Sample records for zircaloy-2 welding estudio

  1. Linear Friction Welding of Dissimilar Materials 316L Stainless Steel to Zircaloy-4

    NASA Astrophysics Data System (ADS)

    Wanjara, P.; Naik, B. S.; Yang, Q.; Cao, X.; Gholipour, J.; Chen, D. L.

    2018-02-01

    In the nuclear industry, there are a number of applications where the transition of stainless steel to Zircaloy is of technological importance. However, due to the differences in their properties there are considerable challenges associated with developing a joining process that will sufficiently limit the heat input and welding time—so as to minimize the extent of interaction at the joint interface and the resulting formation of intermetallic compounds—but still render a functional metallurgical bond between these two alloys. As such, linear friction welding, a solid-state joining technology, was selected in the present study to assess the feasibility of welding 316L stainless steel to Zircaloy-4. The dissimilar alloy welds were examined to evaluate their microstructural characteristics, microhardness evolution across the joint interface, static tensile properties, and fatigue behavior. Microstructural observations revealed a central intermixed region and, on the Zircaloy-4 side, dynamically recrystallized and thermomechanically affected zones were present. By contrast, deformation on the 316L stainless steel side was limited. In the intermixed region a drastic change in the composition was observed along with a local increase in hardness, which was attributed to the presence of intermetallic compounds, such as FeZr3 and Cr2Zr. The average yield (316 MPa) and ultimate tensile (421 MPa) strengths met the minimum strength properties of Zircaloy-4, but the elongation was relatively low ( 2 pct). The tensile and fatigue fracture of the welds always occurred at the interface in the mode of partial cohesive failure.

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

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

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

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

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

    DOE PAGES

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

    2017-11-04

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

  4. Characterisation of metallic glass incorporated Zircaloy-2 weldments

    NASA Astrophysics Data System (ADS)

    Mishra, S.; Savalia, R. T.; Bhanumurthy, K.; Dey, G. K.; Banerjee, S.

    1995-12-01

    In this study the effect of incorporation of Zr based Fe and Ni bearing metallic glass in spot welds in Zircaloy components has been examined. A comparison of strength and microstructure of the welded joint with and without glass has been carried out. The welded joint with metallic glass has been found to be stronger than the one without metallic glass. The microstructure of the welded region with metallic glass has been found to comprise a large region having martensite. This large martensitic region has also been found to have considerable amount of excess solute (Fe, Ni). The higher strength of the weld with metallic glass seems to originate due to solid solution strengthening, small grain size and the presence of martensitic structure over a large region.

  5. Investigation of mechanical and microstructural properties of Zircaloy-4 under different experimental conditions

    DOE PAGES

    Silva, Chinthaka M.; Leonard, Keith J.; Van Abel, Eric; ...

    2017-12-09

    Here two types of Zircaloy-4 (alpha-annealed and beta-quenched) were investigated in their different forms. It was found that mechanical properties of Zircaloy-4 are affected significantly by welding and hydrogen-charging followed by neutron irradiation. Evaluation of microstructural properties of samples showed that these changes are mainly due to the formation of secondary phases such as hydrides—mostly along grain boundaries, dislocation channeling and their disruptions, and the increase in the type dislocation loops.

  6. Investigation of mechanical and microstructural properties of Zircaloy-4 under different experimental conditions

    NASA Astrophysics Data System (ADS)

    Silva, Chinthaka M.; Leonard, Keith J.; Van Abel, Eric; Geringer, J. Wilna; Bryan, Chris D.

    2018-02-01

    Two types of Zircaloy-4 (alpha-annealed and beta-quenched) were investigated in their different forms. It was found that mechanical properties of Zircaloy-4 are affected significantly by welding and hydrogen-charging followed by neutron irradiation. Evaluation of microstructural properties of samples showed that these changes are mainly due to the formation of secondary phases such as hydrides-mostly along grain boundaries, dislocation channeling and their disruptions, and the increase in the type dislocation loops.

  7. Response of Cr and Cr-Al coatings on Zircaloy-2 to high temperature steam

    NASA Astrophysics Data System (ADS)

    Zhong, Weicheng; Mouche, Peter A.; Heuser, Brent J.

    2018-01-01

    The oxidation behavior of chromium (Cr) and chromium-aluminum (CrAl) coatings with various compositions deposited on Zircaloy-2 to 700 °C high-temperature steam (HTS) exposure has been investigated. CrAl coatings with higher Al compositions demonstrate lower oxidation weight gain. A layer of γ-alumina developed on the CrAl coatings with Al composition over 43 at%, while Al2O3 and Cr2O3 developed on CrAl coatings with Al composition below 33 at%. Oxidation of Zircaloy-2 substrate was inhibited by the 1um coatings to 20 h HTS exposure. Coating constituent elements diffused into the substrate and formed intermetallic phases with the Zircaloy substrate. Thicker layers of intermetallic phases developed on the coatings with higher Al composition. The intermetallic phases included Fe and Ni, indicating the dissolution of second phase particles (SPPs) during HTS exposure.

  8. Surface treatment to form a dispersed Y2O3 layer on Zircaloy-4 tubes

    NASA Astrophysics Data System (ADS)

    Jung, Yang-Il; Kim, Hyun-Gil; Guim, Hwan-Uk; Lim, Yoon-Soo; Park, Jung-Hwan; Park, Dong-Jun; Yang, Jae-Ho

    2018-01-01

    Zircaloy-4 is a traditional zirconium-based alloy developed for application in nuclear fuel cladding tubes. The surfaces of Zircaloy-4 tubes were treated using a laser beam to increase their mechanical strength. Laser beam scanning of a tube coated with yttrium oxide (Y2O3) resulted in the formation of a dispersed oxide layer in the tube's surface region. Y2O3 particles penetrated the Zircaloy-4 during the laser treatment and were distributed uniformly in the surface region. The thickness of the dispersed oxide layer varied from 50 to 140 μm depending on the laser beam trajectory. The laser treatment also modified the texture of the tube. The preferred basal orientation along the normal to the tube surface disappeared, and a random structure appeared after laser processing. The most obvious result was an increase in the mechanical strength. The tensile strength of Zircaloy-4 increased by 10-20% with the formation of the dispersed oxide layer. The compressive yield stress also increased, by more than 15%. Brittle fracture was observed in the surface-treated samples during tensile and compressive deformation at room temperature; however, the fracture behavior was changed in ductile at elevated temperatures.

  9. Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

    NASA Astrophysics Data System (ADS)

    Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

    2017-12-01

    FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

  10. Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

    NASA Astrophysics Data System (ADS)

    Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

    2018-02-01

    FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

  11. Texture control of zircaloy tubing during tube reduction

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

    Nagai, N.; Kakuma, T.; Fujita, K.

    1982-01-01

    Seven batches of Zircaloy-2 nuclear fuel cladding tubes with different textures were processed from tube shells of the same size, by different reduction routes, using pilger and 3-roll mills. Based on the texture data of these tubes, the texture control of Zircaloy tubing, the texture gradient across the wall, and the texture change during annealing were studied. The deformation texture of Zicaloy-2 tubing was dependent on the tool's curvature and was independent of the dimensions of the mother tubes. The different slopes of texture gradients were observed between the tubing of higher strain ration and that of lower strain ratio.

  12. Saturn S-2 production operations techniques: Production welding. Volume 1: Bulkhead welding

    NASA Technical Reports Server (NTRS)

    Abel, O. G.

    1970-01-01

    The complex Saturn S-2 welding processes and procedures required considerable development and refinement to establish a production capability that could consistently produce aluminum alloy welds within specified requirements. The special processes and techniques are defined that were established for the welding of gore-to-gore and manhole- or closeout-to-gore.

  13. Crystal plasticity modeling of irradiation growth in Zircaloy-2

    DOE PAGES

    Patra, Anirban; Tome, Carlos; Golubov, Stanislav I.

    2017-05-10

    A reaction-diffusion based mean field rate theory model is implemented in the viscoplastic self-consistent (VPSC) crystal plasticity framework to simulate irradiation growth in hcp Zr and its alloys. A novel scheme is proposed to model the evolution (both number density and radius) of irradiation-induced dislocation loops that can be informed directly from experimental data of dislocation density evolution during irradiation. This framework is used to predict the irradiation growth behavior of cold-worked Zircaloy-2 and trends compared to available experimental data. The role of internal stresses in inducing irradiation creep is discussed. Effects of grain size, texture, and external stress onmore » the coupled irradiation growth and creep behavior are also studied.« less

  14. Crystal plasticity modeling of irradiation growth in Zircaloy-2

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

    Patra, Anirban; Tome, Carlos; Golubov, Stanislav I.

    A reaction-diffusion based mean field rate theory model is implemented in the viscoplastic self-consistent (VPSC) crystal plasticity framework to simulate irradiation growth in hcp Zr and its alloys. A novel scheme is proposed to model the evolution (both number density and radius) of irradiation-induced dislocation loops that can be informed directly from experimental data of dislocation density evolution during irradiation. This framework is used to predict the irradiation growth behavior of cold-worked Zircaloy-2 and trends compared to available experimental data. The role of internal stresses in inducing irradiation creep is discussed. Effects of grain size, texture, and external stress onmore » the coupled irradiation growth and creep behavior are also studied.« less

  15. Influence of shielding gas pressure on welding characteristics in CO2 laser-MIG hybrid welding process

    NASA Astrophysics Data System (ADS)

    Chen, Yanbin; Lei, Zhenglong; Li, Liqun; Wu, Lin

    2006-01-01

    The droplet transfer behavior and weld characteristics have been investigated under different pressures of shielding gas in CO2 laser and metal inert/active gas (laser-MIG) hybrid welding process. The experimental results indicate that the inherent droplet transfer frequency and stable welding range of conventional MIG arc are changed due to the interaction between CO2 laser beam and MIG arc in laser-MIG hybrid welding process, and the shielding gas pressure has a crucial effect on welding characteristics. When the pressure of shielding gas is low in comparison with MIG welding, the frequency of droplet transfer decreases, and the droplet transfer becomes unstable in laser-MIG hybrid welding. So the penetration depth decreases, which shows the characteristic of unstable hybrid welding. However, when the pressure of shielding gas increases to a critical value, the hybrid welding characteristic is changed from unstable hybrid welding to stable hybrid welding, and the frequency of droplet transfer and the penetration depth increase significantly.

  16. TEM/STEM study of Zircaloy-2 with protective FeAl(Cr) layers under simulated BWR environment and high-temperature steam exposure

    NASA Astrophysics Data System (ADS)

    Park, Donghee; Mouche, Peter A.; Zhong, Weicheng; Mandapaka, Kiran K.; Was, Gary S.; Heuser, Brent J.

    2018-04-01

    FeAl(Cr) thin-film depositions on Zircaloy-2 were studied using transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) with respect to oxidation behavior under simulated boiling water reactor (BWR) conditions and high-temperature steam. Columnar grains of FeAl with Cr in solid solution were formed on Zircaloy-2 coupons using magnetron sputtering. NiFe2O4 precipitates on the surface of the FeAl(Cr) coatings were observed after the sample was exposed to the simulated BWR environment. High-temperature steam exposure resulted in grain growth and consumption of the FeAl(Cr) layer, but no delamination at the interface. Outward Al diffusion from the FeAl(Cr) layer occurred during high-temperature steam exposure (700 °C for 3.6 h) to form a 100-nm-thick alumina oxide layer, which was effective in mitigating oxidation of the Zircaloy-2 coupons. Zr intermetallic precipitates formed near the FeAl(Cr) layer due to the inward diffusion of Fe and Al. The counterflow of vacancies in response to the Al and Fe diffusion led to porosity within the FeAl(Cr) layer.

  17. Transition joints between Zircaloy-2 and stainless steel by diffusion bonding

    NASA Astrophysics Data System (ADS)

    Bhanumurthy, K.; Krishnan, J.; Kale, G. B.; Banerjee, S.

    1994-11-01

    The diffusion bonding between Zircaloy-2 and stainless steel (AISI 304L) using niobium, nickel and copper as intermediate layers has been investigated in the temperature range of 750 to 900°C. Bonding was carried out in a vacuum hot press, under compressive loading. Electron probe microanalysis and metallographic analysis showed a good metallurgical compatibility and also indicated the absence of discontunities, micropores and intermetallic compounds at various interfaces. The bond strength of the diffusion bonded assembly was found to be about 400 MPa for the couples bonded at 870°C for 2 h. The dimple structure on the fractured surface is indicative of the ductile mode of failure of the bonded assembly.

  18. Sliding wear and friction behaviour of zircaloy-4 in water

    NASA Astrophysics Data System (ADS)

    Sharma, Garima; Limaye, P. K.; Jadhav, D. T.

    2009-11-01

    In water cooled nuclear reactors, the sliding of fuel bundles in fuel channel handling system can lead to severe wear and it is an important topic to study. In the present study, sliding wear behaviour of zircaloy-4 was investigated in water (pH ˜ 10.5) using ball-on-plate sliding wear tester. Sliding wear resistance zircaloy-4 against SS 316 was examined at room temperature. Sliding wear tests were carried out at different load and sliding frequencies. The coefficient of friction of zircaloy-4 was also measured during each tests and it was found to decrease slightly with the increase in applied load. The micro-mechanisms responsible for wear in zircaloy-4 were identified to be microcutting, micropitting and microcracking of deformed subsurface zones in water.

  19. 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.

  20. Ratcheting fatigue behavior of Zircaloy-2 at room temperature

    NASA Astrophysics Data System (ADS)

    Rajpurohit, R. S.; Sudhakar Rao, G.; Chattopadhyay, K.; Santhi Srinivas, N. C.; Singh, Vakil

    2016-08-01

    Nuclear core components of zirconium alloys experience asymmetric stress or strain cycling during service which leads to plastic strain accumulation and drastic reduction in fatigue life as well as dimensional instability of the component. Variables like loading rate, mean stress, and stress amplitude affect the influence of asymmetric loading. In the present investigation asymmetric stress controlled fatigue tests were conducted with mean stress from 80 to 150 MPa, stress amplitude from 270 to 340 MPa and stress rate from 30 to 750 MPa/s to study the process of plastic strain accumulation and its effect on fatigue life of Zircaloy-2 at room temperature. It was observed that with increase in mean stress and stress amplitude accumulation of ratcheting strain was increased and fatigue life was reduced. However, increase in stress rate led to improvement in fatigue life due to less accumulation of ratcheting strain.

  1. 46 CFR 2.75-70 - Welding procedure and performance qualifications.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 1 2010-10-01 2010-10-01 false Welding procedure and performance qualifications. 2.75... for Construction Personnel § 2.75-70 Welding procedure and performance qualifications. (a) Welding... requirements for the welding of pressure piping, boilers, pressure vessels, and nonpressure vessel type tanks...

  2. 46 CFR 2.75-70 - Welding procedure and performance qualifications.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 46 Shipping 1 2013-10-01 2013-10-01 false Welding procedure and performance qualifications. 2.75... for Construction Personnel § 2.75-70 Welding procedure and performance qualifications. (a) Welding... requirements for the welding of pressure piping, boilers, pressure vessels, and nonpressure vessel type tanks...

  3. 46 CFR 2.75-70 - Welding procedure and performance qualifications.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 1 2011-10-01 2011-10-01 false Welding procedure and performance qualifications. 2.75... for Construction Personnel § 2.75-70 Welding procedure and performance qualifications. (a) Welding... requirements for the welding of pressure piping, boilers, pressure vessels, and nonpressure vessel type tanks...

  4. 46 CFR 2.75-70 - Welding procedure and performance qualifications.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 1 2014-10-01 2014-10-01 false Welding procedure and performance qualifications. 2.75... for Construction Personnel § 2.75-70 Welding procedure and performance qualifications. (a) Welding... requirements for the welding of pressure piping, boilers, pressure vessels, and nonpressure vessel type tanks...

  5. 46 CFR 2.75-70 - Welding procedure and performance qualifications.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 1 2012-10-01 2012-10-01 false Welding procedure and performance qualifications. 2.75... for Construction Personnel § 2.75-70 Welding procedure and performance qualifications. (a) Welding... requirements for the welding of pressure piping, boilers, pressure vessels, and nonpressure vessel type tanks...

  6. Cyclic softening in annealed Zircaloy-2: Role of edge dislocation dipoles and vacancies

    NASA Astrophysics Data System (ADS)

    Sudhakar Rao, G.; Singh, S. R.; Krsjak, Vladimir; Singh, Vakil

    2018-04-01

    The mechanism of cyclic softening in annealed Zircaloy-2 at low strain amplitudes under strain controlled fatigue at room temperature is rationalized. The unusual softening due to continuous decrease in the phenomenological friction stress is found to be associated with decrease in the resistance against movement of dislocations because of the formation and easy glide of pure edge dislocation dipoles and consequent decrease in friction stress from reduction in the shear modulus. Positron annihilation spectroscopy data strongly support the increase in edge dislocation density containing jogs, from increased positron trapping and increase in annihilation lifetime.

  7. Crystal plasticity modeling of irradiation growth in Zircaloy-2

    NASA Astrophysics Data System (ADS)

    Patra, Anirban; Tomé, Carlos N.; Golubov, Stanislav I.

    2017-08-01

    A physically based reaction-diffusion model is implemented in the visco-plastic self-consistent (VPSC) crystal plasticity framework to simulate irradiation growth in hcp Zr and its alloys. The reaction-diffusion model accounts for the defects produced by the cascade of displaced atoms, their diffusion to lattice sinks and the contribution to crystallographic strain at the level of single crystals. The VPSC framework accounts for intergranular interactions and irradiation creep, and calculates the strain in the polycrystalline ensemble. A novel scheme is proposed to model the simultaneous evolution of both, number density and radius, of irradiation-induced dislocation loops directly from experimental data of dislocation density evolution during irradiation. This framework is used to predict the irradiation growth behaviour of cold-worked Zircaloy-2 and trends compared to available experimental data. The role of internal stresses in inducing irradiation creep is discussed. Effects of grain size, texture and external stress on the coupled irradiation growth and creep behaviour are also studied and compared with available experimental data.

  8. Multispectral pyrometry for surface temperature measurement of oxidized Zircaloy claddings

    NASA Astrophysics Data System (ADS)

    Bouvry, B.; Cheymol, G.; Ramiandrisoa, L.; Javaudin, B.; Gallou, C.; Maskrot, H.; Horny, N.; Duvaut, T.; Destouches, C.; Ferry, L.; Gonnier, C.

    2017-06-01

    Non-contact temperature measurement in a nuclear reactor is still a huge challenge because of the numerous constraints to consider, such as the high temperature, the steam atmosphere, and irradiation. A device is currently developed at CEA to study the nuclear fuel claddings behavior during a Loss-of-Coolant Accident. As a first step of development, we designed and tested an optical pyrometry procedure to measure the surface temperature of nuclear fuel claddings without any contact, under air, in the temperature range 700-850 °C. The temperature of Zircaloy-4 cladding samples was retrieved at various temperature levels. We used Multispectral Radiation Thermometry with the hypothesis of a constant emissivity profile in the spectral ranges 1-1.3 μm and 1.45-1.6 μm. To allow for comparisons, a reference temperature was provided by a thermocouple welded on the cladding surface. Because of thermal losses induced by the presence of the thermocouple, a heat transfer simulation was also performed to estimate the bias. We found a good agreement between the pyrometry measurement and the temperature reference, validating the constant emissivity profile hypothesis used in the MRT estimation. The expanded measurement uncertainty (k = 2) of the temperature obtained by the pyrometry method was ±4 °C, for temperatures between 700 and 850 °C. Emissivity values, between 0.86 and 0.91 were obtained.

  9. Investigation of Zircaloy-2 oxidation model for SFP accident analysis

    NASA Astrophysics Data System (ADS)

    Nemoto, Yoshiyuki; Kaji, Yoshiyuki; Ogawa, Chihiro; Kondo, Keietsu; Nakashima, Kazuo; Kanazawa, Toru; Tojo, Masayuki

    2017-05-01

    The authors previously conducted thermogravimetric analyses on Zircaloy-2 in air. By using the thermogravimetric data, an oxidation model was constructed in this study so that it can be applied for the modeling of cladding degradation in spent fuel pool (SFP) severe accident condition. For its validation, oxidation tests of long cladding tube were conducted, and computational fluid dynamics analyses using the constructed oxidation model were proceeded to simulate the experiments. In the oxidation tests, high temperature thermal gradient along the cladding axis was applied and air flow rates in testing chamber were controlled to simulate hypothetical SFP accidents. The analytical outputs successfully reproduced the growth of oxide film and porous oxide layer on the claddings in oxidation tests, and validity of the oxidation model was proved. Influence of air flow rate for the oxidation behavior was thought negligible in the conditions investigated in this study.

  10. Hydride reorientation and its impact on ambient temperature mechanical properties of high burn-up irradiated and unirradiated recrystallized Zircaloy-2 nuclear fuel cladding with an inner liner

    NASA Astrophysics Data System (ADS)

    Auzoux, Q.; Bouffioux, P.; Machiels, A.; Yagnik, S.; Bourdiliau, B.; Mallet, C.; Mozzani, N.; Colas, K.

    2017-10-01

    Precipitation of radial hydrides in zirconium-based alloy cladding concomitant with the cooling of spent nuclear fuel during dry storage can potentially compromise cladding integrity during its subsequent handling and transportation. This paper investigates hydride reorientation and its impact on ductility in unirradiated and irradiated recrystallized Zircaloy-2 cladding with an inner liner (cladding for boiling water reactors) subjected to hydride reorientation treatments. Cooling from 400 °C, hydride reorientation occurs in recrystallized Zircaloy-2 with liner at a lower effective stress in irradiated samples (below 40 MPa) than in unirradiated specimens (between 40 and 80 MPa). Despite significant hydride reorientation, unirradiated recrystallized Zircaloy-2 with liner cladding containing ∼200 wppm hydrogen shows a high diametral strain at fracture (>15%) during burst tests at ambient temperature. This ductile behavior is due to (1) the lower yield stress of the recrystallized cladding materials in comparison to hydride fracture strength (corrected by the compression stress arising from the precipitation) and (2) the hydride or hydrogen-depleted zone as a result of segregation of hydrogen into the liner layer. In irradiated Zircaloy-2 with liner cladding containing ∼340 wppm hydrogen, the conservation of some ductility during ring tensile tests at ambient temperature after reorientation treatment at 400 °C with cooling rates of ∼60 °C/h is also attributed to the existence of a hydride-depleted zone. Treatments at lower cooling rates (∼6 °C/h and 0.6 °C/h) promote greater levels of hydrogen segregation into the liner and allow for increased irradiation defect annealing, both of which result in a significant increase in ductility. Based on this investigation, given the very low cooling rates typical of dry storage systems, it can be concluded that the thermal transients associated with dry storage should not degrade, and more likely should actually

  11. Study on the hydrogenation of Zircaloy-4

    NASA Astrophysics Data System (ADS)

    da Silva Dupim, Ivaldete; Moreira, João M. L.; Silva, Selma Luiza; Silva, Cecilia Chaves Guedes e.; Nunes, Oswaldo; Gomide, Ricardo Gonçalves

    2012-08-01

    In this article we investigate producing Zirconium powder from discarded Zircaloy-4 material through the hydride-dehydride method. We restrict our study to the first part of the method, namely the hydrogenation process. Differential thermal analyses of the hydrogenation process of the Zircaloy-4 show that no hydrogen absorption occurs at temperatures below 573 K and hydrogen gas pressure of 25 kPa. When the system temperature is raised to around 770 K, with the same gas pressure, the protecting oxide layer of the specimens can be overcome and they are quickly hydrogenated. The bulk of the reaction occurs in about 5 min with the precipitation of Zirconium hydrides in the Zr-δ and Zr-ɛ phases. Once the temperature passes 573 K, the incubation time to initiate the reaction is short (about 5 min). Tests in a tube furnace system with larger samples, hydrogen pressure varying from 30 to 180 kPa, and temperature from 700 to 833.15 K, show that the specimens are fully hydrogenated and can be easily pulverized. The results indicate that the hydrogenation of the Zircaloy-4 chips can be successfully undertaken at temperatures around 770 K and hydrogen gas pressure as low as 30 kPa.

