. However, the welding of amorphous alloys to traditional metals in the microscale is not easy to realize in the process with amorphous structures unchanged, which restrains the application in industry. In this paper, a new method of welding Fe-based amorphous alloys (GB1K101) to crystalline copper by laser impact welding (LIW) is investigated. A series of experiments was conducted under different laser energies, during which Fe-based amorphous alloys and crystalline copper were welded successfully by LIW. In addition, the microstructure and mechanical properties of welding joints were observed and measured, respectively. The results showed that the surface wave and springback were observed on the flyer plate after LIW. The welding interface was straight or wavy due to different plastic deformation under different laser energies. The welding interface was directly bonded tightly without visible defects. No visible element diffusion and intermetallic phases were found in the welding interface. The Fe-based amorphous alloys retained amorphous structures after LIW under the laser energy of 835 mJ. The nanoindentation hardness across the welding interface showed an increase on both sides of the welding interface. The results of the lap shearing test showed that the fracture position was on the side of copper coil. PMID:28772886

Experimental Investigation on Laser Impact Welding of Fe-Based Amorphous Alloys to Crystalline Copper.

PubMed

Wang, Xiao; Luo, Yapeng; Huang, Tao; Liu, Huixia

2017-05-12

Recently, amorphous alloys have attracted many researchers' attention for amorphous structures and excellent properties. However, the welding of amorphous alloys to traditional metals in the microscale is not easy to realize in the process with amorphous structures unchanged, which restrains the application in industry. In this paper, a new method of welding Fe-based amorphous alloys (GB1K101) to crystalline copper by laser impact welding (LIW) is investigated. A series of experiments was conducted under different laser energies, during which Fe-based amorphous alloys and crystalline copper were welded successfully by LIW. In addition, the microstructure and mechanical properties of welding joints were observed and measured, respectively. The results showed that the surface wave and springback were observed on the flyer plate after LIW. The welding interface was straight or wavy due to different plastic deformation under different laser energies. The welding interface was directly bonded tightly without visible defects. No visible element diffusion and intermetallic phases were found in the welding interface. The Fe-based amorphous alloys retained amorphous structures after LIW under the laser energy of 835 mJ. The nanoindentation hardness across the welding interface showed an increase on both sides of the welding interface. The results of the lap shearing test showed that the fracture position was on the side of copper coil.

Investigation of Interface Bonding Mechanism of an Explosively Welded Tri-Metal Titanium/Aluminum/Magnesium Plate by Nanoindentation

NASA Astrophysics Data System (ADS)

Zhang, T. T.; Wang, W. X.; Zhou, J.; Cao, X. Q.; Yan, Z. F.; Wei, Y.; Zhang, W.

2018-04-01

A tri-metal titanium/aluminum/magnesium (Ti/Al/Mg) cladding plate, with an aluminum alloy interlayer plate, was fabricated for the first time by explosive welding. Nanoindentation tests and associated microstructure analysis were conducted to investigate the interface bonding mechanisms of the Ti/Al/Mg cladding plate. A periodic wavy bonding interface (with an amplitude of approximately 30 μm and a wavelength of approximately 160 μm) without a molten zone was formed between the Ti and Al plates. The bonding interface between the Al and the Mg demonstrated a similar wavy shape, but the wave at this location was much larger with an amplitude of approximately 390 μm and a wavelength of approximately 1580 μm, and some localized melted zones also existed at this location. The formation of the wavy interface was found to result from a severe deformation at the interface, which was caused by the strong impact or collision. The nanoindentation tests showed that the material hardness decreased with increasing distance from the bonding interface. Material hardness at a location was found to be correlated with the degree of plastic deformation at that site. A larger plastic deformation was correlated with an increase in hardness.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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

Mechanical Properties of Friction Stir Welds in A12195-T8

NASA Technical Reports Server (NTRS)

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

1999-01-01

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

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

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 of the structure and properties of a composite insert applied at laser welding of steel with titanium

NASA Astrophysics Data System (ADS)

Pugacheva, N. B.; Cherepanov, A. N.; Orishich, A. M.; Malikov, A. G.; Drozdov, V. O.; Mali, V. I.; Senaeva, E. I.

2017-10-01

Production of welded bimetallic structures of titanium and steel using a laser beam is a very urgent and important task in the shipbuilding, airspace and power engineering. Laser welding using an intermediate insert is one of the ways to solve this problem. In this paper, we present the results of experimental studies of formation of the structure and properties of composite insert, obtained by explosion welding, after its application at laser welding steel with titanium. A study of a four-layer composite insert obtained by explosion welding showed that it has no brittle intermetallic phases and defects in the form of cracks and pores. The boundaries between the plates to be welded in the composite insert have a characteristic wavy structure with narrow zones of mutual diffusion penetration of elements of the adjacent metals. It is established that the strength of the composite insert is comparable with the maximum strength of Grade 4 alloy, and the destruction of the product during the tensile tests in most cases occurred along the weakest component of the composite insert, i.e. the copper layer, whose strength was significantly increased due to the hardening that took place in the explosion welding.