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

    PubMed

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

    2000-01-01

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

  13. 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

  14. Analysis of droplet transfer mode and forming process of weld bead in CO 2 laser-MAG hybrid welding process

    NASA Astrophysics Data System (ADS)

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

    2012-06-01

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

  15. Bladder welding in rats using controlled temperature CO2 laser system.

    PubMed

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

    1999-05-01

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

  16. General Mechanical Repair. Welding. Volume 2. Teacher's Guide.

    ERIC Educational Resources Information Center

    East Texas State Univ., Commerce. Occupational Curriculum Lab.

    Five units on welding are presented in this teacher's guide. The units are the following: introduction to oxyacetylene welding, oxyacetylene welding positions and applications, use of the cutting torch, introduction to shielded metal arc welding, and welding joints and positions. Each instructional unit generally contains eight components:…

  17. Interaction of both plasmas in CO2 laser-MAG hybrid welding of carbon steel

    NASA Astrophysics Data System (ADS)

    Kutsuna, Muneharu; Chen, Liang

    2003-03-01

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

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

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

    Heiple, C.R.; Burgardt, P.

    1985-06-01

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

  19. 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

  20. Computerized adaptive control weld skate with CCTV weld guidance project

    NASA Technical Reports Server (NTRS)

    Wall, W. A.

    1976-01-01

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

  1. Toughness of 2,25Cr-1Mo steel and weld metal

    NASA Astrophysics Data System (ADS)

    Acarer, Mustafa; Arici, Gökhan; Acar, Filiz Kumdali; Keskinkilic, Selcuk; Kabakci, Fikret

    2017-09-01

    2,25Cr-1Mo steel is extensively used at elevated temperature structural applications in fossil fire power plants for steam pipes, nozzle chambers and petrochemical industry for hydrocracking unit due to its excellent creep resistance and good redundant to oxidation. Also they should have acceptable weldability and toughness. The steels are supplied in quenched and tempered condition and their welded components are subjected to post-weld heat treatment (PWHT). Tempering process is carried out at 690-710°C to improve toughness properties. However they are sensitive to reheat cracking and temper embrittlement. To measure temper embrittlement of the steels and their weld metal, temper embrittlement factor and formula (J factor - Watanabe and X formula- Bruscato) are used. Step cooling heat treatment is also applied to determine temper embrittlement. In this study, toughness properties of Cr Mo (W) steels were reviewed. Also transition temperature curves of 2,25Cr-1Mo steel and its weld metal were constructed before and after step cool heat treatment as experimental study. While 2,25Cr-1Mo steel as base metal was supplied, all weld metal samples were produced in Gedik Welding Company. Hardness measurements and microstructure evaluation were also carried out.

  2. Brazing characteristics of a Zr-Ti-Cu-Fe eutectic alloy filler metal for Zircaloy-4

    NASA Astrophysics Data System (ADS)

    Lee, Jung G.; Lim, C. H.; Kim, K. H.; Park, S. S.; Lee, M. K.; Rhee, C. K.

    2013-10-01

    A Zr-Ti-Cu-Fe quaternary eutectic alloy was employed as a new Be-free brazing filler metal for Zircaloy-4 to supersede physically vapor-deposited Be coatings used conventionally with several disadvantages. The quaternary eutectic composition of Zr58Ti16Cu10Fe16 (at.%) showing a low melting temperature range from 832 °C to 853 °C was designed by a partial substitution of Zr with Ti based on a Zr-Cu-Fe ternary eutectic system. By applying an alloy ribbon with the determined composition, a highly reliable joint was obtained with a homogeneous formation of predominantly grown α-Zr phases owing to a complete isothermal solidification, exhibiting strength higher than that of Zircaloy-4. The homogenization of the joint was rate-controlled by the diffusion of the filler elements (Ti, Cu, and Fe) into the Zircaloy-4 base metal, and the detrimental segregation of the Zr2Fe phase in the central zone was completely eliminated by an isothermal holding at a brazing temperature of 920 °C for 10 min.

  3. Sulfur Content Precision Control Technology for CO2-Shielded Welding Wire Steel

    NASA Astrophysics Data System (ADS)

    Chaofa, Zhang; Huaqiang, Hao; Youbing, Xiang; Shanxi, Liu

    As a kind of impurity and displaying with FeS and MnS form in steel, Sulfur can make the disadvantage effect on the performance of hot-working, welding and corrosion resistance. The high content sulfur in steel can cause the hot brittle phenomenon for the steel. For the welding steel, when the sulfur content is higher, the drawing performance of wire rod become worst and the yield of wire rod decrease. When the sulfur is lower, the automatic wire feeding performance for the gas shielded welding become worst and the weld seam is not smooth. According to the results of welding expert research, 0.010%≤ S≤ 0.020% in CO2-shielded welding wire steel is reasonable.

  4. Standard-less analysis of Zircaloy clad samples by an instrumental neutron activation method

    NASA Astrophysics Data System (ADS)

    Acharya, R.; Nair, A. G. C.; Reddy, A. V. R.; Goswami, A.

    2004-03-01

    A non-destructive method for analysis of irregular shape and size samples of Zircaloy has been developed using the recently standardized k0-based internal mono standard instrumental neutron activation analysis (INAA). The samples of Zircaloy-2 and -4 tubes, used as fuel cladding in Indian boiling water reactors (BWR) and pressurized heavy water reactors (PHWR), respectively, have been analyzed. Samples weighing in the range of a few tens of grams were irradiated in the thermal column of Apsara reactor to minimize neutron flux perturbations and high radiation dose. The method utilizes in situ relative detection efficiency using the γ-rays of selected activation products in the sample for overcoming γ-ray self-attenuation. Since the major and minor constituents (Zr, Sn, Fe, Cr and/or Ni) in these samples were amenable to NAA, the absolute concentrations of all the elements were determined using mass balance instead of using the concentration of the internal mono standard. Concentrations were also determined in a smaller size Zircaloy-4 sample by irradiating in the core position of the reactor to validate the present methodology. The results were compared with literature specifications and were found to be satisfactory. Values of sensitivities and detection limits have been evaluated for the elements analyzed.

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

    NASA Astrophysics Data System (ADS)

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

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

  6. 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.

  7. Effects of anisotropy and irradiation on the deformation behavior of Zircaloy 2. Final report

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

    Pelloux, R.M.; Ballinger, R.; Lucas, G.

    1979-01-01

    An experimental program investigated the effects of texture anisotropy and irradiation on the mechanical behavior of Zircaloy-2. Short time and time dependent mechanical behavior were considered. Irradiation effects were simulated through the use of 4.75 MeV protons. The temperature ranges investigated were 298/sup 0/K and 573 to 673/sup 0/K. Both cold worked-stress relieved and annealed material were used in this experimental program. Short time yield behavior of different crystallographic textures was determined by uniaxial and plane strain tests in the temperature range 298/sup 0/K and 573 to 673/sup 0/K. Monotonic flow loci were constructed for each texture. Yield behavior ismore » a strong function of the crystallographic texture number f at all temperatures investigated. The rotation of texture with increasing plastic strain was investigated as a function of initial texture at 298/sup 0/K and 623/sup 0/K. The rate of texture rotation df/epsilon/sub p/ was found to be a unique function of the initial texture for plastic strains less than 0.08. Time dependent mechanical behavior was investigated in the range 573 to 673/sup 0/K using constant load creep and stress relaxation tests. The tensile creep strength is proportional to the resolved fraction of basal poles in the test direction. In variable stress and temperature tests, the time-hardening rule was found to be inapplicable. The strain-hardening rule was applied with success to data obtained at temperatures less than or equal to 648/sup 0/K. Irradiation creep tests were conducted in vacuum at 598/sup 0/K and 102 to 241 MPa on 80..mu..m thick Zircaloy-2 foil specimens in both the recrystallized and cold worked-stress relieved condition. In the irradiation creep tests irradiation hardening and enhanced irradiation creep were observed. Radiation hardening effects were significant in annealed material but were attenuated in cold worked-stress relieved material.« less

  8. Hardening characteristics of CO2 laser welds in advanced high strength steel

    NASA Astrophysics Data System (ADS)

    Han, Tae-Kyo; Park, Bong-Gyu; Kang, Chung-Yun

    2012-06-01

    When the CO2 laser welder with 6 kW output was used to weld 4 TRIP steels, 2 DP steels and a precipitation-hardened steel, which have the tensile strength in the range of 600-1000 MPa, the effect of welding speed on hardening characteristics was investigated. In the weld of TRIP steels and DP steels, the maximum hardness was shown in the fusion zone and the HAZ near the bond line, and the hardness was decreased from the HAZ to the base metal. Only in the PH600 steel, the maximum hardness was shown in the fusion zone and the hardness was decreased from bond line to the base metal. The maximum hardness value was not changed due to the variation of the welding speed within a given range of the welding speed. When the correlation with maximum hardness value using 6 known carbon equivalents was examined, those of CEL (=C+Si/50+Mn/25+P/2+Cr/25) and PL (=C+Mn/22+14B) were 0.96 and 0.95 respectively, and CEL was better because it could reflect the contribution of Si and Cr added to AHSS. The maximum hardness value could be calculated by the equation "Hmax=701CEL+281". The phase transformation analysis indicated that only martensitic transformation was expected in the given range of the welding conditions. Therefore, the maximum hardness of the weld was the same as that of water cooled steel and not changed with the variation of the welding speed

  9. 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.

  10. Post Quench Ductility Evaluation of Zircaloy-4 and Select Iron Alloys under Design Basis and Extended LOCA Conditions

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

    Yan, Yong; Keiser, James R; Terrani, Kurt A

    2014-01-01

    Oxidation experiments were conducted at 1200 C in flowing steam with tubing specimens of Zircaloy-4, 317, 347 stainless steels, and the commercial FeCrAl alloy APMT. The purpose was to determine the oxidation behavior and post quench ductility of these alloys under postulated loss-of-coolant accident conditions. The parabolic rate constant for Zircaloy-4 tubing samples at 1200 were determined to be k = 2.173 107 g2/cm4/s C, in excellent agreement with the Cathcart-Pawel correlation. The APMT alloy experienced the slowest oxidation rate among all materials examined in this work. The ductility of post quenched samples was evaluated by ring compression tests atmore » 135 C. For Zircaloy-4, the ductile to brittle transition occurs at an equivalent cladding reacted (ECR) of 19.3%. SS-347 was still ductile after being oxidized for 2400 s (CP-ECR 50%), but the maximum load was reduced significantly owing to the metal layer thickness reduction. No ductility decrease was observed for the post-quenched APMT samples oxidized up to four hours.« less

  11. Post-quench ductility evaluation of Zircaloy-4 and select iron alloys under design basis and extended LOCA conditions

    NASA Astrophysics Data System (ADS)

    Yan, Y.; Keiser, J. R.; Terrani, K. A.; Bell, G. L.; Snead, L. L.

    2014-05-01

    Oxidation experiments were conducted at 1200 °C in flowing steam with tubing specimens of Zircaloy-4, 317, 347 stainless steels, and the commercial FeCrAl alloy APMT. The purpose was to determine the oxidation behavior and post-quench ductility under postulated and extended LOCA conditions. The parabolic rate constant for Zircaloy-4 tubing samples at 1200 °C was determined to be k = 2.173 × 107 g2/cm4/s, in excellent agreement with the Cathcart-Pawel correlation. The APMT alloy experienced the slowest oxidation rate among all materials examined in this work. The ductility of post-quenched samples was evaluated by ring compression tests at 135 °C. For Zircaloy-4, the ductile to brittle transition occurs at an equivalent cladding reacted (ECR) of 19.3%. SS-347 was still ductile after being oxidized for 2400 s (CP-ECR ≈ 50%), but the maximum load was reduced significantly owing to the metal layer thickness reduction. No ductility decrease was observed for the post-quenched APMT samples oxidized up to 4 h.

  12. The influence of strain rate and hydrogen on the plane-strain ductility of Zircaloy cladding

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

    Link, T.M.; Motta, A.T.; Koss, D.A.

    1998-03-01

    The authors studied the ductility of unirradiated Zircaloy-4 cladding under loading conditions prototypical of those found in reactivity-initiated accidents (RIA), i.e.: near plane-strain deformation in the hoop direction (transverse to the cladding axis) at room temperature and 300 C and high strain rates. To conduct these studies, they developed a specimen configuration in which near plane-strain deformation is achieved in the gage section, and a testing methodology that allows one to determine both the limit strain at the onset of localized necking and the fracture strain. The experiments indicate that there is little effect of strain rate (10{sup {minus}3} tomore » 10{sup 2} s{sup {minus}1}) on the ductility of unhydrided Zircaloy tubing deformed under near plane-strain conditions at either room temperature or 300 C. Preliminary experiments on cladding containing 190 ppm hydrogen show only a small loss of fracture strain but no clear effect on limit strain. The experiments also indicate that there is a significant loss of Zircaloy ductility when surface flaws are present in the form of thickness imperfections.« less

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

    NASA Astrophysics Data System (ADS)

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

    2014-07-01

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

  14. Nondestructive hydrogen analysis of steam-oxidized Zircaloy-4 by wide-angle neutron scattering

    NASA Astrophysics Data System (ADS)

    Yan, Yong; Qian, Shuo; Garrison, Ben; Smith, Tyler; Kim, Peter

    2018-04-01

    A nondestructive neutron scattering method to precisely measure the hydrogen content in high-temperature steam-oxidized Zircaloy-4 cladding was developed. Zircaloy-4 cladding was used to produce hydrided specimens with hydrogen content up to ≈500 wppm. Following hydrogen charging, the hydrogen content of the hydrided specimens was measured using the vacuum hot extraction method, by which the samples with desired hydrogen concentrations were selected for the neutron study. The hydrided samples were then oxidized in steam up to ≈6.0 wt. % at 1100 °C. Optical microscopy shows that our hydriding procedure results in uniform distribution of circumferential hydrides across the wall thickness, and uniform oxide layers were formed on the sample surfaces by the steam oxidation. Small- and wide-angle neutron scattering were simultaneously performed to provide a quick (less than an hour per sample) measurement of the hydrogen content in various types of hydrided and oxidized Zircaloy-4. Our study demonstrates that the hydrogen in pre-oxidized Zircaloy-4 cladding can be measured very accurately by both small- and wide-angle neutron scattering. For steam-oxidized samples, the small-angle neutron scattering is contaminated with coherent scattering from additional structural features induced by the steam oxidation. However, the scattering intensity of the wide-angle neutron scattering increases proportionally with the hydrogen charged in the samples. The hydrogen content and wide-angle neutron scattering intensity are highly linearly correlated for the oxidized cladding samples examined in this work, and can be used to precisely determine the hydrogen content in steam-oxidized Zircaloy-4 samples. Hydrogen contents determined by neutron scattering of oxidation samples were also found to be consistent with the results of chemical analysis within acceptable margins for error.

  15. Nondestructive hydrogen analysis of steam-oxidized Zircaloy-4 by wide-angle neutron scattering

    DOE PAGES

    Yan, Yong; Qian, Shuo; Garrison, Ben; ...

    2018-04-15

    In this study, a nondestructive neutron scattering method to precisely measure the hydrogen content in high-temperature steam-oxidized Zircaloy-4 cladding was developed. Zircaloy-4 cladding was used to produce hydrided specimens with hydrogen content up to ≈500 wppm. Following hydrogen charging, the hydrogen content of the hydrided specimens was measured using the vacuum hot extraction method, by which the samples with desired hydrogen concentrations were selected for the neutron study. The hydrided samples were then oxidized in steam up to ≈6.0wt. % at 1100°C. Optical microscopy shows that our hydriding procedure results in uniform distribution of circumferential hydrides across the wall thickness,more » and uniform oxide layers were formed on the sample surfaces by the steam oxidation. Small- and wide-angle neutron scattering were simultaneously performed to provide a quick (less than an hour per sample) measurement of the hydrogen content in various types of hydrided and oxidized Zircaloy-4. Our study demonstrates that the hydrogen in pre-oxidized Zircaloy-4 cladding can be measured very accurately by both small- and wide-angle neutron scattering. For steam-oxidized samples, the small-angle neutron scattering is contaminated with coherent scattering from additional structural features induced by the steam oxidation. However, the scattering intensity of the wide-angle neutron scattering increases proportionally with the hydrogen charged in the samples. The hydrogen content and wide-angle neutron scattering intensity are highly linearly correlated for the oxidized cladding samples examined in this work, and can be used to precisely determine the hydrogen content in steam-oxidized Zircaloy-4 samples. Hydrogen contents determined by neutron scattering of oxidation samples were also found to be consistent with the results of chemical analysis within acceptable margins for error.« less

  16. Nondestructive hydrogen analysis of steam-oxidized Zircaloy-4 by wide-angle neutron scattering

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

    Yan, Yong; Qian, Shuo; Garrison, Ben

    In this study, a nondestructive neutron scattering method to precisely measure the hydrogen content in high-temperature steam-oxidized Zircaloy-4 cladding was developed. Zircaloy-4 cladding was used to produce hydrided specimens with hydrogen content up to ≈500 wppm. Following hydrogen charging, the hydrogen content of the hydrided specimens was measured using the vacuum hot extraction method, by which the samples with desired hydrogen concentrations were selected for the neutron study. The hydrided samples were then oxidized in steam up to ≈6.0wt. % at 1100°C. Optical microscopy shows that our hydriding procedure results in uniform distribution of circumferential hydrides across the wall thickness,more » and uniform oxide layers were formed on the sample surfaces by the steam oxidation. Small- and wide-angle neutron scattering were simultaneously performed to provide a quick (less than an hour per sample) measurement of the hydrogen content in various types of hydrided and oxidized Zircaloy-4. Our study demonstrates that the hydrogen in pre-oxidized Zircaloy-4 cladding can be measured very accurately by both small- and wide-angle neutron scattering. For steam-oxidized samples, the small-angle neutron scattering is contaminated with coherent scattering from additional structural features induced by the steam oxidation. However, the scattering intensity of the wide-angle neutron scattering increases proportionally with the hydrogen charged in the samples. The hydrogen content and wide-angle neutron scattering intensity are highly linearly correlated for the oxidized cladding samples examined in this work, and can be used to precisely determine the hydrogen content in steam-oxidized Zircaloy-4 samples. Hydrogen contents determined by neutron scattering of oxidation samples were also found to be consistent with the results of chemical analysis within acceptable margins for error.« less

  17. THE DETERMINATION OF BORON IN ZIRCALOY

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

    Freegarde, M.; Cartwright, J.

    1962-03-01

    An account is given of the development of a simple and reliable procedure for determining boron in Zircaloy at the parts per million level. The sample is dissolved in a mixture of bromine and methanol, and the boron is separated by distillation and determined as its rosocyanin complex with curcumin. The reproducibility of the method is characterized by a standard deviation of 0.03 ppm at the 0.3 ppm level. (auth)

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

    NASA Astrophysics Data System (ADS)

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

    2017-05-01

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

  19. Generation rate of carbon monoxide from CO2 arc welding.

    PubMed

    Ojima, Jun

    2013-01-01

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

  20. High- and Low-Temperature Deformation Behavior of Different Orientation Hot-Rolled Annealed Zircaloy-4

    NASA Astrophysics Data System (ADS)

    Zong, Yingying; Gen, Qingfeng; Jiang, Hongwei; Shan, Debin; Guo, Bin

    2018-03-01

    In this paper, the hot-rolled annealed Zircaloy-4 samples with different orientation were subjected to uniaxial compression with a strain rate of 0.001 s-1 to obtain the stress-strain curves of different initial orientation samples at different temperatures. Electron backscatter diffraction (EBSD) technique and transmission electron microscope (TEM) technique were used to analyze the microstructures and textures of compressed samples. The mechanical properties and microstructural evolution of rolling directions (RD), transverse directions (TD) and normal directions (ND) were investigated under the conditions of - 150 °C low temperature, room temperature and 200 °C high temperature (simulated lunar temperature environment). The results show that the strength of Zircaloy-4 decreases with the increase in deformation temperature, and the strength in three orientations is ND > TD > RD. The deformation mechanism of hot-rolled annealed Zircaloy-4 with different orientation is different. In RD, { 10\\bar{1}0} < {a} > prismatic slip has the highest Schmid factor (SF), so it is most easy to activate the slip, followed by TD orientation, and ND orientation is the most difficult to activate. The deformed grains abide slip→twinning→slip rule, and the different orientation Zircaloy-4 deformation mechanisms mainly are the twinning coordinated with the slip.

  1. Experimental investigation on the weld pool formation process in plasma keyhole arc welding

    NASA Astrophysics Data System (ADS)

    Van Anh, Nguyen; Tashiro, Shinichi; Van Hanh, Bui; Tanaka, Manabu

    2018-01-01

    This paper seeks to clarify the weld pool formation process in plasma keyhole arc welding (PKAW). We adopted, for the first time, the measurement of the 3D convection inside the weld pool in PKAW by stereo synchronous imaging of tungsten tracer particles using two sets of x-ray transmission systems. The 2D convection on the weld pool surface was also measured using zirconia tracer particles. Through these measurements, the convection in a wide range of weld pools from the vicinity of the keyhole to the rear region was successfully visualized. In order to discuss the heat transport process in a weld pool, the 2D temperature distribution on the weld pool surface was also measured by two-color pyrometry. The results of the comprehensive experimental measurement indicate that the shear force due to plasma flow is found to be the dominant driving force in the weld pool formation process in PKAW. Thus, heat transport in a weld pool is considered to be governed by two large convective patterns near the keyhole: (1) eddy pairs on the surface (perpendicular to the torch axis), and (2) eddy pairs on the bulk of the weld pool (on the plane of the torch). They are formed with an equal velocity of approximately 0.35 m s-1 and are mainly driven by shear force. Furthermore, the flow velocity of the weld pool convection becomes considerably higher than that of other welding processes, such as TIG welding and GMA welding, due to larger plasma flow velocity.

  2. Active weld control

    NASA Technical Reports Server (NTRS)

    Powell, Bradley W.; Burroughs, Ivan A.

    1994-01-01

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

  3. Soldadura (Welding). Spanish Translations for Welding.

    ERIC Educational Resources Information Center

    Hohhertz, Durwin

    Thirty transparency masters with Spanish subtitles for key words are provided for a welding/general mechanical repair course. The transparency masters are on such topics as oxyacetylene welding; oxyacetylene welding equipment; welding safety; different types of welds; braze welding; cutting torches; cutting with a torch; protective equipment; arc…

  4. Effects of Mars Atmosphere on Arc Welds: Phase 2

    NASA Technical Reports Server (NTRS)

    Courtright, Z. S.

    2018-01-01

    Gas tungsten arc welding (GTAW) is a vital fusion welding process widely used throughout the aerospace industry. Its use may be critical for the repair or manufacture of systems, rockets, or facilities on the Martian surface. Aluminum alloy AA2219-T87 and titanium alloy Ti-6Al-4V butt welds have been investigated for weldability and weld properties in a simulated Martian gas environment. The resulting simulated Martian welds were compared to welds made in a terrestrial atmosphere, all of which used argon shielding gas. It was found that GTAW is a process that may be used in a Martian gas environment, not accounting for pressure and gravitational effects, as long as adequate argon shielding gas is used to protect the weld metal. Simulated Martian welds exhibited higher hardness in all cases and higher tensile strength in the case of AA2219-T87. This has been attributed to the absorption of carbon into the fusion zone, causing carbide precipitates to form. These precipitates may act to pin dislocations upon tensile testing of AA2219-T87. Dissolved carbon may have also led to carburization, which may have caused the increase in hardness within the fusion zone of the welds. Based on the results of this experiment and other similar experiments, GTAW appears to be a promising process for welding in a Martian gas environment. Additional funding and experimentation is necessary to determine the effects of the low pressure and low gravity environment found on Mars on GTAW.

  5. 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.

  6. Reduction of Biomechanical and Welding Fume Exposures in Stud Welding

    PubMed Central

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

    2016-01-01

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

  7. A Study to Increase Weld Penetration in P91 Steel During TIG Welding by using Activating Fluxes

    NASA Astrophysics Data System (ADS)

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

    2017-08-01

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

  8. The increase in fatigue crack growth rates observed for Zircaloy-4 in a PWR environment

    NASA Astrophysics Data System (ADS)

    Cockeram, B. V.; Kammenzind, B. F.

    2018-02-01

    Cyclic stresses produced during the operation of nuclear reactors can result in the extension of cracks by processes of fatigue. Although fatigue crack growth rate (FCGR) data for Zircaloy-4 in air are available, little testing has been performed in a PWR primary water environment. Test programs have been performed by Gee et al., in 1989 and Picker and Pickles in 1984 by the UK Atomic Energy Authority, and by Wisner et al., in 1994, that have shown an enhancement in FCGR for Zircaloy-2 and Zircaloy-4 in high-temperature water. In this work, FCGR testing is performed on Zircaloy-4 in a PWR environment in the hydrided and non-hydrided condition over a range of stress-intensity. Measurements of crack extension are performed using a direct current potential drop (DCPD) method. The cyclic rate in the PWR primary water environment is varied between 1 cycle per minute to 0.1 cycle per minute. Faster FCGR rates are observed in water in comparison to FCGR testing performed in air for the hydrided material. Hydrided and non-hydrided materials had similar FCGR values in air, but the non-hydrided material exhibited much lower rates of FCGR in a PWR primary water environment than for hydrided material. Hydrides are shown to exhibit an increased tendency for cracking or decohesion in a PWR primary water environment that results in an enhancement in FCGR values. The FCGR in the PWR primary water only increased slightly with decreasing cycle frequency in the range of 1 cycle per minute to 0.1 cycle per minute. Comparisons between the FCGR in water and air show the enhancement from the PWR environment is affected by the applied stress intensity.

  9. 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.

  10. Implications of Zircaloy creep and growth to light water reactor performance

    NASA Astrophysics Data System (ADS)

    Franklin, David G.; Adamson, Ronald B.

    1988-10-01

    Deformation of zirconium alloy components in nuclear reactors has been a concern since the decision of Admiral Rickover to use them in the US Navy submarine reactors. With the exception of the first few light water reactors (LWRs) most of the core structural materials have been fabricated from either Zircaloy-2 or Zircaloy-4. Performance of these alloys has been extremely good, even though the effects of irradiation on deformation magnitudes and mechanisms were not fully appreciated until extensive service and in-reactor tests were accomplished. Since the reactor components are designed to operate at stress levels well below yield for normal conditions, the only significant deformation is time dependent. Although creep was anticipated, the enhancement by neutron irradiation and the stress-free, nearly constant-volume shape change known as irradiation growth were not known prior to materials testing in reactors under controlled conditions. Both of these phenomena have significant impact on performance and must be accounted for properly in design. Although irradiation creep and growth have resulted in only one significant performance problem (creep collapse of fuel cladding, which has been eliminated), deformation magnitudes and, particularly, differentials in strain magnitudes, are a continuing source of interest. Factors that affect dimensional stability due to both creep and growth include temperature, fluence, residual stress, texture, and microstructure. The first two are reactor variables and the others are related to component fabrication history. This paper includes a review of the applications of Zircaloy creep and growth to LWR fuel designs, a review of the impact of in-reactor creep and growth on fuel rod and fuel assembly performance, and comments on potential improvements. Since the reactor design, fuel design and the core environment in BWRs and PWRs are quite different, appropriate separation of the application of effects are made; of course, the basic

  11. The effect of plastic strain on the evolution of crystallographic texture in Zircaloy-2

    NASA Astrophysics Data System (ADS)

    Ballinger, R. G.; Lucas, G. E.; Pelloux, R. M.

    1984-09-01

    The evolution of crystallographic texture during plastic deformation was investigated in Zircaloy-2 using X-ray and metallographic techniques. Inverse pole figures, the resolved fraction of basal poles, and the volume fraction of twinned material, were determined as a function of plastic strain for several strain paths and initial textures at 298 K and 623 K. Incremental transverse platic strain ratios ( R) were mesured as a function of plastic strain. Texture rotation occurs early in the deformation process, after as little as 1.5% plastic strain. For compressive plastic strains, the resolved fraction of basal poles increases in the direction parallel to the strain axis. For tensile plastic strains, the resolved fraction of basal poles decreases in the direction parallel to the strain axis. The rate of change of the resolved fraction of basal poles with plastic strain is a function of the initial resolved fraction of basal poles. The texture rotation can be explained by considering the operation of the principal tensile twinning systems, {101¯2}<1¯011>.

  12. Industrial laser welding evaluation study

    NASA Technical Reports Server (NTRS)

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

    1974-01-01

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

  13. Reduction of Biomechanical and Welding Fume Exposures in Stud Welding.

    PubMed

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

    2016-04-01

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

  14. 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.

  15. Analysis and Comparison of Aluminum Alloy Welded Joints Between Metal Inert Gas Welding and Tungsten Inert Gas Welding

    NASA Astrophysics Data System (ADS)

    Zhao, Lei; Guan, Yingchun; Wang, Qiang; Cong, Baoqiang; Qi, Bojin

    2015-09-01

    Surface contamination usually occurs during welding processing and it affects the welds quality largely. However, the formation of such contaminants has seldom been studied. Effort was made to study the contaminants caused by metal inert gas (MIG) welding and tungsten inert gas (TIG) welding processes of aluminum alloy, respectively. SEM, FTIR and XPS analysis was carried out to investigate the microstructure as well as surface chemistry. These contaminants were found to be mainly consisting of Al2O3, MgO, carbide and chromium complexes. The difference of contaminants between MIG and TIG welds was further examined. In addition, method to minimize these contaminants was proposed.

  16. Study the Effect of SiO2 Based Flux on Dilution in Submerged Arc Welding

    NASA Astrophysics Data System (ADS)

    kumar, Aditya; Maheshwari, Sachin

    2017-08-01

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

  17. Waterside corrosion of Zircaloy-clad fuel rods in a PWR environment

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

    Garzarolli, F.; Jorde, D.; Manzel, R.

    A data base of Zircaloy corrosion behavior under PWR operating conditions has been established from previously published reports as well as from new Kraftwerk Union (KWU) fuel examinations. The data show that the reactor environment increases the corrosion. ZrO/sub 2/ film thermal conductivity is another major factor that influences corrosion behavior. It was inferred from KWU film thickness data that the oxide film thermal conductivity may decrease once circumferential cracks develop in the layer. 57 refs.

  18. Weld pool oscillation during pulsed GTA welding

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

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

    1996-12-31

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

  19. Portable Weld Tester.

    ERIC Educational Resources Information Center

    Eckert, Douglas

    This training manual, which was developed for employees of an automotive plant, is designed to teach trainees to operate a portable weld tester (Miyachi MM-315). In chapter 1, the weld tester's components are illustrated and described, and the procedure for charging its batteries is explained. Chapter 2 illustrates the weld tester's parts,…

  20. Automatic Welding System

    NASA Astrophysics Data System (ADS)

    1982-01-01

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

  1. The Influence of the In-Situ Clad Staining on the Corrosion of Zircaloy in PWR Water Environment

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

    Kammenzind, B.F., Eklund, K.L. and Bajaj, R.

    Zircaloy cladding tubes strain in-situ during service life in the corrosive environment of a Pressurized Water Reactor for a variety of reasons. First, the tube undergoes stress free growth due to the preferential alignment of irradiation induced vacancy loops on basal planes. Positive strains develop in the textured tubes along prism orientations while negative strains develop along basal orientations (Reference (a)). Second, early in life, free standing tubes will often shrink by creep in the diametrical direction under the external pressure of the water environment, but potentially grow later in life in the diametrical direction once the expanding fuel pelletmore » contacts the cladding inner wall (Reference (b)). Finally, the Zircaloy cladding absorbs hydrogen as a by product of the corrosion reaction (Reference (c)). Once above the solubility limit in Zircaloy, the hydride precipitates as zirconium hydride (References (c) through (j)). Both hydrogen in solid solution and precipitated as Zirconium hydride cause a volume expansion of the Zircaloy metal (Reference (k)). Few studies are reported on that have investigated the influence that in-situ clad straining has on corrosion of Zircaloy. If Zircaloy corrosion rates are governed by diffusion of anions through a thin passivating boundary layer at the oxide-to-metal interface (References (l) through (n)), in-situ straining of the cladding could accelerate the corrosion process by prematurely breaking that passivating oxide boundary layer. References (o) through (q) investigated the influence that an applied tensile stress has on the corrosion resistance of Zircaloy. Knights and Perkins, Reference (o), reported that the applied tensile stress increased corrosion rates above a critical stress level in 400 C and 475 C steam, but not at lower temperatures nor in dry oxygen environments. This latter observation suggested that hydrogen either in the oxide or at the oxide-to-metal interface is involved in the observed

  2. Deformation behavior of a 16-8-2 GTA weld as influenced by its solidification substructure

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

    Foulds, J.R.; Moteff, J.; Sikka, V.K.

    1983-07-01

    Weldment sections from formed and welded type 316 stainless steel pipe are characterized with respect to some time-independent (tensile) and time-dependent (creep) mechanical properties at temperatures between 25/sup 0/C and 649/sup 0/C. The GTA weldment, welded with 16-8-2 filler metal, is sectioned from pipe in the formed + welded + solution annealed + straightened condition, as well as in the same condition with an additional re-solution treatment. Detailed room temperature microhardness measurements on these sections before and after reannealing enable a determination of the different recovery characteristics of weld and base metal. The observed stable weld metal solidification dislocation substructuremore » in comparison with the base metal random dislocation structure, in fact, adequately explains weld/base metal elevated temperature mechanical behavior differences from this recovery characteristic standpoint. The weld metal substructure is the only parameter common to the variety of austenitic stainless steel welds exhibiting the consistent parent/weld metal deformation behavior differences described. As such, it must be considered the key to understanding weldment mechanical behavior.« less

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

    PubMed

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

    2014-05-01

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

  4. Effect of Compositional Variation in TiO2-Based Flux-Cored Arc Welding Fluxes on the Thermo-physical Properties and Mechanical Behavior of a Weld Zone

    NASA Astrophysics Data System (ADS)

    Kim, J. B.; Lee, T. H.; Sohn, I.

    2018-04-01

    The effect of compositional variation in TiO2-based flux-cored arc welding fluxes on viscosity, wettability, and electronegativity was studied. The thermo-physical properties of the retrieved fluxes and their relationship with the mechanical properties of the weld zone, including tensile strength and micro-Vickers hardness, after welding were identified. Microstructural observation under similar welding conditions revealed significant grain coarsening at a corrected optical basicity (Λcorr) of 0.62, resulting in reduced strength and hardness due to greater heat transfer. Welding fluxes containing TiO2-based simple structural units should result in greater heat transfer due to the deficiency in complex [AlO4]5-- and [SiO4]4--based structural units, as identified through spectroscopic analyses using fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. The electronegativity of the retrieved fluxes was also evaluated since higher electronegativity results in greater absorption of electrons in the arc, resulting in arc condensation towards the center direction. Consequently, deeper penetration could be obtained, where the highest electronegativity was identified to be approximately 0.62 of the corrected optical basicity. Thus, both the thermal conductivity and electronegativity of the welding fluxes were identified to determine the heat transfer phenomenon during flux-cored arc welding.

  5. Effect of Compositional Variation in TiO2-Based Flux-Cored Arc Welding Fluxes on the Thermo-physical Properties and Mechanical Behavior of a Weld Zone

    NASA Astrophysics Data System (ADS)

    Kim, J. B.; Lee, T. H.; Sohn, I.

    2018-07-01

    The effect of compositional variation in TiO2-based flux-cored arc welding fluxes on viscosity, wettability, and electronegativity was studied. The thermo-physical properties of the retrieved fluxes and their relationship with the mechanical properties of the weld zone, including tensile strength and micro-Vickers hardness, after welding were identified. Microstructural observation under similar welding conditions revealed significant grain coarsening at a corrected optical basicity (Λcorr) of 0.62, resulting in reduced strength and hardness due to greater heat transfer. Welding fluxes containing TiO2-based simple structural units should result in greater heat transfer due to the deficiency in complex [AlO4]5-- and [SiO4]4--based structural units, as identified through spectroscopic analyses using fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. The electronegativity of the retrieved fluxes was also evaluated since higher electronegativity results in greater absorption of electrons in the arc, resulting in arc condensation towards the center direction. Consequently, deeper penetration could be obtained, where the highest electronegativity was identified to be approximately 0.62 of the corrected optical basicity. Thus, both the thermal conductivity and electronegativity of the welding fluxes were identified to determine the heat transfer phenomenon during flux-cored arc welding.

  6. Welding.

    ERIC Educational Resources Information Center

    South Carolina State Dept. of Education, Columbia. Office of Vocational Education.

    This curriculum guide is designed for use by South Carolina vocational education teachers as a continuing set of lesson plans for a two-year course on welding. Covered in the individual sections of the guide are the following topics: an orientation to welding, oxyacetylene welding, advanced oxyacetylene welding, shielded metal arc welding, TIG…

  7. 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.

  8. Urinary β2 microglobulin in workers exposed to arc welding fumes.

    PubMed

    Aminian, Omid; Eftekhari, Saeid; Mazaheri, Maria; Sharifian, Seyed Akbar; Sadeghniiat-Haghighi, Khosro

    2011-01-01

    Welding is a process in which two or more metals are attached by the use of heat and, in some cases, pressure. Direct exposure and inhalation of welding fumes causes acute and chronic side effects in humans. Kidney damage is one of these important side effects. β(2) microglobulin is an 11.8 kilodalton protein and levels increase in the case of some inflammatory and viral diseases, or kidney malfunction and autoimmune diseases. In this study measurements of β(2) microglobulin were used as a criterion for assessing effects on the kidneys of workers exposed to welding fumes. The study population were electric arc welders in an industrial plant in Tehran, Iran. For control we selected workers who did not have any exposure to welding fumes. Both groups were selected on the basis of a questionnaire and the consideration of criteria for inclusion and exclusion. In the end 50 cases and 50 controls were chosen. A urine sample was collected from all participants and urinary pH was set to between 6-8 using NaOH (1M). Sample transportation to the laboratory complied with the related standards. The samples were assessed using the ORG 5BM kit. For quantitative assessment of β(2) microglobulin we used the Enzyme-linked Immunosorbent Assay (ELISA) method. The ages of the welders ranged from 21 to 48 years (mean=30.5 ± 5.9 yrs) and of controls from 23 to 56 years (mean=31.8 ± 5.9 yrs). Mean employment duration was 7.86 ± 5.01 years (range 2 to 27 years) for welders. Mean β(2) microglobulin level was 0.10 ± 0.096 μg/ml in welders and 0.11 ± 0.06 in controls. This difference was not statistically significant (P=0.381). In conclusion we don't find that exposure to electric arc welding fumes cause a significant change in urinary β(2) microglobulin compared to the control group.

  9. 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.

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

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

    Hovanski, Yuri; Carsley, John; Carlson, Blair

    2014-01-15

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

  11. Welding polarity effects on weld spatters and bead geometry of hyperbaric dry GMAW

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

  12. Nuclear Technology. Course 28: Welding Inspection. Module 28-2, Shielded Metal Arc and Oxyacetylene Welding.

    ERIC Educational Resources Information Center

    Espy, John; Selleck, Ben

    This second in a series of ten modules for a course titled Welding Inspection describes the key features of the oxyacetylene and shielded metal arc welding process. The apparatus, process techniques, procedures, applications, associated defects, and inspections are presented. The module follows a typical format that includes the following…

  13. 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.

  14. Plasma arc welding weld imaging

    NASA Technical Reports Server (NTRS)

    Rybicki, Daniel J. (Inventor); Mcgee, William F. (Inventor)

    1994-01-01

    A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

  15. Relationship between apposition pressure during welding and tensile strength of the acute weld

    NASA Astrophysics Data System (ADS)

    Wu, Paul J.; Walsh, Joseph T., Jr.

    2001-05-01

    Dye-assisted photothermal welding is a technique used to close wounds by thermally cross-linking collagen across apposed tissue edges. For a successful weld, not only do laser parameters have to be optimized, but also apposition of the incision has to be consistent and controlled. The objective of this study was to quantify the relationship between the applied apposition pressure (i.e., the compressive force holding the wound closed during the welding procedure divided by the area of the skin-to-skin interface) and the tensile strength of the wound following the welding procedure. By using a clamping device made of two complementary pieces, each 3 cm wide with a row of 10 equally spaced blunt wire mesh tips, the apposition pressure along a 2-cm-long incision in each albino guinea pig was quantified using a 127-micrometers -thick load cell and varied from 0-1.8 kgf/cm2. A continuous wave, Nd:YAG laser emitting 10.0 W of 1.06-micrometers radiation from a 600-micrometers -diameter fiber irradiating a 5-mm-diameter spot size was scanned across the incision in order to deliver 300 J of total energy. As the apposition pressure of the incisions was increased, the resulting tensile strength of welded skin increased in a sigmoidal manner. For this welding technique, an apposition pressure of at least 1.2 kgf/cm2 is necessary to obtain maximum weld strength of the skin (2.56+/- 0.36 kg/cm2).

  16. Mechanical properties of welded joints of the reduced-activation ferritic steel: 8% Cr-2% W-0.2% V-0.04% Ta-Fe

    NASA Astrophysics Data System (ADS)

    Hayakawa, H.; Yoshitake, A.; Tamura, M.; Natsume, S.; Gotoh, A.; Hishinuma, A.

    1991-03-01

    A reduced-activation ferritic steel, 8Cr-2W-0.2V-0.04Ta-Fe (F-82H) has been developed by JAERI and NKK to improve creep properties and toughness as compared with HT9. The mechanical properties and phase stability of the steel were reported at the previous conferences, ICFRM-2 and 3. This paper is concerned with the mechanical properties of weld metal and welded joints using a newly-developed filler wire of F-82H which contains less C and Ta than the base metal. The design concept of chemical composition of the filler wire was based on as much reduction of activity after irradiation as possible and considerations of the hardenability and toughness of the weld metal. Mechanical properties, such as tensile strength and toughness, of the weld metal and welded joints produced by GTAW after stress-relieving heat treatment were investigated. The results showed that this welding material has almost the same properties as the base metal.

  17. Welding of hermetic connectors

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

    Hieber, D.E.

    1976-08-01

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

  18. 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.

  19. The choice: Welding with CO2 or Nd:YAG lasers

    NASA Astrophysics Data System (ADS)

    Leong, Keng H.

    The recent commercial availability of multi-kilowatt Nd:YAG lasers has opened new avenues for rapid laser processing as well as intensified the competition (cost effectiveness) between CO2 and Nd:YAG laser systems. Vendors offering Nd:YAG laser systems may claim lower operating costs (than CO2) and fiberoptic beam delivery flexibility while CO2 systems vendors may emphasize lower capital cost and well established processing requirements and experience. The capital and operating costs of a laser system are impacted by demand and supply economics and technological advances. Frequently the total cost of a workcell using a laser for processing has to be considered rather than the laser system alone. Consequently it is not very practical to approach the selection of a laser system based on its capital cost and estimated operating cost only. This presentation describes a more pragmatic approach to aid the user in the selection of the optimal multi-kilowatt laser system for a particular processing requirement with emphasis on welding. CO2 laser systems are well established on the factory floor. Consequently, emphasis is given to the comparative application of Nd:YAG lasers, process requirements and performance. Requirements for the laser welding of different metals are examined in the context of hardware (laser system and beam delivery) selection and examples of welding speeds that can be achieved using CO2 and Nd:YAG lasers are examined.

  20. 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.

  1. Welding Curriculum.

    ERIC Educational Resources Information Center

    EASTCONN Regional Educational Services Center, North Windham, CT.

    The purpose of this welding program is to provide students with skills and techniques to become employed as advanced apprentice welders. The welding program manual includes the following sections: (1) course description; (2) general objectives; (3) competencies; (4) curriculum outline for 13 areas; (5) 13 references; and (6) student progress…

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

    NASA Astrophysics Data System (ADS)

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

    2010-10-01

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

  3. Oxide particle size distribution from shearing irradiated and unirradiated LWR fuels in Zircaloy and stainless steel cladding: significance for risk assessment

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

    Davis, W. Jr.; West, G.A.; Stacy, R.G.