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.

Fluid-Structure Interaction of Channel Driven Cavity Flow

DTIC Science & Technology

2016-06-01

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

77 FR 25679 - Antidumping or Countervailing Duty Order, Finding, or Suspended Investigation; Opportunity To...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-05-01

......... 5/1/11-9/14/11 India: Silicomanganese, A-533-823 5/1/11-4/30/12 Welded Carbon Steel Pipes and Tubes... of Korea: Polyester Staple Fiber, A-580-839 5/1/11-4/30/12 Stainless Steel Plate in Coils, A-580-831...: Circular Welded Carbon Steel Pipes and Tubes, A- 5/1/11-4/30/12 583-008 Polyethylene Retail Carrier Bags, A...

Characteristic evaluation of process parameters of friction stir welding of aluminium 2024 hybrid composites

NASA Astrophysics Data System (ADS)

Sadashiva, M.; Shivanand, H. K.; Vidyasagar, H. N.

2018-04-01

The Current work is aimed to investigate the effect of process parameters in friction stir welding of Aluminium 2024 base alloy and Aluminium 2024 matrix alloy reinforced with E Glass and Silicon Carbide reinforcements. The process involved a set of synthesis techniques incorporating stir casting methodology resulting in fabrication of the composite material. This composite material that is synthesized is then machined to obtain a plate of dimensions 100 mm * 50 mm * 6 mm. The plate is then friction stir welded at different set of parameters viz. the spindle speed of 600 rpm, 900 rpm and 1200 rpm and feed rate of 40 mm/min, 80 mm/min and 120 mm/min for analyzing the process capability. The study of the given set of parameters is predominantly important to understand the physics of the process that may lead to better properties of the joint, which is very much important in perspective to its use in advanced engineering applications, especially in aerospace domain that uses Aluminium 2024 alloy for wing and fuselage structures under tension.

PWSCC Susceptibility in Heat Affected Zones of Alloy 600

NASA Astrophysics Data System (ADS)

Couvant, Thierry; Brossier, Thomas; Cossange, Christian

The recent field experience and several experimental results have shown the possible deleterious effect of a heat affected zone (HAZ) induced by welding on the susceptibility to the stress corrosion cracking (SCC) of Alloy 600 of bottom penetrations exposed to primary water of PWRs. This work tried to quantify the increasing susceptibility to initiation and crack propagation in 600/182 HAZ. The rolled plate did not exhibit any susceptibility to SCC except for a cold work higher than 10% typically. By contrast, the weld metal was well known for its high susceptibility to SCC. Metallurgical and mechanical characterizations of the HAZ indicated a slight gradient of Vickers micro hardness close to the fusion line (up to few mm) and a lack of intergranular precipitates up to 500 µm from the fusion line. SCC tests clearly demonstrated that a non-susceptible plate may exhibit a significant susceptibility to SCC propagation in the HAZ. Results of initiation tests did not allow to observe any SCC in the base metal, due to the high susceptibility to SCC of the weld.

Effect of pre-strain on creep of three AISI 316 austenitic stainless steels in relation to reheat cracking of weld-affected zones

NASA Astrophysics Data System (ADS)

Auzoux, Q.; Allais, L.; Caës, C.; Monnet, I.; Gourgues, A. F.; Pineau, A.

2010-05-01

Microstructural modifications induced by welding of 316 stainless steels and their effect on creep properties and relaxation crack propagation were examined. Cumulative strain due to multi-pass welding hardens the materials by increasing the dislocation density. Creep tests were conducted on three plates from different grades of 316 steel at 600 °C, with various carbon and nitrogen contents. These plates were tested both in the annealed condition and after warm rolling, which introduced pre-strain. It was found that the creep strain rate and ductility after warm rolling was reduced compared with the annealed condition. Moreover, all steels exhibited intergranular crack propagation during relaxation tests on Compact Tension specimens in the pre-strained state, but not in the annealed state. These results confirmed that the reheat cracking risk increases with both residual stress triaxiality and pre-strain. On the contrary, high solute content and strain-induced carbide precipitation, which are thought to increase reheat cracking risk of stabilised austenitic stainless steels did not appear as key parameters in reheat cracking of 316 stainless steels.

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

NASA Astrophysics Data System (ADS)

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

2013-09-01

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

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.

Hydrogen Cracking in Gas Tungsten Arc Welding of an AISI Type 321 Stainless Steel

NASA Astrophysics Data System (ADS)

Rozenak, P.; Unigovski, Ya.; Shneck, R.