    1979-03-22

    Sieve fractionation was performed with oxide particles dislodged during shearing of unirradiated or irradiated fuel bundles or single rods of UO/sub 2/ or 96 to 97% ThO/sub 2/--3 to 4% UO/sub 2/. Analyses of these data by nonlinear least-squares techniques demonstrated that the particle size distribution is lognormal. Variables involved in the numerical analyses include lognormal median size, lognormal standard deviation, and shear cut length. Sieve-fractionation data are presented for unirradiated bundles of stainless-steel-clad or Zircaloy-2-clad UO/sub 2/ or ThO/sub 2/--UO/sub 2/ sheared into lengths from 0.5 to 2.0 in. Data are also presented for irradiated single rods (sheared intomore » lengths of 0.25 to 2.0 in.) of Zircaloy-2-clad UO/sub 2/ from BWRs and of Zircaloy-4-clad UO/sub 2/ from PWRs. Median particle sizes of UO/sub 2/ from shearing irradiated stainless-steel-clad fuel ranged from 103 to 182 ..mu..m; particle sizes of ThO/sub 2/--UO/sub 2/, under these same conditions, ranged from 137 to 202 ..mu..m. Similarly, median particle sizes of UO/sub 2/ from shearing unirradiated Zircaloy-2-clad fuel ranged from 230 to 957 ..mu..m. Irradiation levels of fuels from reactors ranged from 9,000 to 28,000 MWd/MTU. In general, particle sizes from shearing these irradiated fuels are larger than those from the unirradiated fuels; however, unirradiated fuel from vendors was not available for performing comparative shearing experiments. In addition, variations in particle size parameters pertaining to samples of a single vendor varied as much as those between different vendors. The fraction of fuel dislodged from the cladding is nearly proportional to the reciprocal of the shear cut length, until the cut length attains some minimum value below which all fuel is dislodged. Particles of fuel are generally elongated with a long-to-short axis ratio usually less than 3. Using parameters of the lognormal distribution estimates can be made of fractions of dislodged fuel

  4. Investigation on mechanical properties of welded material under different types of welding filler (shielded metal arc welding)

    NASA Astrophysics Data System (ADS)

    Tahir, Abdullah Mohd; Lair, Noor Ajian Mohd; Wei, Foo Jun

    2018-05-01

    The Shielded Metal Arc Welding (SMAW) is (or the Stick welding) defined as a welding process, which melts and joins metals with an arc between a welding filler (electrode rod) and the workpieces. The main objective was to study the mechanical properties of welded metal under different types of welding fillers and current for SMAW. This project utilized the Design of Experiment (DOE) by adopting the Full Factorial Design. The independent variables were the types of welding filler and welding current, whereas the other welding parameters were fixed at the optimum value. The levels for types of welding filler were by the models of welding filler (E6013, E7016 and E7018) used and the levels for welding current were 80A and 90A. The responses were the mechanical properties of welded material, which include tensile strength and hardness. The experiment was analyzed using the two way ANOVA. The results prove that there are significant effects of welding filler types and current levels on the tensile strength and hardness of the welded metal. At the same time, the ANOVA results and interaction plot indicate that there are significant interactions between the welding filler types and the welding current on both the hardness and tensile strength of the welded metals, which has never been reported before. This project found that when the amount of heat input with increase, the mechanical properties such as tensile strength and hardness decrease. The optimum tensile strength for welded metal is produced by the welding filler E7016 and the optimum of hardness of welded metal is produced by the welding filler E7018 at welding current of 80A.

  5. Effects of alloying element on weld characterization of laser-arc hybrid welding of pure copper

    NASA Astrophysics Data System (ADS)

    Hao, Kangda; Gong, Mengcheng; Xie, Yong; Gao, Ming; Zeng, Xiaoyan

    2018-06-01

    Effects of alloying elements of Si and Sn on weld characterizations of laser-arc hybrid welded pure copper (Cu) with thickness of 2 mm was studied in detail by using different wires. The weld microstructure was analyzed, and the mechanical properties (micro-hardness and tensile property), conductivity and corrosion resistance were tested. The results showed that the alloying elements benefit the growth of column grains within weld fusion zone (FZ), increase the ultimate tensile strength (UTS) of the FZ and weld corrosion resistance, and decrease weld conductivity. The mechanisms were discussed according to the results.

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

    NASA Technical Reports Server (NTRS)

    Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

    2003-01-01

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

  7. Shielding gas effect on weld characteristics in arc-augmented laser welding process of super austenitic stainless steel

    NASA Astrophysics Data System (ADS)

    Sathiya, P.; Kumar Mishra, Mahendra; Soundararajan, R.; Shanmugarajan, B.

    2013-02-01

    A series of hybrid welding (gas metal arc welding-CO2 laser beam welding) experiments were conducted on AISI 904L super austenitic stainless steel sheet of 5 mm thickness. A detailed study of CO2 Laser-GMAW hybrid welding experiments with different shielding gas mixtures (100% He, 50% He+50% Ar, 50%He+45% Ar+5% O2, and 45% He+45% Ar+10% N2) were carried out and the results are presented. The resultant welds were subjected to detailed mechanical and microstructural characterization. Hardness testing revealed that the hardness values in the fusion zone were higher than the base material irrespective of the parameters. Transverse tensile testing showed that the joint efficiency is 100% with all the shielding gas experimented. Impact energy values of the welds were also found to be higher than the base material and the fractrograph taken in scanning electron microscope (SEM) has shown that the welds exhibited dimple fracture similar to the base material.

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

    NASA Astrophysics Data System (ADS)

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

    2008-03-01

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

  9. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

  10. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

  11. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

  12. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

  13. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

  14. Repair welding of gamma titanium aluminide castings

    NASA Astrophysics Data System (ADS)

    Kelly, T. J.

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

  15. 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

  16. Adaptive weld control for high-integrity welding applications

    NASA Technical Reports Server (NTRS)

    Powell, Bradley W.

    1993-01-01

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

  17. Optical Sensor for real-time Monitoring of CO(2) Laser Welding Process.

    PubMed

    Ancona, A; Spagnolo, V; Lugarà, P M; Ferrara, M

    2001-11-20

    An optical sensor for real-time monitoring of laser welding based on a spectroscopic study of the optical emission of plasma plumes has been developed. The welding plasma's electron temperature was contemporarily monitored for three of the chemical species that constitute the plasma plume by use of related emission lines. The evolution of electron temperature was recorded and analyzed during several welding procedures carried out under various operating conditions. A clear correlation between the mean value and the standard deviation of the plasma's electron temperature and the quality of the welded joint has been found. We used this information to find optimal welding parameters and for real-time detection of weld defects such as crater formation, lack of penetration, weld disruptions, and seam oxidation.

  18. Structure and phase composition of welded joints modified by different welding techniques

    NASA Astrophysics Data System (ADS)

    Smirnov, Aleksander; Popova, Natalya; Nikonenko, Elena; Ozhiganov, Eugeniy; Ababkov, Nikolay; Koneva, Nina

    2017-12-01

    The paper presents the results of transmission electron microscopy (TEM) during the study of structure and phase composition of heat-affected zone (HAZ) of welded joints modified via four welding techniques, namely: electrode welding and electropercussive welding both with and without artificial flaws. The artificial flows represent aluminum pieces. TEM studies are carried out within the heat-affected zone, i.e. between the deposited and base metal, at 0.5 mm distance to the former. The 0.09C-2Mn-1Si-Fe steel type is used for welding. It is shown how the type of welding affects steel morphology, phase composition, defect structure and its parameters. The type of carbide phase is detected as well as the shape and location of particles. Volume fractions are estimated for the structural steel components, alongside with such parameters as the size of α-phase fragments, scalar and excess dislocation densities, and bending-torsion amplitude of the crystal lattice. Based on these results, we determine the welding technique and the structural component thus launching a mechanism of microcrack nucleation.

  19. Microstructures and electrochemical behaviors of the friction stir welding dissimilar weld.

    PubMed

    Shen, Changbin; Zhang, Jiayan; Ge, Jiping

    2011-06-01

    By using optical microscope, the microstructures of 5083/6082 friction stir welding (FSW) weld and parent materials were analyzed. Meanwhile, at ambient temperature and in 0.2 mol/L NaHS03 and 0.6 mol/L NaCl solutionby gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation, the electrochemical behavior of 5083/6082 friction stir welding weld and parent materials were comparatively investigated by gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation. The results indicated that at given processing parameters, the anti-corrosion property of the dissimilar weld was superior to those of the 5083 and 6082 parent materials. Copyright © 2011 The Research Centre for Eco-Environmental Sciences, Chinese Academy of Sciences. Published by Elsevier B.V. All rights reserved.

  20. 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).

  1. 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.

  2. High Resolution Neutron Radiography and Tomography of Hydrided Zircaloy-4 Cladding Materials

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

    Smith, Tyler S; Bilheux, Hassina Z; Ray, Holly B

    2015-01-01

    Neutron radiography for hydrogen analysis was performed with several Zircaloy-4 cladding samples with controlled hydrogen concentrations up to 1100 ppm. Hydrogen charging was performed in a process tube that was heated to facilitate hydrogen absorption by the metal. A correlation between the hydrogen concentration in the hydrided tubes and the neutron intensity was established, by which hydrogen content can be determined precisely in a small area (55 m x 55 m). Radiography analysis was also performed to evaluate the heating rate and its correlation with the hydrogen distribution through hydrided materials. In addition to radiography analysis, tomography experiments were performedmore » on Zircaloy-4 tube samples to study the local hydrogen distribution. Through tomography analysis a 3D reconstruction of the tube was evaluated in which an uneven hydrogen distribution in the circumferential direction can be observed.« less

  3. Effect of rotation speed and welding speed on Friction Stir Welding of AA1100 Aluminium alloy

    NASA Astrophysics Data System (ADS)

    Raja, P.; Bojanampati, S.; Karthikeyan, R.; Ganithi, R.

    2018-04-01

    Aluminum AA1100 is the most widely used grade of Aluminium due to its excellent corrosion resistance, high ductility and reflective finish, the selected material was welded with Friction Stir Welding (FSW) process on a CNC machine, using a combination of different tool rotation speed (1500 rpm, 2500 rpm, 3500 rpm) and welding speed (10 mm/min, 30 mm/min, 50 mm/min) as welding parameters. The effect of FSW using this welding parameter was studied by measuring the ultimate tensile strength of the welded joints. A high-speed steel tool was prepared for welding the Aluminium AA1100 alloy having an 8mm shoulder diameter and pin dimension of 4mm diameter and 2.8 mm length. The welded joints were tested using the universal testing machine. It was found that Ultimate Tensile Strength of FSW specimen was highest with a value of 98.08 MPa when the weld was performed at rotation speed of 1500 RPM and welding speed of 50 mm/min.

  4. Effects of Flux Precoating and Process Parameter on Welding Performance of Inconel 718 Alloy TIG Welds

    NASA Astrophysics Data System (ADS)

    Lin, Hsuan-Liang; Wu, Tong-Min; Cheng, Ching-Min

    2014-01-01

    The purpose of this study is to investigate the effect of activating flux on the depth-to-width ratio (DWR) and hot cracking susceptibility of Inconel 718 alloy tungsten inert gas (TIG) welds. The Taguchi method is employed to investigate the welding parameters that affect the DWR of weld bead and to achieve optimal conditions in the TIG welds that are coated with activating flux in TIG (A-TIG) process. There are eight single-component fluxes used in the initial experiment to evaluate the penetration capability of A-TIG welds. The experimental results show that the Inconel 718 alloy welds precoated with 50% SiO2 and 50% MoO3 flux were provided with better welding performance such as DWR and hot cracking susceptibility. The experimental procedure of TIG welding process using mixed-component flux and optimal conditions not only produces a significant increase in DWR of weld bead, but also decreases the hot cracking susceptibility of Inconel 718 alloy welds.

  5. Welding in Space Workshop

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.

    1990-01-01

    The potential was discussed for welding in space, its advantages and disadvantages, and what type of programs can benefit from the capability. Review of the various presentations and comments made in the course of the workshop suggests several routes to obtaining a better understanding of how welding processes can be used in NASA's initiatives in space. They are as follows: (1) development of a document identifying well processes and equipment requirements applicable to space and lunar environments; (2) more demonstrations of welding particular hardware which are to be used in the above environments, especially for space repair operations; (3) increased awareness among contractors responsible for building space equipment as to the potential for welding operations in space and on other planetary bodies; and (4) continuation of space welding research projects is important to maintain awareness within NASA that welding in space is viable and beneficial.

  6. Stress corrosion cracking of Zircaloys in unirradiated and irradiated CsI

    NASA Astrophysics Data System (ADS)

    Cox, B.; Surette, B. A.; Wood, J. C.

    1986-03-01

    Unirradiated split-ring specimens of Zircaloy fuel cladding, coated with CsI, cracked when stressed at elevated temperatures. The specimens have been reexamined fractographically and metallographically in order to confirm that the cause of cracking was stress corrosion (SCC) and not delayed hydride cracking (DHC). Further specimens have been cracked at 350°C by a solution of CsI in a fused mixture of nitrates of rubidium, cesium, strontium and barium, by a similar mechanism. CsI dissolved in a fused molybdate melt was not stable at 400°C, and rapidly evolved iodine, leaving a melt that was incapable of causing SCC. Irradiation of stressed split-ring specimens of Zircaloy fuel cladding in a γ-irradiator of 10 6 R/h and in the U-5 loop in the NRU reactor at an estimated 10 9 R/h caused SCC when the specimens were packed in dry CsI powder. Care had to be taken to dry the CsI, otherwise cracking occurred by a DHC mechanism from hydrogen absorbed from residual moisture in the CsI. Fractography showed that the crack surfaces obtained with dry CsI were typical of iodine-induced SCC rather than cesium-induced metal vapour embrittlement. Thus, if a transport process is provided for the iodide to obtain access to the zirconium surface, CsI is capable of causing SCC of Zircaloy. This transport process might be ionic diffusion in a fission product oxide melt in the fuel-clad gap, however, radiolysis of CsI to form a volatile iodine species in a radiation field is the more probable explanation of PCI failures.

  7. Friction welding.

    NASA Technical Reports Server (NTRS)

    Moore, T. J.

    1972-01-01

    Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

  8. Advanced Welding Concepts

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2010-01-01

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

  9. Friction plug welding

    NASA Technical Reports Server (NTRS)

    Takeshita, Riki (Inventor); Hibbard, Terry L. (Inventor)

    2001-01-01

    Friction plug welding (FPW) usage is advantageous for friction stir welding (FSW) hole close-outs and weld repairs in 2195 Al--Cu--Li fusion or friction stir welds. Current fusion welding methods of Al--Cu--Li have produced welds containing varied defects. These areas are found by non-destructive examination both after welding and after proof testing. Current techniques for repairing typically small (<0.25) defects weaken the weldment, rely heavily on welders' skill, and are costly. Friction plug welding repairs increase strength, ductility and resistance to cracking over initial weld quality, without requiring much time or operator skill. Friction plug welding while pulling the plug is advantageous because all hardware for performing the weld can be placed on one side of the workpiece.

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

    NASA Astrophysics Data System (ADS)

    Sampath, K.

    2009-12-01

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

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

    PubMed

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

    2013-01-01

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

  12. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.300-9 Section 179.300-9... Specifications for Multi-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal... fusion welded on class DOT-110A tanks. Welding procedures, welders and fabricators must be approved in...

  13. Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

    NASA Technical Reports Server (NTRS)

    Looney, Alan

    1991-01-01

    Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.

  14. Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur C., Jr.

    2008-01-01

    Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

  15. The integrity of welded interfaces in ultra-high molecular weight polyethylene: Part 2--interface toughness.

    PubMed

    Haughie, David W; Buckley, C Paul; Wu, Junjie

    2006-07-01

    In Part 2 of a study of welding of ultra-high molecular weight polyethylene (UHMWPE), experiments were conducted to measure the interfacial fracture energy of butt welds, for various welding times and temperatures above the melting point. Their toughness was investigated at 37 degrees C in terms of their fracture energy, obtained by adapting the essential work of fracture (EWF) method. However, a proportion of the welded samples (generally decreasing with increasing welding time or temperature) failed in dual ductile/brittle mode, hence invalidating the EWF test. Even those failing in purely ductile mode showed a measurable interface work of fracture only for the highest weld temperature and time: 188 degrees C and 90 min. Results from the model presented in Part 1 show that this corresponds to the maximum reptated molecular weight reaching close to the peak in the molar mass distribution. Hence this work provides the first experimental evidence that the slow rate of self-diffusion in UHMWPE leads to welded interfaces acting as low-toughness crack paths. Since such interfaces exist around every powder particle in processed UHMWPE this problem cannot be avoided, and it must be accommodated in design of hip and knee bearing surfaces made from this polymer.

  16. Alternate Welding Processes for In-Service Welding

    DOT National Transportation Integrated Search

    2009-04-24

    Conducting weld repairs and attaching hot tap tees onto pressurized pipes has the advantage of avoiding loss of service and revenue. However, the risks involved with in-service welding need to be managed by ensuring that welding is performed in a rep...

  17. Welding. Performance Objectives. Basic Course.

    ERIC Educational Resources Information Center

    Vincent, Kenneth

    Several intermediate performance objectives and corresponding criterion measures are listed for each of eight terminal objectives for a basic welding course. The materials were developed for a 36-week (2 hours daily) course developed to teach the fundamentals of welding shop work, to become familiar with the operation of the welding shop…

  18. Thermal Stir Welding: A New Solid State Welding Process

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffery; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    Thermal Stir Shielding is a revolutionary new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating and stirring functions are independent allowing more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

  19. Automated Welding System

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  20. Microstructure Formation in Dissimilar Metal Welds: Electron Beam Welding of Ti/Ni

    NASA Astrophysics Data System (ADS)

    Chatterjee, Subhradeep; Abinandanan, T. A.; Reddy, G. Madhusudhan; Chattopadhyay, Kamanio

    2016-02-01

    We present results for electron beam welding of a binary Ti/Ni dissimilar metal couple. The difference in physical properties of the base metals and metallurgical features (thermodynamics and kinetics) of the system influence both macroscopic transport and microstructure development in the weld. Microstructures near the fusion interfaces are markedly different from those inside the weld region. At the Ti side, Ti2Ni dendrites are observed to grow toward the fusion interface, while in the Ni side, layered growth of γ-Ni, Ni3Ti, and Ni3Ti + NiTi eutectic is observed. Different morphologies of the latter eutectic constitute the predominant microstructure inside the weld metal region. These results are compared and contrasted with those from laser welding of the same binary couple, and a scheme of solidification is proposed to explain the observations. This highlights notable departures from welding of similar and other dissimilar metals such as a significant asymmetry in heat transport that governs progress of solidification from each side of the couple, and a lack of unique liquidus isotherm characterizing the liquid-solid front.

  1. Factors affecting weld root morphology in laser keyhole welding

    NASA Astrophysics Data System (ADS)

    Frostevarg, Jan

    2018-02-01

    Welding production efficiency is usually optimised if full penetration can be achieved in a single pass. Techniques such as electron and laser beam welding offer deep high speed keyhole welding, especially since multi-kilowatt lasers became available. However, there are limitations for these techniques when considering weld imperfections such as weld cap undercuts, interior porosity or humps at the root. The thickness of sheets during full penetration welding is practically limited by these root humps. The mechanisms behind root morphology formation are not yet satisfactory understood. In this paper root humping is studied by reviewing previous studies and findings and also by sample examination and process observation by high speed imaging. Different process regimes governing root quality are presented, categorized and explained. Even though this study mainly covers laser beam and laser arc hybrid welding, the presented findings can generally be applied full penetration welding in medium to thick sheets, especially the discussion of surface tension effects. As a final result of this analysis, a map of methods to optimise weld root topology is presented.

  2. The effect of welding parameters on penetration in GTA welds

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

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

    1993-07-01

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

  3. 49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

  4. 49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

  5. 49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

  6. 49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

  7. 49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

  8. Forming Completely Penetrated Welded T-joints when Pulsed Arc Welding

    NASA Astrophysics Data System (ADS)

    Krampit, N. Yu; Krampit, M. A.; Sapozhkov, A. S.

    2016-04-01

    The paper is focused on revealing the influence of welding parameters on weld formation when pulsed arc welding. As an experimental sample a T-joint over 10 mm was selected. Welding was carried out in flat position, which required no edge preparation but provided mono-directional guaranteed root penetration. The following parameters of welding were subjected to investigation: gap in the joint, wire feed rate and incline angles of the torch along and across the weld axis. Technological recommendations have been made with respect to pulsed arc welding; the cost price of product manufacturing can be reduced on their basis due to reduction of labor input required by machining, lowering consumption of welding materials and electric power.

  9. Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

    NASA Technical Reports Server (NTRS)

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

    1991-01-01

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

  10. Influence of Welding Strength Matching Coefficient and Cold Stretching on Welding Residual Stress in Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Lu, Yaqing; Hui, Hu; Gong, Jianguo

    2018-05-01

    Austenitic stainless steel is widely used in pressure vessels for the storage and transportation of liquid gases such as liquid nitrogen, liquid oxygen, and liquid hydrogen. Cryogenic pressure vessel manufacturing uses cold stretching technology, which relies heavily on welding joint performance, to construct lightweight and thin-walled vessels. Residual stress from welding is a primary factor in cases of austenitic stainless steel pressure vessel failure. In this paper, on the basis of Visual Environment 10.0 finite element simulation technology, the residual stress resulting from different welding strength matching coefficients (0.8, 1, 1.2, 1.4) for two S30408 plates welded with three-pass butt welds is calculated according to thermal elastoplastic theory. In addition, the stress field was calculated under a loading as high as 410 MPa and after the load was released. Path 1 was set to analyze stress along the welding line, and path 2 was set to analyze stress normal to the welding line. The welding strength matching coefficient strongly affected both the longitudinal residual stress (center of path 1) and the transverse residual stress (both ends of path 1) after the welding was completed. However, the coefficient had little effect on the longitudinal and transverse residual stress of path 2. Under the loading of 410 MPa, the longitudinal and transverse stress decreased and the stress distribution, with different welding strength matching coefficients, was less diverse. After the load was released, longitudinal and transverse stress distribution for both path 1 and path 2 decreased to a low level. Cold stretching could reduce the effect of residual stress to various degrees. Transverse strain along the stretching direction was also taken into consideration. The experimental results validated the reliability of the partial simulation.

  11. a Study on the Fretting Fatigue Life of Zircaloy Alloys

    NASA Astrophysics Data System (ADS)

    Kwon, Jae-Do; Park, Dae-Kyu; Woo, Seung-Wan; Chai, Young-Suck

    Studies on the strength and fatigue life of machines and structures have been conducted in accordance with the development of modern industries. In particular, fine and repetitive cyclic damage occurring in contact regions has been known to have an impact on fretting fatigue fractures. The main component of zircaloy alloy is Zr, and it possesses good mechanical characteristics at high temperatures. This alloy is used in the fuel rod material of nuclear power plants because of its excellent resistance. In this paper, the effect of the fretting damage on the fatigue behavior of the zircaloy alloy is studied. Further, various types of mechanical tests such as tension and plain fatigue tests are performed. Fretting fatigue tests are performed with a flat-flat contact configuration using a bridge-type contact pad and plate-type specimen. Through these experiments, it is found that the fretting fatigue strength decreases by about 80% as compared to the plain fatigue strength. Oblique cracks are observed in the initial stage of the fretting fatigue, in which damaged areas are found. These results can be used as the basic data for the structural integrity evaluation of corrosion-resisting alloys considering the fretting damages.

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

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

  13. Deconvoluting the Friction Stir Weld Process for Optimizing Welds

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Nunes, Arthur C.

    2008-01-01

    In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

  14. Welding IV.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

    Instructional objectives and performance requirements are outlined in this course guide for Welding IV, a competency-based course in advanced arc welding offered at the Community College of Allegheny County to provide students with proficiency in: (1) single vee groove welding using code specifications established by the American Welding Society…

  15. Welding.

    ERIC Educational Resources Information Center

    Lehigh County Area Vocational-Technical School, Schnecksville, PA.

    This curriculum guide provides materials for a 12-unit secondary course in welding. Purpose stated for the flexible entry and exit course is to help students master manipulative skills to develop successful welding techniques and to gain an understanding of the specialized tools and equipment used in the welding field. Units cover oxyacetylene…

  16. Effects of Fusion Tack Welds on Self-Reacting Friction Stir Welds

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.; Pendleton, M. L.; Brooke, S. A.; Russell, C. K.

    2012-01-01

    In order to know whether fusion tack welds would affect the strength of self-reacting friction stir seam welds in 2195-T87 aluminum alloy, the fracture stresses of 144 tensile test coupons cut from 24 welded panels containing segments of friction stir welds were measured. Each of the panels was welded under unique processing conditions. A measure of the effect of the tack welds for each panel was devised. An analysis of the measures of the tack weld effect supported the hypothesis that fusion tack welds do not affect the strength of self-reacting friction stir welds to a 5% level of confidence.

  17. EPRI-NASA Cooperative Project on Stress Corrosion Cracking of Zircaloys. [nuclear fuel failures

    NASA Technical Reports Server (NTRS)

    Cubicciotti, D.; Jones, R. L.

    1978-01-01

    Examinations of the inside surface of irradiated fuel cladding from two reactors show the Zircaloy cladding is exposed to a number of aggressive substances, among them iodine, cadmium, and iron-contaminated cesium. Iodine-induced stress corrosion cracking (SCC) of well characterized samples of Zircaloy sheet and tubing was studied. Results indicate that a threshold stress must be exceeded for iodine SCC to occur. The existence of a threshold stress indicates that crack formation probably is the key step in iodine SCC. Investigation of the crack formation process showed that the cracks responsible for SCC failure nucleated at locations in the metal surface that contained higher than average concentrations of alloying elements and impurities. A four-stage model of iodine SCC is proposed based on the experimental results and the relevance of the observations to pellet cladding interaction failures is discussed.

  18. Welding Curriculum.

    ERIC Educational Resources Information Center

    Alaska State Dept. of Education, Juneau. Div. of Adult and Vocational Education.

    This competency-based curriculum guide is a handbook for the development of welding trade programs. Based on a survey of Alaskan welding employers, it includes all competencies a student should acquire in such a welding program. The handbook stresses the importance of understanding the principles associated with the various elements of welding.…

  19. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation PIPELINE AND HAZARDOUS MATERIALS SAFETY... Design Requirements § 179.11 Welding certification. (a) Welding procedures, welders and fabricators shall...

  20. Automatic Welding of Stainless Steel Tubing

    NASA Technical Reports Server (NTRS)

    Clautice, W. E.

    1978-01-01

    To determine if the use of automatic welding would allow reduction of the radiographic inspection requirement, and thereby reduce fabrication costs, a series of welding tests were performed. In these tests an automatic welder was used on stainless steel tubing of 1/2, 3/4, and 1/2 inch diameter size. The optimum parameters were investigated to determine how much variation from optimum in machine settings could be tolerate and still result in a good quality weld. The process variables studied were the welding amperes, the revolutions per minute as a function of the circumferential weld travel speed, and the shielding gas flow. The investigation showed that the close control of process variables in conjunction with a thorough visual inspection of welds can be relied upon as an acceptable quality assurance procedure, thus permitting the radiographic inspection to be reduced by a large percentage when using the automatic process.

  1. Decreasing biotoxicity of fume particles produced in welding process.

    PubMed

    Yu, Kuei-Min; Topham, Nathan; Wang, Jun; Kalivoda, Mark; Tseng, Yiider; Wu, Chang-Yu; Lee, Wen-Jhy; Cho, Kuk

    2011-01-30

    Welding fumes contain heavy metals, such as chromium, manganese, and nickel, which cause respiratory diseases and cancer. In this study, a SiO(2) precursor was evaluated as an additive to the shielding gas in an arc welding process to reduce the biotoxicity caused by welding fume particles. Transmission electron micrographic images show that SiO(2) coats on the surface of welding fume particles and promotes particle agglomeration. Energy dispersive X-ray spectroscopy further shows that the relative amount of silicon in these SiO(2)-coated agglomerates is higher than in baseline agglomerates. In addition, Escherichia coli (E. coli) exposed to different concentrations of pure SiO(2) particles generated from the arc welding process exhibits similar responses, suggesting that SiO(2) does not contribute to welding fume particle toxicity. The trend of E. coli growth in different concentrations of baseline welding fume particle shows the most significant inhibition occurs in higher exposure concentrations. The 50% lethal logarithmic concentrations for E. coli in arc welding particles of baseline, 2%, and 4.2% SiO(2) precursor additives were 823, 1605, and 1800 mg/L, respectively. Taken together, these results suggest that using SiO(2) precursors as an additive to arc welding shielding gas can effectively reduce the biotoxicity of welding fume. Copyright © 2010 Elsevier B.V. All rights reserved.

  2. Discrete element weld model, phase 2

    NASA Technical Reports Server (NTRS)

    Prakash, C.; Samonds, M.; Singhal, A. K.

    1987-01-01

    A numerical method was developed for analyzing the tungsten inert gas (TIG) welding process. The phenomena being modeled include melting under the arc and the flow in the melt under the action of buoyancy, surface tension, and electromagnetic forces. The latter entails the calculation of the electric potential and the computation of electric current and magnetic field therefrom. Melting may occur at a single temperature or over a temperature range, and the electrical and thermal conductivities can be a function of temperature. Results of sample calculations are presented and discussed at length. A major research contribution has been the development of numerical methodology for the calculation of phase change problems in a fixed grid framework. The model has been implemented on CHAM's general purpose computer code PHOENICS. The inputs to the computer model include: geometric parameters, material properties, and weld process parameters.

  3. Thermal Stir Welding: A New Solid State Welding Process

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey

    2003-01-01

    Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

  4. Thermal Stir Welding: A New Solid State Welding Process

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

    Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

  5. Effect of welding position on porosity formation in aluminum alloy welds

    NASA Technical Reports Server (NTRS)

    Haryung, J.; Wroth, R. S.

    1967-01-01

    Program investigates the effects of varied welding positions on weld qualities. Progressive changes in bead geometry occur as the weld plane angle is varied from upslope to downslope. The gravitational effect on the weld puddle varies greatly with welding position.

  6. Auto Body Welding 2 (Course Outline), Automotive Body Repair and Refinishing 1: 9033.04.

    ERIC Educational Resources Information Center

    Dade County Public Schools, Miami, FL.

    The 90-hour course is a foundation quinmester course in welding for the auto body repairman. The outline consists of seven blocks of instruction (orientation, 6 hours; auto body oxyacetylene welding, 10 hours; electric arc welding equipment, 6 hours; auto body electric arc welding, 8 hours; position welding, 40 hours; electric spot welders, 16…

  7. Replacement of seam welded hot reheat pipe using narrow groove GTA machine welding

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

    Richardson, R.R.; Yanes, J.; Bryant, R.

    1995-12-31

    Southern California Edison, recognizing a potential safety concern, scrutinized its existing seam welded hot reheat pipe manufactured by the same supplier as that which failed. Alternatives were narrowed to two in dealing with the installed seam welded pipe. The overriding consideration, however, was one of safety. With this in mind, the utility company evaluated replacement of the seam welded hot reheat pipe with seamless pipe or increasing the frequency of its inspection program. Although increased inspection was much costly, pipe replacement was chosen due to potential safety concerns with seam welded pipe even with more frequent inspection. The utility companymore » then proceeded to determine the most effective method to complete this work. Analysis showed machine-made (automatic) gas tungsten arc welds (GTAW) as the method of choice due to cleanliness and superior mechanical properties. In conjunction with this method, the narrow groove (3{degree} bevel) weld joint as opposed to the traditional groove (37 1/2{degree} bevel) was shown to provide significant technical advantages.« less

  8. Sustainability of Welding Process through Bobbin Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Sued, M. K.; Samsuri, S. S. M.; Kassim, M. K. A. M.; Nasir, S. N. N. M.

    2018-03-01

    Welding process is in high demand, which required a competitive technology to be adopted. This is important for sustaining the needs of the joining industries without ignoring the impact of the process to the environment. Friction stir welding (FSW) is stated to be benefitting the environment through low energy consumption, which cannot be achieved through traditional arc welding. However, this is not well documented, especially for bobbin friction stir welding (BFSW). Therefore, an investigation is conducted by measuring current consumption of the machine during the BFSW process. From the measurement, different phases of BFSW welding process and its electrical demand are presented. It is found that in general total energy in BFSW is about 130kW inclusive of all identified process phases. The phase that utilise for joint formation is in weld phase that used the highest total energy of 120kWs. The recorded total energy is still far below the traditional welding technology and the conventional friction stir welding (CFSW) energy demand. This indicates that BFSW technology with its vast benefit able to sustain the joining technology in near future.

  9. Enabling high speed friction stir welding of aluminum tailor welded blanks

    NASA Astrophysics Data System (ADS)

    Hovanski, Yuri

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

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

    NASA Astrophysics Data System (ADS)

    Dai, Hongbin; Peng, Jun

    2016-11-01

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

  11. Nuclear Technology. Course 28: Welding Inspection. Module 28-9, Weld Repair Control.

    ERIC Educational Resources Information Center

    Espy, John

    This ninth in a series of ten modules for a course titled Welding Inspection describes the purposes, essential elements, and application of a weld control program. The module follows a typical format that includes the following sections: (1) introduction, (2) module prerequisites, (3) objectives, (4) notes to instructor/student, (5) subject…

  12. The Influence of Friction Stir Weld Tool Form and Welding Parameters on Weld Structure and Properties: Nugget Bulge in Self-Reacting Friction Stir Welds

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Nunes, Arthur C., Jr.; Brendel, Michael S.

    2010-01-01

    Although friction stir welding (FSW) was patented in 1991, process development has been based upon trial and error and the literature still exhibits little understanding of the mechanisms determining weld structure and properties. New concepts emerging from a better understanding of these mechanisms enhance the ability of FSW engineers to think about the FSW process in new ways, inevitably leading to advances in the technology. A kinematic approach in which the FSW flow process is decomposed into several simple flow components has been found to explain the basic structural features of FSW welds and to relate them to tool geometry and process parameters. Using this modelling approach, this study reports on a correlation between the features of the weld nugget, process parameters, weld tool geometry, and weld strength. This correlation presents a way to select process parameters for a given tool geometry so as to optimize weld strength. It also provides clues that may ultimately explain why the weld strength varies within the sample population.

  13. A novel procedure employing laser ultrasound technique and simplex algorism for the characterization of mechanical and geometrical properties in Zircaloy tubes with different levels of hydrogen charging

    NASA Astrophysics Data System (ADS)

    Liu, I.-Hung; Yang, Che-Hua

    2011-01-01

    In this research, a procedure employing a laser ultrasound technique (LUT) and an inversion algorism is reported for nondestructive characterization of mechanical and geometrical properties in Zircaloy tubes with different levels of hydrogen charging. With the LUT, guided acoustic waves are generated to propagate in the Zircaloy tubes and are detected remotely by optical means. By measuring the dispersive wavespeeds followed by the inversion algorism, mechanical properties such as elastic moduli and geometrical property such as wall-thickness of Zircaloy tubes are characterized for different levels of hydrogen charging. Having the advantages of remote, non-contact and point-wise generation/detection, the reported procedure serves as a competitive candidate for the characterization of Zircaloy tubes generally operated in irradiative and temperature-elevated environments.

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

    NASA Astrophysics Data System (ADS)

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

    2017-12-01

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

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

    NASA Technical Reports Server (NTRS)

    Henon, B. K.

    1985-01-01

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

  16. 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

  17. 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.

  18. Design of a robust fuzzy controller for the arc stability of CO(2) welding process using the Taguchi method.

    PubMed

    Kim, Dongcheol; Rhee, Sehun

    2002-01-01

    CO(2) welding is a complex process. Weld quality is dependent on arc stability and minimizing the effects of disturbances or changes in the operating condition commonly occurring during the welding process. In order to minimize these effects, a controller can be used. In this study, a fuzzy controller was used in order to stabilize the arc during CO(2) welding. The input variable of the controller was the Mita index. This index estimates quantitatively the arc stability that is influenced by many welding process parameters. Because the welding process is complex, a mathematical model of the Mita index was difficult to derive. Therefore, the parameter settings of the fuzzy controller were determined by performing actual control experiments without using a mathematical model of the controlled process. The solution, the Taguchi method was used to determine the optimal control parameter settings of the fuzzy controller to make the control performance robust and insensitive to the changes in the operating conditions.

  19. Influence of Welding Process and Post Weld Heat Treatment on Microstructure and Pitting Corrosion Behavior of Dissimilar Aluminium Alloy Welds

    NASA Astrophysics Data System (ADS)

    Venkata Ramana, V. S. N.; Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

    2018-03-01

    Welding of dissimilar Aluminum alloy welds is becoming important in aerospace, shipbuilding and defence applications. In the present work, an attempt has been made to weld dissimilar aluminium alloys using conventional gas tungsten arc welding (GTAW) and friction stir welding (FSW) processes. An attempt was also made to study the effect of post weld heat treatment (T4 condition) on microstructure and pitting corrosion behaviour of these welds. Results of the present investigation established the differences in microstructures of the base metals in T4 condition and in annealed conditions. It is evident that the thickness of the PMZ is relatively more on AA2014 side than that of AA6061 side. In FS welds, lamellar like shear bands are well noticed on the top of the stir zone. The concentration profile of dissimilar friction stir weld in T4 condition revealed that no diffusion has taken place at the interface. Poor Hardness is observed in all regions of FS welds compared to that of GTA welds. Pitting corrosion resistance of the dissimilar FS welds in all regions was improved by post weld heat treatment.

  20. Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

    NASA Technical Reports Server (NTRS)

    Querin, Joseph A.; Schneider, Judy A.

    2008-01-01

    In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

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

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

    Hovanski, Yuri; Upadhyay, Piyush; Carsley, John

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

  2. The effect of weld porosity on the cryogenic fatigue strength of ELI grade Ti-5Al-2.5Sn

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

  3. Laser weld jig

    DOEpatents

    Van Blarigan, Peter; Haupt, David L.

    1982-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

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

  5. Versatile Friction Stir Welding/Friction Plug Welding System

    NASA Technical Reports Server (NTRS)

    Carter, Robert

    2006-01-01

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

  6. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.400-11 Section 179.400-11...-11 Welding. (a) Except for closure of openings and a maximum of two circumferential closing joints in... subchapter). (d) Each welding procedure, welder, and fabricator must be approved. [Amdt. 179-32, 48 FR 27708...

  7. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.220-10 Section 179.220-10... Specifications for Non-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints... of this subchapter). Welding procedures, welders, and fabricators shall be approved. (b) Radioscopy...

  8. 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

  9. Vaccum Gas Tungsten Arc Welding, phase 1

    NASA Astrophysics Data System (ADS)

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

    1995-03-01

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

  10. Vaccum Gas Tungsten Arc Welding, phase 1

    NASA Technical Reports Server (NTRS)

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

    1995-01-01

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

  11. Monitoring the quality of welding based on welding current and ste analysis

    NASA Astrophysics Data System (ADS)

    Mazlan, Afidatusshimah; Daniyal, Hamdan; Izzani Mohamed, Amir; Ishak, Mahadzir; Hadi, Amran Abdul

    2017-10-01

    Qualities of welding play an important part in industry especially in manufacturing field. Post-welding non-destructive test is one of the importance process to ensure the quality of welding but it is time consuming and costly. To reduce the chance of defects, online monitoring had been utilized by continuously sense some of welding parameters and predict welding quality. One of the parameters is welding current, which is rich of information but lack of study focus on extract them at signal analysis level. This paper presents the analysis of welding current using Short Time Energy (STE) signal processing to quantify the pattern of the current. GMAW set with carbon steel specimens are used in this experimental study with high-bandwidth and high sampling rate oscilloscope capturing the welding current. The results indicate welding current as signatures have high correlation with the welding process. Continue with STE analysis, the value below 5000 is declare as good welding, meanwhile the STE value more than 6000 is contained defect.

  12. 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.

  13. Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

    NASA Astrophysics Data System (ADS)

    Ji, Shude; Yang, Zhanpeng; Wen, Quan; Yue, Yumei; Zhang, Liguo

    2018-04-01

    Trailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

  14. Displaced electrode process for welding

    DOEpatents

    Heichel, L.J.

    1975-08-26

    A method is described for the butt-welding of a relatively heavy mass to a relatively small mass such as a thin-wall tube. In butt-welding heat is normally applied at the joint between the two pieces which are butt-welded together. The application of heat at the joint results in overheating the tube which causes thinning of the tube walls and porosity in the tube material. This is eliminated by displacing the welding electrode away from the seam toward the heavier mass so that heat is applied to the heavy mass and not at the butt seam. Examples of the parameters used in welding fuel rods are given. The cladding and end plugs were made of Zircalloy. The electrode used was of 2 percent thoriated tungsten. (auth)

  15. Fusion welding process

    DOEpatents

    Thomas, Kenneth C.; Jones, Eric D.; McBride, Marvin A.

    1983-01-01

    A process for the fusion welding of nickel alloy steel members wherein a ferrite containing pellet is inserted into a cavity in one member and melted by a welding torch. The resulting weld nugget, a fusion of the nickel containing alloy from the members to be welded and the pellet, has a composition which is sufficiently low in nickel content such that ferrite phases occur within the weld nugget, resulting in improved weld properties. The steel alloys encompassed also include alloys containing carbon and manganese, considered nickel equivalents.

  16. Friction Stir Welding Development

    NASA Technical Reports Server (NTRS)

    Romine, Peter L.

    1998-01-01

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

  17. Performance of iron-chromium-aluminum alloy surface coatings on Zircaloy 2 under high-temperature steam and normal BWR operating conditions

    NASA Astrophysics Data System (ADS)

    Zhong, Weicheng; Mouche, Peter A.; Han, Xiaochun; Heuser, Brent J.; Mandapaka, Kiran K.; Was, Gary S.

    2016-03-01

    Iron-chromium-aluminum (FeCrAl) coatings deposited on Zircaloy 2 (Zy2) and yttria-stabilized zirconia (YSZ) by magnetron sputtering have been tested with respect to oxidation weight gain in high-temperature steam. In addition, autoclave testing of FeCrAl-coated Zy2 coupons under pressure-temperature-dissolved oxygen coolant conditions representative of a boiling water reactor (BWR) environment has been performed. Four different FeCrAl compositions have been tested in 700 °C steam; compositions that promote alumina formation inhibited oxidation of the underlying Zy2. Parabolic growth kinetics of alumina on FeCrAl-coated Zy2 is quantified via elemental depth profiling. Autoclave testing under normal BWR operating conditions (288 °C, 9.5 MPa with normal water chemistry) up to 20 days demonstrates observable weight gain over uncoated Zy2 simultaneously exposed to the same environment. However, no FeCrAl film degradation was observed. The 900 °C eutectic in binary Fe-Zr is addressed with the FeCrAl-YSZ system.

  18. Intelligent Weld Manufacturing: Role of Integrated Computational Welding Engineering

    DOE PAGES

    David, Stan A.; Chen, Jian; Feng, Zhili; ...

    2017-12-02

    A master welder uses his sensory perceptions to evaluate the process and connect them with his/her knowledge base to take the necessary corrective measures with his/her acquired skills to make a good weld. All these actions must take place in real time. Success depends on intuition and skills, and the procedure is labor-intensive and frequently unreliable. The solution is intelligent weld manufacturing. The ultimate goal of intelligent weld manufacturing would involve sensing and control of heat source position, weld temperature, weld penetration, defect formation and ultimately control of microstructure and properties. This involves a solution to a problem (welding) withmore » many highly coupled and nonlinear variables. The trend is to use an emerging tool known as intelligent control. This approach enables the user to choose a desirable end factor such as properties, defect control, or productivity to derive the selection of process parameters such as current, voltage, or speed to provide for appropriate control of the process. Important elements of intelligent manufacturing are sensing and control theory and design, process modeling, and artificial intelligence. Significant progress has been made in all these areas. Integrated computational welding engineering (ICWE) is an emerging field that will aid in the realization of intelligent weld manufacturing. The paper will discuss the progress in process modeling, microstructure, properties, and process control and automation and the importance of ICWE. Also, control and automation strategies for friction stir welding will be discussed.« less

  19. Intelligent Weld Manufacturing: Role of Integrated Computational Welding Engineering

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

    David, Stan A.; Chen, Jian; Feng, Zhili

    A master welder uses his sensory perceptions to evaluate the process and connect them with his/her knowledge base to take the necessary corrective measures with his/her acquired skills to make a good weld. All these actions must take place in real time. Success depends on intuition and skills, and the procedure is labor-intensive and frequently unreliable. The solution is intelligent weld manufacturing. The ultimate goal of intelligent weld manufacturing would involve sensing and control of heat source position, weld temperature, weld penetration, defect formation and ultimately control of microstructure and properties. This involves a solution to a problem (welding) withmore » many highly coupled and nonlinear variables. The trend is to use an emerging tool known as intelligent control. This approach enables the user to choose a desirable end factor such as properties, defect control, or productivity to derive the selection of process parameters such as current, voltage, or speed to provide for appropriate control of the process. Important elements of intelligent manufacturing are sensing and control theory and design, process modeling, and artificial intelligence. Significant progress has been made in all these areas. Integrated computational welding engineering (ICWE) is an emerging field that will aid in the realization of intelligent weld manufacturing. The paper will discuss the progress in process modeling, microstructure, properties, and process control and automation and the importance of ICWE. Also, control and automation strategies for friction stir welding will be discussed.« less

  20. Effects of pretreatment processes for Zr electrorefining of oxidized Zircaloy-4 cladding tubes

    NASA Astrophysics Data System (ADS)

    Hwa Lee, Chang; Lee, Yoo Lee; Jeon, Min Ku; Choi, Yong Taek; Kang, Kweon Ho; Park, Geun Il

    2014-06-01

    The effect of pretreatment processes for the Zr electrorefining of oxidized Zircaloy-4 cladding tubes is examined in LiCl-KCl-ZrCl4 molten salts at 500 °C. The cyclic voltammetries reveal that the Zr dissolution kinetics is highly dependent on the thickness of a Zr oxide layer formed at 500 °C under air atmosphere. For the Zircaloy-4 tube covered with a 1 μm thick oxide layer, the Zr dissolution process is initiated from a non-stoichiometric Zr oxide surface through salt treatment at an open circuit potential in the molten salt electrolyte. The Zr dissolution of the samples in the middle range of oxide layer thickness appears to be more effectively derived by the salt treatment coupled with an anodic potential application at an oxidation potential of Zr. A modification of the process scheme offers an applicability of Zr electrorefining for the treatment of oxidized cladding hull wastes.