The effects of in situ cathodic charging on the tensile properties and susceptibility to cracking of an AISI type 321 stainless steel, welded by the gas tungsten arc welding (GTAW) process, was studied by various treatments. Appearance of delta-ferrite phase in the as-welded steels in our tested conditions was observed with discontinuous grain boundaries (M23C6) and a dense distribution of metal carbides MC ((Ti, Nb)C), which precipitated in the matrix. Shielding gas rates changes the mechanical properties of the welds. Ultimate tensile strength and ductility are increases with the resistance to the environments related the increase of the supplied shielding inert gas rates. Charged specimens, caused mainly in decreases in the ductility of welded specimens. However, more severe decrease in ductility was obtained after post weld heat treatment (PWHT). The fracture of sensitized specimens was predominantly intergranular, whereas the as-welded specimens exhibited massive transgranular regions. Both types of specimen demonstrated narrow brittle zones at the sides of the fracture surface and ductile micro-void coalescences in the middle. Ferrite δ was form after welding with high density of dislocation structures and stacking faults formation and the thin stacking fault plates with e-martensite phase were typically found in the austenitic matrix after the cathodical charging process.

Improvements in Cold-Plate Fabrication

NASA Technical Reports Server (NTRS)

Zaffetti, Mark A.; Taddey, Edmund P.; Laurin, Michael B.; Chabebe, Natalia

2012-01-01

Five improvements are reported in cold-plate fabrication. This cold plate is part of a thermal control system designed to serve on space missions. The first improvement is the merging of the end sheets of the cold plate with the face sheets of the structural honeycomb panel. The cold plate, which can be a brazed assembly, uses the honeycomb face sheet as its end sheet. Thus, when the honeycomb panel is fabricated, the face sheet that is used is already part of the cold plate. In addition to reducing weight, costs, and steps, the main benefit of this invention is that it creates a more structurally sound assembly. The second improvement involves incorporation of the header into the closure bar to pass the fluid to a lower layer. Conventional designs have used a separate header, which increases the geometry of the system. The improvement reduces the geometry, thus allowing the cold plate to fit into smaller area. The third improvement eliminates the need of hose, tube, or manifold to supply the cooling fluid externally. The external arrangement can be easily damaged and is vulnerable to leakage. The new arrangement incorporates an internal fluid transfer tube. This allows the fluid to pass from one cold plate to the other without any exposed external features. The fourth improvement eliminates separate fabrication of cold plate(s) and structural members followed by a process of attaching them to each other. Here, the structural member is made of material that can be brazed just as that of the cold plate. Now the structural member and the cold plate can be brazed at the same time, creating a monolithic unit, and thus a more structurally sound assembly. Finally, the fifth improvement is the elimination of an additional welding step that can damage the braze joints. A tube section, which is usually welded on after the braze process, is replaced with a more structurally sound configuration that can be brazed at the same time as the rest of the cold plate.

Welding of titanium and nickel alloy by combination of explosive welding and spark plasma sintering technologies

NASA Astrophysics Data System (ADS)

Malyutina, Yu. N.; Bataev, A. A.; Mali, V. I.; Anisimov, A. G.; Shevtsova, L. I.

2015-10-01

A possibility of titanium and nickel-based alloys composite materials formation using combination of explosive welding and spark plasma sintering technologies was demonstrated in the current research. An employment of interlayer consisting of copper and tantalum thin plates makes possible to eliminate a contact between metallurgical incompatible titanium and nickel that are susceptible to intermetallic compounds formation during their interaction. By the following spark plasma sintering process the bonding has been received between titanium and titanium alloy VT20 through the thin powder layer of pure titanium that is distinguished by low defectiveness and fine dispersive structure.

Influence of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite

NASA Astrophysics Data System (ADS)

DijuSamuel, G.; Raja Dhas, J. Edwin

2017-10-01

This paper focus on impact of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite. For fabrication of metal matrix composite AA6061 is used as matrix and activated carbon is used as reinforcement and it is casted using modified stir casting technique. After casting metal matrix composite has undergone various microstructure tests like SEM,EDAX and XRD. FSW is carried out in this metal matrix composite by choosing various tool pin profile like square,round,Threaded round, hexagon and taper. The quality of welded plates is measured in terms of ultimate tensile strength and hardness.

Welding of titanium and nickel alloy by combination of explosive welding and spark plasma sintering technologies

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

Malyutina, Yu. N., E-mail: iuliiamaliutina@gmail.com; Bataev, A. A., E-mail: bataev@adm.nstu.ru; Shevtsova, L. I., E-mail: edeliya2010@mail.ru

A possibility of titanium and nickel-based alloys composite materials formation using combination of explosive welding and spark plasma sintering technologies was demonstrated in the current research. An employment of interlayer consisting of copper and tantalum thin plates makes possible to eliminate a contact between metallurgical incompatible titanium and nickel that are susceptible to intermetallic compounds formation during their interaction. By the following spark plasma sintering process the bonding has been received between titanium and titanium alloy VT20 through the thin powder layer of pure titanium that is distinguished by low defectiveness and fine dispersive structure.