  1. Characterizing Shipyard Welding Emissions and Associated Control Options (The National Shipbuilding Research Program)

    DTIC Science & Technology

    1995-08-01

    TRl) Occupational Health and Safety Administration (OSHA) Air Quality Legislation Hexavalent Chromium and the Legislation List-of-list Chemicals and...2.2.7 2.2.8 Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Gas Metal Arc Welding (GMAW) Gas Tungsten Arc Welding ( GTAW ) Flux Core Arc... GTAW Welding Processes Advantages and Disadvantages of FCAW Welding Processes Welding Process Comparison Matrix Diagram of SMAW Welding Process

  2. Weld procedure produces quality welds for thick sections of Hastelloy-X

    NASA Technical Reports Server (NTRS)

    Flens, F. J.; Fletcher, C. W.; Glasier, L. F., Jr.

    1967-01-01

    Welding program produces premium quality, multipass welds in heavy tube sections of Hastelloy-X. It develops semiautomatic tungsten/inert gas procedures, weld wire procurement specifications material weld properties, welder-operator training, and nondestructive testing inspection techniques and procedures.

  3. METALLURGY OF ZIRCALOY-2. PART II. THE EFFECTS OF FABRICATION VARIABLES ON THE PREFERRED ORIENTATION AND ANISOTROPY OF STRAIN BEHAVIOR

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

    Rittenhouse, P.L.; Picklesimer, M.L.

    1961-02-01

    The preferred orientation and anisotropy of strain behavior of Zircaloy- 2 were studied as functions of fabrication variables. An inverse-pole-figure technique was used for the preferred orientation determinations. Evaluation of the effects of the fabrication variables on the anisotropy of strain behavior was accomplished by a contractile strainaxial strain analysis. An analysis of strain behavior in the normal direction was developed on the basis of theory of plastic flow of anisotropic metals. A simple intuitively derivable relation was found to exist between the strainstrain analysis and the preferred orientation data. Correlations of the strain-strain data with true-stress-truestrain diagrams and mechanicalmore » properties were attempted. The preferred orientation of Zircaloy-2 produced by the Oak Ridge National Laboratory-Homogeneous Reactor Project (ORNL- HRP) metallurgy fabrication schedule (ingot breakdown at 1500 to 1900 deg F, major reduction at 1800 to 1900 deg F or 1350 to 1450 deg F, a heat treatment of 30 min at 1800 at 1550 deg F followed by a water quench or rapid air cool to below 1200 deg F, a final reduction of 25 to 40% at 1000 deg F. and a 3O-min anneal at 1400 to 1425 deg F) was weak compared to that of most of the other schedules investigated. Elimination of the beta heat treatment (1800 to 1850 deg F for 30 min) between the major reduction and final reduction steps resulted in a material with a high degree of preferred orienation and with a state of pseudoisotropy in ihe rolling plane. A unique and quite high degree of preferred orientaion was developed when the ORNL-HRP metallurgy fabrication procedure was used, but the ingot axis was in the transverse rather than the rolling direction of the finished plate permitting more contractile sirain to occur in the normal direction than in either the rolling or transverse directions. The strain-strain analyses of the materials were consistent with the conclusions reached by the preferred

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

  5. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.100-9 Section 179.100-9... Specifications for Pressure Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All..., appendix W (IBR, see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be...

  6. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.200-10 Section 179.200-10... Specifications for Non-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints... W (IBR, see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be...

  7. Advanced Welding Applications

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2010-01-01

    Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

  8. Training Materials Sourcebook. Welding, Brazing, and Flame-Cutting. Voc./Tec. Resources Series Number 2.

    ERIC Educational Resources Information Center

    Canadian Commission of Employment and Immigration, Ottawa (Ontario).

    Second in a resource series (see note), this annotated bibliography provides detailed information on training curriculum and instructional materials for welding, brazing, and flame-cutting. The materials are divided into thirty-fie sections by topic and type. Specific topic areas include gas and arc welding; arc welding; oxyacetylene welding and…

  9. WELDING METHOD

    DOEpatents

    Cornell, A.A.; Dunbar, J.V.; Ruffner, J.H.

    1959-09-29

    A semi-automatic method is described for the weld joining of pipes and fittings which utilizes the inert gasshielded consumable electrode electric arc welding technique, comprising laying down the root pass at a first peripheral velocity and thereafter laying down the filler passes over the root pass necessary to complete the weld by revolving the pipes and fittings at a second peripheral velocity different from the first peripheral velocity, maintaining the welding head in a fixed position as to the specific direction of revolution, while the longitudinal axis of the welding head is disposed angularly in the direction of revolution at amounts between twenty minutas and about four degrees from the first position.

  10. Nuclear Technology. Course 28: Welding Inspection. Module 28-1, Welding Fundamentals and Processes.

    ERIC Educational Resources Information Center

    Espy, John

    This first in a series of ten modules for a course titled Welding Inspection describes the role and responsbilities of the quality assurance/quality control technician in welding inspections. The module follows a typical format that includes the following sections: (1) introduction, (2) module prerequisites, (3) objectives, (4) notes to…

  11. Friction stir welding tool and process for welding dissimilar materials

    DOEpatents

    Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

    2013-05-07

    A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

  12. Characterisation of weld zone reactions in dissimilar glass-to-aluminium pulsed picosecond laser welds

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

    Ciuca, Octav P., E-mail: octav.ciuca@manchester.ac

    Precision welded joints, produced between fused silica glass and aluminium by a newly-developed picosecond-pulse laser technique, have been analysed for the first time using a full range of electron microscopy methods. The welds were produced as lap joints by focusing a 1.2 μm diameter laser beam through the transparent glass top sheet, slightly below the surface of the metal bottom sheet. Despite the extremely short interaction time, extensive reaction was observed in the weld zone, which involved the formation of nanocrystalline silicon and at least two transitional alumina phases, γ- and δ-Al{sub 2}O{sub 3}. The weld formation process was foundmore » to be complex and involved: the formation of a constrained plasma cavity at the joint interface, non-linear absorption in the glass, and the creation of multiple secondary keyholes in the metal substrate by beam scattering. The joint area was found to expand outside of the main interaction volume, as the energy absorbed into the low conductivity and higher melting point silica glass sheet melted the aluminium surface across a wider contact area. The reasons for the appearance of nanocrystalline Si and transitional alumina reaction products within the welds are discussed. - Highlights: •Pulsed laser welding of dissimilar materials causes extensive chemical reactivity. •Metastable Al{sub 2}O{sub 3} phases form due to laser-induced highly-transient thermal regime. •Fused silica is reduced by Al to form nanocrystalline Si. •Mechanism of joint formation is discussed.« less

  13. Syllabus in Trade Welding.

    ERIC Educational Resources Information Center

    New York State Education Dept., Albany. Bureau of Secondary Curriculum Development.

    The syllabus outlines material for a course two academic years in length (minimum two and one-half hours daily experience) leading to entry-level occupational ability in several welding trade areas. Fourteen units covering are welding, gas welding, oxyacetylene welding, cutting, nonfusion processes, inert gas shielded-arc welding, welding cast…

  14. Space Shuttle ET Friction Stir Weld Machines

    NASA Technical Reports Server (NTRS)

    Thompson, Jack M.

    2003-01-01

    NASA and Lockheed-Martin approached the FSW machine vendor community with a specification for longitudinal barrel production FSW weld machines and a shorter travel process development machine in June of 2000. This specification was based on three years of FSW process development on the Space Shuttle External Tank alloys, AL2 195-T8M4 and AL22 19-T87. The primary motivations for changing the ET longitudinal welds from the existing variable polarity Plasma Arc plasma weld process included: (1) Significantly reduced weld defect rates and related reduction in cycle time and uncertainty; (2) Many fewer process variables to control (5 vs. 17); (3) Fewer manufacturing steps; (4) Lower residual stresses and distortion; (5) Improved weld strengths, particularly at cryogenic temperatures; (6) Fewer hazards to production personnel. General Tool was the successful bidder. The equipment is at this writing installed and welding flight hardware. This paper is a means of sharing with the rest of the FSW community the unique features developed to assure NASA/L-M of successful production welds.

  15. Microhardness Testing of Aluminum Alloy Welds

    NASA Technical Reports Server (NTRS)

    Bohanon, Catherine

    2009-01-01

    A weld is made when two pieces of metal are united or fused together using heat or pressure, and sometimes both. There are several different types of welds, each having their own unique properties and microstructure. Strength is a property normally used in deciding which kind of weld is suitable for a certain metal or joint. Depending on the weld process used and the heat required for that process, the weld and the heat-affected zone undergo microstructural changes resulting in stronger or weaker areas. The heat-affected zone (HAZ) is the region that has experienced enough heat to cause solid-state microstructural changes, but not enough to melt the material. This area is located between the parent material and the weld, with the grain structure growing as it progresses respectively. The optimal weld would have a short HAZ and a small fluctuation in strength from parent metal to weld. To determine the strength of the weld and decide whether it is suitable for the specific joint certain properties are looked at, among these are ultimate tensile strength, 0.2% offset yield strength and hardness. Ultimate tensile strength gives the maximum load the metal can stand while the offset yield strength gives the amount of stress the metal can take before it is 0.2% longer than it was originally. Both of these are good tests, but they both require breaking or deforming the sample in some way. Hardness testing, however, provides an objective evaluation of weld strengths, and also the difference or variation in strength across the weld and HAZ which is difficult to do with tensile testing. Hardness is the resistance to permanent or plastic deformation and can be taken at any desired point on the specimen. With hardness testing, it is possible to test from parent metal to weld and see the difference in strength as you progress from parent material to weld. Hardness around grain boundaries and flaws in the material will show how these affect the strength of the metal while still

  16. 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.

  17. 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.

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

    NASA Technical Reports Server (NTRS)

    Adams, Glynn; Venable, Richard; Lawless, Kirby

    2003-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Shenghai, Zhang; Yifu, Shen; Huijuan, Qiu

    2013-06-01

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

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

    NASA Astrophysics Data System (ADS)

    Kumar, Aniruddha; Gupta, Mool C.

    2009-11-01

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

  1. The effect of travel speed on thermal response in CO2 laser welding of small electronic components

    NASA Astrophysics Data System (ADS)

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

    A comprehensive three-dimensional numerical investigation of the effect of beat source travel speed on temperatures and resulting thermal stresses was performed for CO2-laser welding. The test specimen was a small thermal battery header containing several stress-sensitive glass-to-metal seals surrounding the electrical connections and a temperature sensitive ignitor located under the header near the center. Predictions of the thermal stresses and temperatures in the battery header were made for several travel speeds of the laser. The travel speeds examined ranged from 10mm/sec to 50mm/sec. The results indicate that faster weld speeds result in lower temperatures and stresses for the same size weld. This is because the higher speed welds are more efficient, requiring less energy to produce a given weld. Less energy absorbed by the workpiece results in lower temperatures, which results in lower stresses.

  2. Heat-affected zone and phase composition of 0.09 C-2 Mn-1 Si-Fe steel depending on welding technique

    NASA Astrophysics Data System (ADS)

    Popova, Natalya; Ozhiganov, Eugeniy; Nikonenko, Elena; Ababkov, Nikolay; Smirnov, Aleksander; Koneva, Nina

    2017-11-01

    The paper presents the transmission electron microscopy (TEM) investigations of the structure and phase composition of the heat-affected zone (HAZ) in welded joint modified by four types of welding, namely: electrode welding and electropercussive welding both with and without the introduction of artificial flaws. Artificial flows are aluminum pieces. TEM investigations are carried out within HAZ between the deposited and base metal at 1 mm distance to the latter. The type 0.09C-2Mn-1Si-Fe steel is used as weld material. It is shown that the welding process has an effect on the material morphology, phase composition, faulted structure and its parameters. Long-range stresses are divided into plastic and elastic components. It is demonstrated that the type of welding does not change the structural quality of welded joint represented by perlite and ferrite as contrasted with their volume fraction. According to observations, any type of welding with the introduction of artificial flaws results in the destruction of perlite. Polarization of the dislocation structure occurs. The amplitude of mean internal stresses does not practically depend on the welding type. It is shown that the introduction of artificial flaws both during electrode and electropercussive welding reduce the quantitative parameters of the faulted structure.

  3. Survey of welding processes.

    DOT National Transportation Integrated Search

    2003-07-01

    The current KYTC SPECIAL PROVISION NO. 4 WELDING STEEL BRIDGES prohibits the use of welding processes other than shielded metal arc welding (SMAW) and submerged arc welding (SAW). Nationally, bridge welding is codified under ANSI/AASHTO/AWS D1....

  4. 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.

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

    NASA Astrophysics Data System (ADS)

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

    1997-07-01

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

  6. Welding Technician

    ERIC Educational Resources Information Center

    Smith, Ken

    2009-01-01

    About 95% of all manufactured goods in this country are welded or joined in some way. These welded products range in nature from bicycle handlebars and skyscrapers to bridges and race cars. The author discusses what students need to know about careers for welding technicians--wages, responsibilities, skills needed, career advancement…

  7. METHOD OF OBTAINING AN IMPROVED WELD IN INERT ARC WELDING

    DOEpatents

    Correy, T.B.

    1962-12-11

    A method is reported for inert arc welding. An a-c welding current is applied to the workpiece and welding electrode such that the positive portion of each cycle thereof, with the electrode positive, has only sufficient energy to clean the surface of the workpiece and the negative portion of each cycle thereof, with the electrode negative, contains the energy required to weld. (AEC)

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

    PubMed

    Ren, Jie; Wang, Yanrang

    2015-12-01

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

  9. Introduction to Welding.

    ERIC Educational Resources Information Center

    Fortney, Clarence; Gregory, Mike

    This curriculum guide provides six units of instruction on basic welding. Addressed in the individual units of instruction are the following topics: employment opportunities for welders, welding safety and first aid, welding tools and equipment, basic metals and metallurgy, basic math and measuring, and procedures for applying for a welding job.…

  10. Arc Welding Dictionary 2. Project HIRE.

    ERIC Educational Resources Information Center

    Gardner, David C.; And Others

    Designed as supplemental material to on-going instruction in the vocational program, this second of three picture dictionary booklets in the Arc Welding series is intended to assist the learning handicapped student to master the core vocabulary taught in the trade. Intended for individual or small group instruction with minimal supervision, this…

  11. Pre-weld heat treatment improves welds in Rene 41

    NASA Technical Reports Server (NTRS)

    Prager, M.

    1968-01-01

    Cooling of Rene 41 prior to welding reduces the incidence of cracking during post-weld heat treatment. The microstructure formed during the slow cooling rate favors elevated temperature ductility. Some vestiges of this microstructure are apparently retained during welding and thus enhance strain-age crack resistance in air.

  12. Texture and hydride orientation relationship of Zircaloy-4 fuel clad tube during its fabrication for pressurized heavy water reactors

    NASA Astrophysics Data System (ADS)

    Vaibhaw, Kumar; Rao, S. V. R.; Jha, S. K.; Saibaba, N.; Jayaraj, R. N.

    2008-12-01

    Zircaloy-4 material is used for cladding tube in pressurized heavy water reactors (PHWRs) of 220 MWe and 540 MWe capacity in India. These tubes are fabricated by using various combinations of thermo-mechanical processes to achieve desired mechanical and corrosion properties. Cladding tube develops crystallographic texture during its fabrication, which has significant influence on its in-reactor performance. Due to radiolytic decomposition of water Zircaloy-4 picks-up hydrogen. This hydrogen in excess of its maximum solubility in reactor operating condition (˜300 °C), precipitates as zirconium hydrides causing embrittlement of cladding tube. Hydride orientation in the radial direction of the tube limits the service life and lowers the fuel burn-up in reactor. The orientation of the hydride primarily depends on texture developed during fabrication. A correlation between hydride orientation ( F n) with the texture in the tube during its fabrication has been developed using a second order polynomial. The present work is aimed at quantification and correlation of texture evolved in Zircaloy-4 cladding tube using Kearn's f-parameter during its fabrication process.

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

    NASA Astrophysics Data System (ADS)

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

    2015-05-01

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

  14. Ultrasonic Welding of Thin Alumina and Aluminum Using Inserts

    NASA Astrophysics Data System (ADS)

    Ishikuro, Tomoaki; Matsuoka, Shin-Ichi

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

  15. Numerical and experimental determination of weld pool shape during high-power diode laser welding

    NASA Astrophysics Data System (ADS)

    Klimpel, Andrzej; Lisiecki, Aleksander; Szymanski, Andrzej; Hoult, Anthony P.

    2003-10-01

    In this paper, results of investigations on the shape of weld pool during High Power Diode Laser (HPDL) welding are presented. The results of tests showed that the shape of weld pool and mechanism of laser welding with a rectangular pattern of 808 nm laser radiation differs distinctly from previous laser welding mechanisms. For all power densities the conduction mode welds were observed and weld pool geometry depends significantly on the welding parameters.

  16. Structure of welded joints obtained by contact weld in nanostructured titanium

    NASA Astrophysics Data System (ADS)

    Klimenov, V. A.; Klopotov, A. A.; Gnysov, S. F.; Vlasov, V. A.; Lychagin, D. V.; Chumaevskii, A. V.

    2015-10-01

    The paper presents the research of the weld structure of two Ti specimens of the type VT6 that have nano- and submicrocrystalline structures. Electrical contact welding is used to obtain welds. The acicular structure is formed in the weld area. Two types of defects are detected, namely micropores and microcracks.

  17. Welded joints integrity analysis and optimization for fiber laser welding of dissimilar materials

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

  18. Weld-Bead Shaver

    NASA Technical Reports Server (NTRS)

    Guirguis, Kamal; Price, Daniel S.

    1990-01-01

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

  19. Nd:YAG laser welding of coated sheet steel

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

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

    1994-12-31

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

  20. 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.

  1. Gas metal arc welding fume generation using pulsed current

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

    Castner, H.R.

    1994-12-31

    This paper describes a study of the effects of pulsed welding current on the amount of welding fume and ozone produced during gas metal arc welding (GMAW) using a range of welding procedures and pulse parameters. The results reported in this paper show that pulsed current can reduce GMAW fumes compared to steady current. This research also shows that welding parameters need to be properly controlled if pulsed current is to be used to reduce welding fumes. Fume and ozone generation rates were measured during this study for GMAW of mild steel using copper-coated ER70S-3 electrode wire and 95%Ar-5%CO{sub 2}more » and 85%Ar-15%CO{sub 2} shielding gases. Welds were made with both steady current and pulsed current over a wide range of welding parameters. Fume generation rates for steady current were found to be typically between 0.2 g/min and 0.8 g/min which agrees with other researchers. No significant difference was found in the chemical composition of welding fumes from pulsed current compared to the composition of fumes generated by steady current. New technology that can reduce arc welding fumes is of significant interest to a wide range of companies that use arc welding processes and this research should assist these users in evaluating the potential for the application of this technology to their own operations.« less

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

  3. Welding of Thin Steel Plates by Hybrid Welding Process Combined TIG Arc with YAG Laser

    NASA Astrophysics Data System (ADS)

    Kim, Taewon; Suga, Yasuo; Koike, Takashi

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

  4. [New welding processes and health effects of welding].

    PubMed

    La Vecchia, G Marina; Maestrelli, Piero

    2011-01-01

    This paper describes some of the recent developments in the control technology to enhance capability of Pulse Gas Metal Arc Welding. Friction Stir Welding (FSW) processing has been also considered. FSW is a new solid-state joining technique. Heat generated by friction at the rotating tool softens the material being welded. FSW can be considered a green and energy-efficient technique without deleterious fumes, gas, radiation, and noise. Application of new welding processes is limited and studies on health effects in exposed workers are lacking. Acute and chronic health effects of conventional welding have been described. Metal fume fever and cross-shift decline of lung function are the main acute respiratory effects. Skin and eyes may be affected by heat, electricity and UV radiations. Chronic effects on respiratory system include chronic bronchitis, a benign pneumoconiosis (siderosis), asthma, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders.

  5. 3D hierarchical MnO2 nanorod/welded Ag-nanowire-network composites for high-performance supercapacitor electrodes.

    PubMed

    Qiao, Zhensong; Yang, Xiaopeng; Yang, Shuhua; Zhang, Liqiang; Cao, Bingqiang

    2016-06-28

    3D MnO2 nanorod/welded Ag-nanowire-network supercapacitor electrodes were prepared. Welding treatment of the Ag nanowire-network leads to low resistance and long lifetime. Galvanostatic charge/discharge (GCD) induces an ever-lasting morphology changing from flower-like to honeycomb-like for MnO2, which manifests as increasing specific capacitance to 663.4 F g(-1) after 7000 GCD cycles.

  6. Weld analysis and control system

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  7. Effects of Post-Weld Heat Treatment on the Mechanical Properties of Similar- and Dissimilar-Alloy Friction Stir Welded Blanks

    NASA Astrophysics Data System (ADS)

    Zadpoor, Amir Abbas; Sinke, Jos

    2011-01-01

    Friction stir welding is a solid state joining process with relatively low welding temperatures. Nevertheless, the mechanical properties of friction stir welded blanks are degraded after welding. Indeed, both strength and ductility of the welds are decreased after welding. Often, the resulting friction stir welded blanks need to be formed to their final structural shape. Therefore, the formability of friction stir welded blanks is of primary importance in the manufacturing of structural parts. This paper studies how the mechanical properties and particularly formability of friction stir welded blanks can be improved by applying a post weld heat treatment. Two aluminum alloys from 2000 and 7000 series, namely 2024-T3 and 7075-T6, are selected for the study. The sheet thickness of both materials is 2,0 mm. The selected alloys are welded in three configurations: 2024-T3 and 2024-T3, 7075-T6 and 7075-T6, and 2024-T3 and 7075-T6. The resulting welds are naturally aged for a few months. Three sets of standard dog bone shape tensile test specimens are then machined from the welds. The first set of the specimens is tested without any heat treatment. The second set of the specimens is solution heat treated and quenched before testing. The third set of the specimens is solution heat treated, quenched, and naturally aged for a week before testing. The mechanical properties of the three different sets of specimens are compared with each other. It is shown that careful selection of post weld heat-treatment can greatly improve the formability of friction stir welded blanks.

  8. Laser welding in space

    NASA Technical Reports Server (NTRS)

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

    1991-01-01

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

  9. 46 CFR 59.10-30 - Seal welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 2 2010-10-01 2010-10-01 false Seal welding. 59.10-30 Section 59.10-30 Shipping COAST... VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-30 Seal welding. Where leaks occur in riveted joints or connections, they shall be carefully investigated to...

  10. 46 CFR 59.10-30 - Seal welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 2 2014-10-01 2014-10-01 false Seal welding. 59.10-30 Section 59.10-30 Shipping COAST... VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-30 Seal welding. Where leaks occur in riveted joints or connections, they shall be carefully investigated to...

  11. 46 CFR 59.10-30 - Seal welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 46 Shipping 2 2013-10-01 2013-10-01 false Seal welding. 59.10-30 Section 59.10-30 Shipping COAST... VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-30 Seal welding. Where leaks occur in riveted joints or connections, they shall be carefully investigated to...

  12. 46 CFR 59.10-30 - Seal welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 2 2012-10-01 2012-10-01 false Seal welding. 59.10-30 Section 59.10-30 Shipping COAST... VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-30 Seal welding. Where leaks occur in riveted joints or connections, they shall be carefully investigated to...

  13. Cryogen spray cooling during laser tissue welding.

    PubMed

    Fried, N M; Walsh, J T

    2000-03-01

    Cryogen cooling during laser tissue welding was explored as a means of reducing lateral thermal damage near the tissue surface and shortening operative time. Two centimetre long full-thickness incisions were made on the epilated backs of guinea pigs, in vivo. India ink was applied to the incision edges then clamps were used to appose the edges. A 4 mm diameter beam of 16 W, continuous-wave, 1.06 microm, Nd:YAG laser radiation was scanned over the incisions, producing approximately 100 ms pulses. There was a delay of 2 s between scans. The total irradiation time was varied from 1-2 min. Cryogen was delivered to the weld site through a solenoid valve in spurt durations of 20, 60 and 100 ms. The time between spurts was either 2 or 4 s, corresponding to one spurt every one or two laser scans. Histology and tensile strength measurements were used to evaluate laser welds. Total irradiation times were reduced from 10 min without surface cooling to under 1 min with surface cooling. The thermal denaturation profile showed less denaturation in the papillary dermis than in the mid-dermis. Welds created using optimized irradiation and cooling parameters had significantly higher tensile strengths (1.7 +/- 0.4 kg cm(-2)) than measured in the control studies without cryogen cooling (1.0 +/- 0.2 kg cm(-2)) (p < 0.05). Cryogen cooling of the tissue surface during laser welding results in increased weld strengths while reducing thermal damage and operative times. Long-term studies will be necessary to determine weld strengths and the amount of scarring during wound healing.

  14. Dual wire welding torch and method

    DOEpatents

    Diez, Fernando Martinez; Stump, Kevin S.; Ludewig, Howard W.; Kilty, Alan L.; Robinson, Matthew M.; Egland, Keith M.

    2009-04-28

    A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

  15. Skin welding using pulsed laser radiation and a dye

    NASA Astrophysics Data System (ADS)

    Fried, Nathaniel M.; Walsh, Joseph T., Jr.

    1998-07-01

    Previous skin welding studies have used continuous wave (CW) delivery of radiation. However, heat diffusion during irradiation prevents strong welds from being achieved without creating large zones of thermal damage to surrounding tissue. This damage may prevent normal wound healing. Strong welds and minimal thermal damage can be achieved by introducing a dye and delivering the radiation in a pulsed mode. Two-cm-long, full-thickness incisions were made in guinea pig skin. India ink was used as an absorber, and egg white albumin was used as an adhesive. A 5-mm-diameter spot of CW, 1.06-micrometer Nd:YAG laser radiation was scanned over the weld site, producing 100 millisecond pulses. The cooling time between scans and number of scans was varied. Thermal damage zones were measured using a transmission polarizing microscope to identify birefringence changes in tissue. Tensile strengths were measured using a tensiometer. For pulsed welding and long cooling times, weld strengths of 2.4 kg/cm2 were measured, and thermal damage to the epidermis was limited to approximately 500 micrometers. With CW welding, comparable weld strengths resulted in approximately 2700 micrometer of thermal damage. CW laser radiation weld strengths were only 0.6 kg/cm2 when thermal damage in the epidermis was limited to approximately 500 micrometers.

  16. Improving the Quality of Welding Seam of Automatic Welding of Buckets Based on TCP

    NASA Astrophysics Data System (ADS)

    Hu, Min

    2018-02-01

    Since February 2014, the welding defects of the automatic welding line of buckets have been frequently appeared. The average repair time of each bucket is 26min, which seriously affects the production efficiency and welding quality. We conducted troubleshooting, and found the main reasons for the welding defects of the buckets were the deviations of the center points of the robot tools and the poor quality of the locating welding. We corrected the gripper, welding torch, and accuracy of repeat positioning of robots to control the quality of positioning welding. The welding defect rate of buckets was reduced greatly, ensuring the production efficiency and welding quality.

  17. 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.

  18. Characterization of the structural details of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor

    NASA Astrophysics Data System (ADS)

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

    2014-06-01

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

  19. Diffusion welding. [heat treatment of nickel alloys following single step vacuum welding process

    NASA Technical Reports Server (NTRS)

    Holko, K. H. (Inventor)

    1974-01-01

    Dispersion-strengthened nickel alloys are sanded on one side and chemically polished. This is followed by a single-step welding process wherein the polished surfaces are forced into intimate contact at 1,400 F for one hour in a vacuum. Diffusion, recrystallization, and grain growth across the original weld interface are obtained during postheating at 2,150 F for two hours in hydrogen.

  20. Comparison between hybrid laser-MIG welding and MIG welding for the invar36 alloy

    NASA Astrophysics Data System (ADS)

    Zhan, Xiaohong; Li, Yubo; Ou, Wenmin; Yu, Fengyi; Chen, Jie; Wei, Yanhong

    2016-11-01

    The invar36 alloy is suitable to produce mold of composite materials structure because it has similar thermal expansion coefficient with composite materials. In the present paper, the MIG welding and laser-MIG hybrid welding methods are compared to get the more appropriate method to overcome the poor weldability of invar36 alloy. According to the analysis of the experimental and simulated results, it has been proved that the Gauss and cone combined heat source model can characterize the laser-MIG hybrid welding heat source well. The total welding time of MIG welding is 8 times that of hybrid laser-MIG welding. The welding material consumption of MIG welding is about 4 times that of hybrid laser-MIG welding. The stress and deformation simulation indicate that the peak value of deformation during MIG welding is 3 times larger than that of hybrid laser-MIG welding.

  1. Assessment of the LC-2 Prelaunch Fatigue Spectra of the CM-to-SM Flange Weld

    NASA Technical Reports Server (NTRS)

    Dawicke, David S.; Newman, John A.

    2008-01-01

    The pad stay and rollout components of the Ares I-X life cycle can generate cyclic stress oscillations to the vehicle that could initiate and grow fatigue cracks from weld defects. The Ares I-X Project requested that a study be performed to determine if stabilization of the vehicle is required to reduce the stresses that could initiate and grow fatigue cracks at the flange-to-skin weld of the Command Module (CM) and Service Module (SM) interface. A fatigue crack growth analysis was conducted that used loads (LC-2) and stress analyses developed by the Ares I-X Project and utilized material data and analysis methods developed by a critical initial flaw size (CIFS) analysis conducted by NASA Engineering and Safety Center (NESC) for the Upper Stage Simulator (USS) of the Ares I-X vehicle. A full CIFS analysis for the CM-to-SM flange-to-skin weld was not performed because the full flight spectrum was not provided and was not necessary to answer the question posed by the Ares I-X Project. Instead, an approach was developed to determine if the crack growth due to the pad stay and rollout components of the flight spectrum would adversely influence the CIFS. The approach taken used a number of conservative assumptions that eliminated the need for high-fidelity analyses and additional material testing, but still provided a bounding solution for the uncertainties of the problem. The results from this analysis indicate that the LC-2 pad stay and rollout spectrum components would not produce significant fatigue crack growth on the CM-to-SM flange-to-skin weld. Thus, from a fatigue crack growth standpoint, no stabilization is required to reduce the LC-2 pad stay and rollout cyclic stresses on the CM-to-SM flange-to-skin weld.

  2. Narrow gap laser welding

    DOEpatents

    Milewski, John O.; Sklar, Edward

    1998-01-01

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables.

  3. Narrow gap laser welding

    DOEpatents

    Milewski, J.O.; Sklar, E.

    1998-06-02

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables. 34 figs.

  4. Repair welding of cast iron coated electrodes

    NASA Astrophysics Data System (ADS)

    Żuk, M.; Górka, J.; Dojka, R.; Czupryński, A.

    2017-08-01

    Welding cast iron is a complex production procedure. Repair welding was used to repair damaged or poorly made castings. This is due to a tendency to cracking of the material during welding as well as after it. Welding cast iron can be carried out on hot or on cold. Hot welding requires high heat material and the use of welding material in the form of cast iron. In the case of cold welding, it is possible to use different materials. Mostly used filler metals are nickel and copper based. The work shows the course of research concerning repairmen of ductile iron with arc welding method. For the reparation process four types of ESAB company coated electrodes dedicated for cast iron were used with diameter 3.2 and 4 mm: ES 18-8-6B (4mm), EB 150 (4mm), OK NiCl, EŻM. In the cast iron examined during the testing grooves were made using plasma methods, in order to simulate the removed casting flaws. Then the welding process with coated electrodes was executed. The process utilized low welding current row of 100A, so there would only be a small amount of heat delivered to the heat affected zone (HAZ). Short stitches were made, after welding it was hammered, in order to remove stresses. After the repair welding the part of studies commenced which purpose was finding surface defects using visual testing (VT) and penetration testing (PT). In the second part, a series of macro and microscopic studies were executed witch the purpose of disclosuring the structure. Then the hardness tests for welds cross sections were performed. An important aspect of welding cast iron is the colour of the padding weld after welding, more precisely the difference between the base material and padding weld, the use of different materials extra gives the extra ability to select the best variant. The research of four types of coated electrode was executed, based on the demands the best option in terms of aesthetic, strength and hardness.

  5. 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.

  6. Post-weld Tempered Microstructure and Mechanical Properties of Hybrid Laser-Arc Welded Cast Martensitic Stainless Steel CA6NM

    NASA Astrophysics Data System (ADS)

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

    2016-12-01

    Manufacturing of hydroelectric turbine components involves the assembly of thick-walled stainless steels using conventional multi-pass arc welding processes. By contrast, hybrid laser-arc welding may be an attractive process for assembly of such materials to realize deeper penetration depths, higher production rates, narrower fusion, and heat-affected zones, and lower distortion. In the present work, single-pass hybrid laser-arc welding of 10-mm thick CA6NM, a low carbon martensitic stainless steel, was carried out in the butt joint configuration using a continuous wave fiber laser at its maximum power of 5.2 kW over welding speeds ranging from 0.75 to 1.2 m/minute. The microstructures across the weldment were characterized after post-weld tempering at 873 K (600 °C) for 1 hour. From microscopic examinations, the fusion zone was observed to mainly consist of tempered lath martensite and some residual delta-ferrite. The mechanical properties were evaluated in the post-weld tempered condition and correlated to the microstructures and defects. The ultimate tensile strength and Charpy impact energy values of the fully penetrated welds in the tempered condition were acceptable according to ASTM, ASME, and industrial specifications, which bodes well for the introduction of hybrid laser-arc welding technology for the manufacturing of next generation hydroelectric turbine components.

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

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

    Goussain, J.C.; Vire, S.

    1996-12-31

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

  8. An improved diffusion welding technique for TD-NiCr

    NASA Technical Reports Server (NTRS)

    Holko, K. H.

    1973-01-01

    An improved diffusion welding technique has been developed for TD-NiCr sheet. In the most preferred form, the improved technique consists of diffusion welding 320-grit sanded plus chemically polished surfaces of unrecrystallized TD-NiCr at 760 C under 140 MN/m2 pressure for 1hr followed by postheating at 1180 C for 2hr. Compared to previous work, this improved technique has the advantages of shorter welding time, lower welding temperature, lower welding pressure, and a simpler and more reproducible surface preparation procedure. Weldments were made that had parent-metal creep-rupture shear strength at 1100 C.

  9. Electric arc welding gun

    DOEpatents

    Luttrell, Edward; Turner, Paul W.

    1978-01-01

    This invention relates to improved apparatus for arc welding an interior joint formed by intersecting tubular members. As an example, the invention is well suited for applications where many similar small-diameter vertical lines are to be welded to a long horizontal header. The improved apparatus includes an arc welding gun having a specially designed welding head which is not only very compact but also produces welds that are essentially free from rolled-over solidified metal. The welding head consists of the upper end of the barrel and a reversely extending electrode holder, or tip, which defines an acute angle with the barrel. As used in the above-mentioned example, the gun is positioned to extend upwardly through the vertical member and the joint to be welded, with its welding head disposed within the horizontal header. Depending on the design of the welding head, the barrel then is either rotated or revolved about the axis of the vertical member to cause the electrode to track the joint.

  10. Performance of repair welds on aged Cr-Mo piping girth welds

    NASA Astrophysics Data System (ADS)

    Viswanathan, R.; Gandy, D. W.

    1999-10-01

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

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

    NASA Astrophysics Data System (ADS)

    Saibaba, N.

    2008-12-01

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

  12. Integration of NASA-sponsored studies on aluminum welding

    NASA Technical Reports Server (NTRS)

    Masubuchi, K.

    1972-01-01

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

  13. A novel weld seam detection method for space weld seam of narrow butt joint in laser welding

    NASA Astrophysics Data System (ADS)

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

    2018-02-01

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

  14. Introduction to Welding. Instructor Edition. Introduction to Construction Series.

    ERIC Educational Resources Information Center

    Oklahoma State Dept. of Vocational and Technical Education, Stillwater. Curriculum and Instructional Materials Center.

    This document contains the materials necessary to teach four instructional units on welding that are designed to prepare learners for entry-level employment. The following instructional units are presented: (1) welding materials; (2) welding tools; (3) welding layout and basic skills; and (4) oxyacetylene cutting. The document begins with a copy…

  15. 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.

  16. Study of Mechanical Properties and Characterization of Pipe Steel welded by Hybrid (Friction Stir Weld + Root Arc Weld) Approach

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

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

    Friction stir welding (FSW) has recently attracted attention as an alternative construction process for gas/oil transportation applications due to advantages compared to fusion welding techniques. A significant advantage is the ability of FSW to weld the entire or nearly the entire wall thickness in a single pass, while fusion welding requires multiple passes. However, when FSW is applied to a pipe or tube geometry, an internal back support anvil is required to resist the plunging forces exerted during FSW. Unfortunately, it may not be convenient or economical to use internal backing support due to limited access for some applications. Tomore » overcome this issue, ExxonMobil recently developed a new concept, combining root arc welding and FSW. That is, a root arc weld is made prior to FSW that supports the normal loads associated with FSW. In the present work, mechanical properties of a FSW + root arc welded pipe steel are reported including microstructure and microhardness.« less

  17. 46 CFR 59.10-30 - Seal welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 2 2011-10-01 2011-10-01 false Seal welding. 59.10-30 Section 59.10-30 Shipping COAST... VESSELS AND APPURTENANCES Welding Repairs to Boilers and Pressure Vessels in -Service § 59.10-30 Seal... determine the cause. Such leaks may be made tight by seal welding the edge, if, in the opinion of the...

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

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

    Kiefer, J.J.

    1994-12-31

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

  19. Certification of a weld produced by friction stir welding

    DOEpatents

    Obaditch, Chris; Grant, Glenn J

    2013-10-01

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

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

    NASA Astrophysics Data System (ADS)

    Ahmadi, E.; Ebrahimi, A. R.

    2015-02-01

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

  1. An evaluation of welding processes to reduce hexavalent chromium exposures and reduce costs by using better welding techniques.

    PubMed

    Keane, Michael J

    2014-01-01

    A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr(6+)) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr(6+) were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr(6+) emissions, and greatly reduce costs relative to SMAW.

  2. An Evaluation of Welding Processes to Reduce Hexavalent Chromium Exposures and Reduce Costs by Using Better Welding Techniques

    PubMed Central

    Keane, Michael J

    2014-01-01

    A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr6+) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr6+ were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr6+ emissions, and greatly reduce costs relative to SMAW. PMID:25574138

  3. Penetration in GTA welding

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

    Heiple, C.R.; Burgardt, P.

    1990-01-01

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

  4. 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.

  5. Ultrasonic Stir Welding

    NASA Technical Reports Server (NTRS)

    Nabors, Sammy

    2015-01-01

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

  6. Tool For Friction Stir Tack Welding of Aluminum Alloys

    NASA Technical Reports Server (NTRS)

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

    2003-01-01

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

  7. 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

  8. Risk Communication Concerning Welding Fumes for the Primary Preventive Care of Welding Apprentices in Southern Brazil

    PubMed Central

    Cezar-Vaz, Marta Regina; Bonow, Clarice Alves; Cezar Vaz, Joana

    2015-01-01

    This study’s aim was to assess the perceptions of welding apprentices concerning welding fumes being associated with respiratory and cardiovascular disorders and assess the implementation of risk communication as a primary prevention tool in the welding training process. This quasi-experimental, non-randomized study with before-and-after design was conducted with 84 welding apprentices in Southern Brazil. Poisson Regression analysis was used. Relative Risk was the measure used with a 95% confidence interval and 5% (p ≤ 0.05) significance level. Significant association was found between perceptions of worsened symptoms of respiratory disorders caused by welding fumes and educational level (p = 0.049), the use of goggles to protect against ultraviolet rays (p = 0.023), and access to services in private health facilities without insurance coverage (p = 0.001). Apprentices younger than 25 years old were 4.9 times more likely to perceive worsened cardiovascular symptoms caused by welding fumes after risk communication (RR = 4.91; CI 95%: 1.09 to 22.2). The conclusion is that risk communication as a primary preventive measure in continuing education processes implemented among apprentices, who are future welders, was efficacious. Thus, this study confirms that risk communication can be implemented as a primary prevention tool in welding apprenticeships. PMID:25607606

  9. Risk communication concerning welding fumes for the primary preventive care of welding apprentices in southern Brazil.

    PubMed

    Cezar-Vaz, Marta Regina; Bonow, Clarice Alves; Vaz, Joana Cezar

    2015-01-19

    This study's aim was to assess the perceptions of welding apprentices concerning welding fumes being associated with respiratory and cardiovascular disorders and assess the implementation of risk communication as a primary prevention tool in the welding training process. This quasi-experimental, non-randomized study with before-and-after design was conducted with 84 welding apprentices in Southern Brazil. Poisson Regression analysis was used. Relative Risk was the measure used with a 95% confidence interval and 5% (p ≤ 0.05) significance level. Significant association was found between perceptions of worsened symptoms of respiratory disorders caused by welding fumes and educational level (p = 0.049), the use of goggles to protect against ultraviolet rays (p = 0.023), and access to services in private health facilities without insurance coverage (p = 0.001). Apprentices younger than 25 years old were 4.9 times more likely to perceive worsened cardiovascular symptoms caused by welding fumes after risk communication (RR = 4.91; CI 95%: 1.09 to 22.2). The conclusion is that risk communication as a primary preventive measure in continuing education processes implemented among apprentices, who are future welders, was efficacious. Thus, this study confirms that risk communication can be implemented as a primary prevention tool in welding apprenticeships.

  10. The effects of welded joint characteristics on its properties in HDPE thermal fusion welding

    NASA Astrophysics Data System (ADS)

    Dai, Hongbin; Peng, Jun

    2017-05-01

    In this paper, PE100 pipes with the diameter of 200 mm and the thickness of 11.9 mm were used as material. The welded joints were obtained in different welding pressures with the optimal welding temperature of 220∘C. Reheating process on the welded joints with the temperature of 130∘C was carried out. The joints exhibited X-type, and the cause of X-type joints was discussed. The temperature field in the forming process of welded joints was measured, and tensile and bending tests on welded joints were carried out. The fracture surface of welded joints was observed by scanning electron microscopy (SEM), and crystallinity calculation was taken by X-ray diffraction (XRD). The mechanism of X-type weld profile effects on welded joints properties was analyzed. It was concluded that the mechanical properties of welded joints decrease with the reduced X distance between lines.

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

    PubMed

    Gorban', L N

    1990-01-01

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

  12. Laser welded versus resistance spot welded bone implants: analysis of the thermal increase and strength.

    PubMed

    Fornaini, Carlo; Meleti, Marco; Bonanini, Mauro; Lagori, Giuseppe; Vescovi, Paolo; Merigo, Elisabetta; Nammour, Samir

    2014-01-01

    The first aim of this "ex vivo split mouth" study was to compare the thermal elevation during the welding process of titanium bars to titanium implants inserted in pig jaws by a thermal camera and two thermocouples. The second aim was to compare the strength of the joints by a traction test with a dynamometer. Six pigs' jaws were used and three implants were placed on each side of them for a total of 36 fixtures. Twelve bars were connected to the abutments (each bar on three implants) by using, on one side, laser welding and, on the other, resistance spot welding. Temperature variations were recorded by thermocouples and by thermal camera while the strength of the welded joint was analyzed by a traction test. For increasing temperature, means were 36.83 and 37.06, standard deviations 1.234 and 1.187, and P value 0.5763 (not significant). For traction test, means were 195.5 and 159.4, standard deviations 2.00 and 2.254, and P value 0.0001 (very significant). Laser welding was demonstrated to be able to connect titanium implant abutments without the risk of thermal increase into the bone and with good results in terms of mechanical strength.