Residual stress characterization of steel TIG welds by neutron diffraction and by residual magnetic stray field mappings

NASA Astrophysics Data System (ADS)

Stegemann, Robert; Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas; Wimpory, Robert; Boin, Mirko; Kreutzbruck, Marc

2017-03-01

The residual stress distribution of tungsten inert gas welded S235JRC+C plates was determined by means of neutron diffraction (ND). Large longitudinal residual stresses with maxima around 600 MPa were found. With these results as reference, the evaluation of residual stress with high spatial resolution GMR (giant magneto resistance) sensors was discussed. The experiments performed indicate a correlation between changes in residual stresses (ND) and the normal component of local residual magnetic stray fields (GMR). Spatial variations in the magnetic field strength perpendicular to the welds are in the order of the magnetic field of the earth.

CHARACTERIZATION OF DEFECTS IN ALLOY 152, 52 AND 52M WELDS

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

Bruemmer, Stephen M.; Toloczko, Mychailo B.; Olszta, Matthew J.

2009-08-27

Defect distributions have been documented by optical metallography, scanning electron microscopy and electron backscatter diffraction in alloy 152 and 52 mockups welds, alloy 52 and 52M overlay mockups and an alloy 52M inlay. Primary defects were small cracks at grain boundaries except for more extensive cracking in the dilution zone of an alloy 52 overlay on 304SS. Detailed characterizations of the dilution zone cracks were performed by analytical transmission electron microscopy identifying grain boundary titanium-nitride precipitation associated with the intergranular separations. I. INTRODUCTION Weldments continue to be a primary location of stress-corrosion cracking (SCC) in light-water reactor systems. While problemsmore » related to heat-affected-zone (HAZ) sensitization and intergranular (IG) SCC of austenitic stainless alloys in boiling-water reactors (BWRs) have been significantly reduced, SCC has now been observed in HAZs of non-sensitized materials and in dissimilar metal welds where Ni-base alloy weld metals are used. IGSCC in weld metals has been observed in both BWRs and pressurized water reactors (PWRs) with recent examples for PWR pressure vessel penetrations producing the most concern. This has led to the replacement of alloy 600/182/82 welds with higher Cr, more corrosion-resistant replacement materials (alloy 690/152/52/52M). Complicating this issue has been a known susceptibility to cracking during welding [1-7] of these weld metals. There is a critical need for an improved understanding of the weld metal metallurgy and defect formation in Ni-base alloy welds to effectively assess long-term performance. A series of macroscopic to microscopic examinations were performed on available mockup welds made with alloy 52 or alloy 152 plus selected overlay and inlay mockups. The intent was to expand our understanding of weld metal structures in simulated LWR service components with a focus on as-welded defects. Microstructural features, defect distributions, defect characteristics and weld residual strains were examined by optical metallography, scanning electron microscopy, electron backscatter diffraction and transmission electron microscopy. Industry-supplied mock-up welds were characterized including alloy 52 and 152 weldments, alloy 52M overlay and inlay welds, and an alloy 52 overlay. II. WELDMENTS II.A. Alloy 52 and 152 Weld Mockups The alloy 52 and 152 weld mockups were fabricated by MHI for the Kewaunee reactor and were obtained from the EPRI NDE Center. The mockups were U-groove welds joining two plates of 304SS as shown in Figure 1. Alloy 152 butter (heat 307380) was placed on the U-groove surface for both mockups by shielded metal arc welding (SMAW). For the alloy 152 weld mockup, the alloy 152 fill (heat 307380) was also applied using SMAW while for the alloy 52 weld mockup, the alloy 52 fill (heat NX2686JK) was applied using gas tungsten arc welding (GTAW). Welding parameters for the fill materials were substantially different with the alloy 152 SMAW having a deposition speed of 4-25 cm/min with a current of 95-145 A and the alloy 52 GTAW having a deposition speed of 4-10 cm/min with a current of 150-300 A. One prominent feature in these mockup welds is the presence of a crack starting at the 304SS butt joint at the bottom of the U-groove and extending up into the weld. It appears that the 304SS plate on either side of the butt joint acted as an anchor for the weld resulting in a stress rise across the slit that drove crack formation and extension up into the fill weld. As will be shown in the next section, the extent of the cracking around this stress riser was much greater in the MHI 52 weld mockup.« less

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.

Prediction of Weld Penetration in FCAW of HSLA steel using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

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

2011-01-01

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