  13. Laser Welded versus Resistance Spot Welded Bone Implants: Analysis of the Thermal Increase and Strength

    PubMed Central

    Fornaini, Carlo; Meleti, Marco; Bonanini, Mauro; Lagori, Giuseppe; Vescovi, Paolo; Merigo, Elisabetta; Nammour, Samir

    2014-01-01

    Introduction. The first aim of this “ex vivo split mouth” study was to compare the thermal elevation during the welding process of titanium bars to titanium implants inserted in pig jaws by a thermal camera and two thermocouples. The second aim was to compare the strength of the joints by a traction test with a dynamometer. Materials and Methods. Six pigs' jaws were used and three implants were placed on each side of them for a total of 36 fixtures. Twelve bars were connected to the abutments (each bar on three implants) by using, on one side, laser welding and, on the other, resistance spot welding. Temperature variations were recorded by thermocouples and by thermal camera while the strength of the welded joint was analyzed by a traction test. Results. For increasing temperature, means were 36.83 and 37.06, standard deviations 1.234 and 1.187, and P value 0.5763 (not significant). For traction test, means were 195.5 and 159.4, standard deviations 2.00 and 2.254, and P value 0.0001 (very significant). Conclusion. Laser welding was demonstrated to be able to connect titanium implant abutments without the risk of thermal increase into the bone and with good results in terms of mechanical strength. PMID:25110731

  14. Effects of activating fluxes on the weld penetration and corrosion resistant property of laser welded joint of ferritic stainless steel

    NASA Astrophysics Data System (ADS)

    Wang, Yonghui; Hu, Shengsun; Shen, Junqi

    2015-10-01

    This study was based on the ferritic stainless steel SUS430. Under the parallel welding conditions, the critical penetration power values (CPPV) of 3mm steel plates with different surface-coating activating fluxes were tested. Results showed that, after coating with activating fluxes, such as ZrO2, CaCO3, CaF2 and CaO, the CPPV could reduce 100~250 W, which indicating the increases of the weld penetrations (WP). Nevertheless, the variation range of WP with or without activating fluxes was less than 16.7%. Compared with single-component ones, a multi-component activating flux composed of 50% ZrO2, 12.09% CaCO3, 10.43% CaO, and 27.49% MgO was testified to be much more efficient, the WP of which was about 2.3-fold of that without any activating fluxes. Furthermore, a FeCl3 spot corrosion experiment was carried out with samples cut from weld zone to test the effects of different activating fluxes on the corrosion resistant (CR) property of the laser welded joints. It was found that all kinds of activating fluxes could improve the CR of the welded joints. And, it was interesting to find that the effect of the mixed activating fluxes was inferior to those single-component ones. Among all the activating fluxes, the single-component of CaCO3 seemed to be the best in resisting corrosion. By means of Energy Dispersive Spectrometer (EDS) testing, it was found that the use of activating fluxes could effectively restrain the loss of Cr element of weld zone in the process of laser welding, thus greatly improving the CR of welded joints.

  15. Programmable Positioner For Spot Welding

    NASA Technical Reports Server (NTRS)

    Roden, William A.

    1989-01-01

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

  16. WELDING TORCH

    DOEpatents

    Correy, T.B.

    1961-10-01

    A welding torch into which water and inert gas are piped separately for cooling and for providing a suitable gaseous atmosphere is described. A welding electrode is clamped in the torch by a removable collet sleeve and a removable collet head. Replacement of the sleeve and head with larger or smaller sleeve and head permits a larger or smaller welding electrode to be substituted on the torch. (AEC)

  17. The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading.

    PubMed

    Araque, Oscar; Arzola, Nelson; Hernández, Edgar

    2018-04-12

    This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe.

  18. The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading

    PubMed Central

    Arzola, Nelson; Hernández, Edgar

    2018-01-01

    This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe. PMID:29649117

  19. Effect of oxygen on weld shape and crystallographic orientation of duplex stainless steel weld using advanced A-TIG (AA-TIG) welding method

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

    Zou, Ying, E-mail: yingzou@jwri.osaka-u.ac.jp; Ueji, Rintaro; Fujii, Hidetoshi

    The double-shielded advanced A-TIG (AA-TIG) welding method was adopted in this study for the welding of the SUS329J4L duplex stainless steel with the shielding gases of different oxygen content levels. The oxygen content in the shielding gas was controlled by altering the oxygen content in the outer layer gas, while the inner layer remained pure argon to suppress oxidation on the tungsten electrode. As a result, a deep weld penetration was obtained due to the dissolution of oxygen into the weld metals. Additionally, the microstructure of the weld metal was changed by the dissolution of oxygen. The austenite phase atmore » the ferrite grain boundary followed a Kurdjumov–Sachs (K–S) orientation relationship with the ferrite matrix phase at any oxide content. On the other hand, the orientation relationship between the intragranular austenite phase and the ferrite matrix phase exhibited different patterns under different oxygen content levels. When there was little oxide in the fusion zone, only a limited part of the intragranular austenite phase and the ferrite matrix phase followed the K–S orientation relationship. With the increase of the oxide, the correspondence of the K–S relationship increased and fit very well in the 2.5% O{sub 2} shielded sample. The investigation of this phenomenon was carried out along with the nucleation mechanisms of the intragranular austenite phases. - Highlights: • Weld penetration increased with the increase of the oxygen content. • Average diameter and number density of oxide were changed by the oxygen content. • K-S relationship of Widmanstätten austenite/ferrite wasn’t varied by oxide. • Orientation relationship of intragranular austenite/ferrite was varied by oxide.« less

  20. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1988-01-01

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

  1. Fluid Flow Phenomena during Welding

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

    Zhang, Wei

    2011-01-01

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

  2. Multihole Arc-Welding Orifice

    NASA Technical Reports Server (NTRS)

    Swaim, Benji D.

    1989-01-01

    Modified orifice for variable-polarity plasma-arc welding directs welding plume so it creates clean, even welds on both Inconel(R) and aluminum alloys. Includes eight holes to relieve back pressure in plasma. Quality of welds on ferrous and nonferrous alloys improved as result.

  3. Microstructure and Mechanical Properties of Dissimilar Joints of Al-Mg2Si and 5052 Aluminum Alloy by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Huang, B. W.; Qin, Q. D.; Zhang, D. H.; Wu, Y. J.; Su, X. D.

    2018-03-01

    Al-Mg2Si alloy and 5052 Al alloy were welded successfully by friction stir welding (FSW) in this study. The results show that the alloy consists of three distinct zones after FSW: the base material zone (BMZ), the transitional zone, and the weld nugget (WN). The morphologies of the primary Mg2Si phases are identified as coarse equiaxed crystals for Al-Mg2Si alloys in the BMZ. The WN is a mixture of rich Al-Mg2Si and rich 5052 alloy, and a banded structure is formed in the zone. Interestingly, in the WN, the equiaxed crystals changed to polygonal particles with substantially reduced sizes in the rich Al-Mg2Si zone. However, in addition to the white rich Mg phase appearing in the rich 5052 zone near the interface, the 5052 alloy does not show obvious changes. The hardness gradually increases from the BMZ of the 5052 to the welded joint to the Al-Mg2Si BMZ. In addition, the ultimate tensile strength (UTS) of the welded joint is higher than that of the base material of the Al-Mg2Si, whereas it is lower than that of the 5052 base alloy. The results of the elongation are similar to the UTS results. The fracture mechanism is also investigated.

  4. Narrow groove welding gas diffuser assembly and welding torch

    DOEpatents

    Rooney, Stephen J.

    2001-01-01

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

  5. Welding Experiments of Aluminum Alloy by Space GHTA Welding at ISS Orbital Pressure

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

    As a feasible welding method in space, the authors previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. However, space GHTA welding with a high-frequency device for arc start may cause electromagnetic noise problems for the computer equipment placed on the ISS (International Space Station). Therefore, in this report, welding experiments of space GHTA welding using aluminum alloy with a high-voltage DC device for arc start were carried out at the ISS orbital pressure, 10-5 Pa. It is clear from the experiments using a high-voltage DC device in a high-vacuum condition, that there is a shifting phenomenon in which the spark discharge shifts to either a glow discharge or an arc discharge when starting the arc. Welding projects in space need an arc discharge, so we investigated the effects of welding parameters on the arc formation ratio. As a result, space GHTA welding with a high-voltage DC device can be used for arc start when welding at the ISS orbital pressure.

  6. Improving fatigue performance of rail thermite welds

    NASA Astrophysics Data System (ADS)

    Jezzini-Aouad, M.; Flahaut, P.; Hariri, S.; Winiar, L.

    2010-06-01

    Rail transport development offers economic and ecological interests. Nevertheless, it requires heavy investments in rolling material and infrastructure. To be competitive, this transportation means must rely on safe and reliable infrastructure, which requires optimization of all implemented techniques and structure. Rail thermite (or aluminothermic) welding is widely used within the railway industry for in-track welding during re-rail and defect replacement. The process provides numerous advantages against other welding technology commonly used. Obviously, future demands on train traffic are heavier axle loads, higher train speeds and increased traffic density. Thus, a new enhanced weld should be developed to prevent accidents due to fracture of welds and to lower maintenance costs. In order to improve such assembly process, a detailed metallurgical study coupled to a thermomechanical modelling of the phenomena involved in the thermite welding process is carried out. Obtained data enables us to develop a new improved thermite weld (type A). This joint is made by modifying the routinely specified procedure (type B) used in a railway rail by a standard gap alumino-thermic weld. Joints of type A and B are tested and compared. Based on experimental temperature measurements, a finite element analysis is used to calculate the thermal residual stresses induced. In the vicinity of the weld, the residual stress patterns depend on the thermal conditions during welding as it also shown by litterature [1, 2]. In parallel, X-Ray diffraction has been used to map the residual stress field that is generated in welded rail of types A and B. Their effect on fatigue crack growth in rail welds is studied. An experimental study based on fatigue tests of rails welded by conventional and improved processes adjudicates on the new advances and results will be shown.

  7. 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.

  8. Alternating-Polarity Arc Welding

    NASA Technical Reports Server (NTRS)

    Schwinghamer, R. J.

    1987-01-01

    Brief reversing polarity of welding current greatly improves quality of welds. NASA technical memorandum recounts progress in art of variable-polarity plasma-arc (VPPA) welding, with emphasis on welding of aluminum-alloy tanks. VPPA welders offer important advantages over conventional single-polarity gas/tungsten arc welders.

  9. Fast, Nonspattering Inert-Gas Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.

    1991-01-01

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

  10. Development of Welding Fumes Health Index (WFHI) for Welding Workplace's Safety and Health Assessment.

    PubMed

    Hariri, Azian; Paiman, Nuur Azreen; Leman, Abdul Mutalib; Md Yusof, Mohammad Zainal

    2014-08-01

    This study aimed to develop an index that can rank welding workplace that associate well with possible health risk of welders. Welding Fumes Health Index (WFHI) were developed based on data from case studies conducted in Plant 1 and Plant 2. Personal sampling of welding fumes to assess the concentration of metal constituents along with series of lung function tests was conducted. Fifteen metal constituents were investigated in each case study. Index values were derived from aggregation analysis of metal constituent concentration while significant lung functions were recognized through statistical analysis in each plant. The results showed none of the metal constituent concentration was exceeding the permissible exposure limit (PEL) for all plants. However, statistical analysis showed significant mean differences of lung functions between welders and non-welders. The index was then applied to one of the welding industry (Plant 3) for verification purpose. The developed index showed its promising ability to rank welding workplace, according to the multiple constituent concentrations of welding fumes that associates well with lung functions of the investigated welders. There was possibility that some of the metal constituents were below the detection limit leading to '0' value of sub index, thus the multiplicative form of aggregation model was not suitable for analysis. On the other hand, maximum or minimum operator forms suffer from compensation issues and were not considered in this study.

  11. Microstructural and mechanical characterization of CO{sub 2} laser and gas tungsten arc welds of an Al-Li-Cu alloy 2195

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

    Hou, K.H.; Baeslack, W.A. III; Szabo, A.

    1994-12-31

    Lithium-containing aluminum alloys offer an attractive combination of low density and high strength and stiffness and have been the focus of vigorous research for their promising aerospace applications. To achieve the full potential advantages in using these alloys, the integrity of welded joints, both n the fusion zone and the heat-affected zone, must be ensured. In the present study, Weldalite{sup TM} 049 (designated as alloy 2195) with nominal composition of Al-1.0Li-4.0Cu-0.4Mg0.4Ag-0.14Zr (wt%) was welded autogenously using the gas tungsten-arc (GTA) and CO{sub 2} laser beam (LB) welding processes. The average ultimate tensile strengths for as-welded, 160{degrees}C/16 h-aged, and 190{degrees}C/16 h-agedmore » GTA welds were 296.4 MPa, 304.6 MPa, and 336.8 MPa, and corresponded to joint efficiencies of 61.4%, 48.1% and 56.0%, respectively. Porosity was found occasionally in the laser welds and slightly affected the performance of the aluminum weldments. For laser welds, average ultimate tensile strengths and corresponding joint efficiencies for a-welded, 160{degrees}C/16 h-aged, and 190{degrees}C/16 h-aged weldments were 293.2 MPa (60.8%) 305.9 MPa (48.3%), and 331.0 MPa (55.0%), respectively. Scanning electron fractography revealed that failure of the GTA and LB tensile specimens occurred either within the weld metal or along the fusion boundary. The latter was related to the existence of an equiaxed band along the fusion boundary.« less

  12. Influence of the arc plasma parameters on the weld pool profile in TIG welding

    NASA Astrophysics Data System (ADS)

    Toropchin, A.; Frolov, V.; Pipa, A. V.; Kozakov, R.; Uhrlandt, D.

    2014-11-01

    Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

  13. Study of metal transfer in CO2 laser+GMAW-P hybrid welding using argon-helium mixtures

    NASA Astrophysics Data System (ADS)

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

    2014-03-01

    The metal transfer in CO2 Laser+GMAW-P hybrid welding by using argon-helium mixtures was investigated and the effect of the laser on the mental transfer is discussed. A 650 nm laser, in conjunction with the shadow graph technique, is used to observe the metal transfer process. In order to analyze the heat input to the droplet and the droplet internal current line distribution. An optical emission spectroscopy system was employed to estimate default parameter and optimized plasma temperature, electron number densities distribution. The results indicate that the CO2 plasma plume have a significant impact to the electrode melting, droplet formation, detachment, impingement onto the workpiece and weld morphology. Since the current distribution direction flow changes to the keyhole, to obtain a metal transfer mode of one droplet per pulse, the welding parameters should be adjusted to a higher pulse time (TP) and a lower voltage.

  14. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1989-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Luo, Masiyang; Shin, Yung C.

    2015-01-01

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

  16. Coil Welding Aid

    NASA Technical Reports Server (NTRS)

    Wiesenbach, W. T.; Clark, M. C.

    1983-01-01

    Positioner holds coil inside cylinder during tack welding. Welding aid spaces turns of coil inside cylinder and applies contact pressure while coil is tack-welded to cylinder. Device facilitates fabrication of heat exchangers and other structures by eliminating hand-positioning and clamping of individual coil turns.

  17. Feasibility study of the welding of SiC

    NASA Technical Reports Server (NTRS)

    Moore, T. J.

    1985-01-01

    In a brief study of the feasibility of welding sintered alpha-SiC, solid-state welding and brazing were investigated. Joint quality was determined solely by microstructural examination. Hot-pressure welding was shown to be feasible at 1950 C. Diffusion welding and brazing were also successful under hot isostatic pressure at 1950 C when boride, carbide, and silicide interlayers were used. Furnace brazing was accomplished at 1750 C when a TiSi2 interlayer was introduced.

  18. Grinding Parts For Automatic Welding

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.; Hoult, William S.

    1989-01-01

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

  19. VPPA weld model evaluation

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

  20. Welding arc plasma physics

    NASA Technical Reports Server (NTRS)

    Cain, Bruce L.

    1990-01-01

    The problems of weld quality control and weld process dependability continue to be relevant issues in modern metal welding technology. These become especially important for NASA missions which may require the assembly or repair of larger orbiting platforms using automatic welding techniques. To extend present welding technologies for such applications, NASA/MSFC's Materials and Processes Lab is developing physical models of the arc welding process with the goal of providing both a basis for improved design of weld control systems, and a better understanding of how arc welding variables influence final weld properties. The physics of the plasma arc discharge is reasonably well established in terms of transport processes occurring in the arc column itself, although recourse to sophisticated numerical treatments is normally required to obtain quantitative results. Unfortunately the rigor of these numerical computations often obscures the physics of the underlying model due to its inherent complexity. In contrast, this work has focused on a relatively simple physical model of the arc discharge to describe the gross features observed in welding arcs. Emphasis was placed of deriving analytic expressions for the voltage along the arc axis as a function of known or measurable arc parameters. The model retains the essential physics for a straight polarity, diffusion dominated free burning arc in argon, with major simplifications of collisionless sheaths and simple energy balances at the electrodes.

  1. Thermo-Mechanical Analysis of a Single-Pass Weld Overlay and Girth Welding in Lined Pipe

    NASA Astrophysics Data System (ADS)

    Obeid, Obeid; Alfano, Giulio; Bahai, Hamid

    2017-08-01

    The paper presents a nonlinear heat-transfer and mechanical finite-element (FE) analyses of a two-pass welding process of two segments of lined pipe made of a SUS304 stainless steel liner and a C-Mn steel pipe. The two passes consist of the single-pass overlay welding (inner lap weld) of the liner with the C-Mn steel pipe for each segment and the single-pass girth welding (outer butt weld) of the two segments. A distributed power density of the moving welding torch and a nonlinear heat-transfer coefficient accounting for both radiation and convection have been used in the analysis and implemented in user subroutines for the FE code ABAQUS. The modeling procedure has been validated against previously published experimental results for stainless steel and carbon steel welding separately. The model has been then used to determine the isotherms induced by the weld overlay and the girth welding and to clarify their influence on the transient temperature field and residual stress in the lined pipe. Furthermore, the influence of the cooling time between weld overlay and girth welding and of the welding speed have been examined thermally and mechanically as they are key factors that can affect the quality of lined pipe welding.

  2. 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.

  3. Sensing the gas metal arc welding process

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  4. Sensing the gas metal arc welding process

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

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

    1992-01-01

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

  5. Sensing the gas metal arc welding process

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

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

    1992-10-01

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

  6. Dye-enhanced laser welding for skin closure.

    PubMed

    DeCoste, S D; Farinelli, W; Flotte, T; Anderson, R R

    1992-01-01

    The use of a laser to weld tissue in combination with a topical photosensitizing dye permits selective delivery of energy to the target tissue. A combination of indocyanine green (IG), absorption peak 780 nm, and the near-infrared (IR) alexandrite laser was studied with albino guinea pig skin. IG was shown to bind to the outer 25 microns of guinea pig dermis and appeared to be bound to collagen. The optical transmittance of full-thickness guinea pig skin in the near IR was 40% indicating that the alexandrite laser should provide adequate tissue penetration. Laser "welding" of skin in vivo was achieved at various concentrations of IG from 0.03 to 3 mg/cc using the alexandrite at 780 nm, 250-microseconds pulse duration, 8 Hz, and a 4-mm spot size. A spectrum of welds was obtained from 1- to 20-W/cm2 average irradiance. Weak welds occurred with no thermal damage obtained at lower irradiances: stronger welds with thermal damage confined to the weld site occurred at higher irradiances. At still higher irradiances, local vaporization occurred with failure to "weld." Thus, there was an optimal range of irradiances for "welding," which varied inversely with dye concentration. Histology confirmed the thermal damage results that were evident clinically. IG dye-enhanced laser welding is possible in skin and with further optimization may have practical application.

  7. 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

  8. Understanding thermally activated plastic deformation behavior of Zircaloy-4

    NASA Astrophysics Data System (ADS)

    Kumar, N.; Alomari, A.; Murty, K. L.

    2018-06-01

    Understanding micromechanics of plastic deformation of existing materials is essential for improving their properties further and/or developing advanced materials for much more severe load bearing applications. The objective of the present work was to understand micromechanics of plastic deformation of Zircaloy-4, a zirconium-based alloy used as fuel cladding and channel (in BWRs) material in nuclear reactors. The Zircaloy-4 in recrystallized (at 973 K for 4 h) condition was subjected to uniaxial tensile testing at a constant cross-head velocity at temperatures in the range 293 K-1073 K and repeated stress relaxation tests at 293 K, 573 K, and 773 K. The minimum in the total elongation was indicative of dynamic strain aging phenomenon in this alloy in the intermediate temperature regime. The yield stress of the alloy was separated into effective and athermal components and the transition from thermally activated dislocation glide to athermal regime took place at around 673 K with the athermal stress estimated to be 115 MPa. The activation volume was found to be in the range of 40 b3 to 160 b3. The activation volume values and the data analyses using the solid-solution models in literature indicated dislocation-solute interaction to be a potential deformation mechanism in thermally activated regime. The activation energy calculated at 573 K was very close to that found for diffusivity of oxygen in α-Zr that was suggestive of dislocations-oxygen interaction during plastic deformation. This type of information may be helpful in alloy design in selecting different elements to control the deformation behavior of the material and impart desired mechanical properties in those materials for specific applications.

  9. Preliminary investigation of inertia friction welding B2 aluminides

    NASA Technical Reports Server (NTRS)

    Whittenberger, J. Daniel; Moore, Thomas J.; Kuruzar, Daniel L.

    1987-01-01

    An attempt is made to achieve inertia friction-welding in FeAl and NiAl samples, taking into account their intermetallics' compositions, extrusion parameters, and microstructural data. The energy required for the weld is stored in a rotating flywheel mass attached to one of the two pieces to be joined; when enough energy is introduced, the flywheel is disconnected and an axial load is applied which forces the spinning piece against the stationary one, converting the energy into heat by means of friction. Due to the inherent brittleness of the aluminides, a step-load program was used in which an initial, low-pressure heat buildup increased the work pieces' ductility.

  10. Pulsed Magnetic Welding for Advanced Core and Cladding Steel

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

    Cao, Guoping; Yang, Yong

    2013-12-19

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

  11. Dual wire weld feed proportioner

    NASA Technical Reports Server (NTRS)

    Nugent, R. E.

    1968-01-01

    Dual feed mechanism enables proportioning of two different weld feed wires during automated TIG welding to produce a weld alloy deposit of the desired composition. The wires are fed into the weld simultaneously. The relative feed rates of the wires and the wire diameters determine the weld deposit composition.

  12. Weld defect identification in friction stir welding using power spectral density

    NASA Astrophysics Data System (ADS)

    Das, Bipul; Pal, Sukhomay; Bag, Swarup

    2018-04-01

    Power spectral density estimates are powerful in extraction of useful information retained in signal. In the current research work classical periodogram and Welch periodogram algorithms are used for the estimation of power spectral density for vertical force signal and transverse force signal acquired during friction stir welding process. The estimated spectral densities reveal notable insight in identification of defects in friction stir welded samples. It was observed that higher spectral density against each process signals is a key indication in identifying the presence of possible internal defects in the welded samples. The developed methodology can offer preliminary information regarding presence of internal defects in friction stir welded samples can be best accepted as first level of safeguard in monitoring the friction stir welding process.

  13. Instructional Guidelines. Welding.

    ERIC Educational Resources Information Center

    Fordyce, H. L.; Doshier, Dale

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

  14. Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints

    NASA Astrophysics Data System (ADS)

    Srinivasa Rao, P.; Ramachandran, Pragash; Jebaraj, S.

    2016-02-01

    During the process of Gas Metal Arc (GMAW) welding, the weld joints mechanical properties are influenced by the welding parameters such as welding current and arc voltage. These parameters directly will influence the quality of the weld in terms of mechanical properties. Even small variation in any of the cited parameters may have an important effect on depth of penetration and on joint strength. In this study, S45C Constructional Steel is taken as the base metal to be tested using the parameters wire feed rate, voltage and type of shielding gas. Physical properties considered in the present study are tensile strength and hardness. The testing of weld specimen is carried out as per ASTM Standards. Mathematical models to predict the tensile strength and depth of penetration of weld joint have been developed by regression analysis using the experimental results.

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

    NASA Astrophysics Data System (ADS)

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

    2018-05-01

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

  16. Fibre Laser Welding of HY-80 Steel: Procedure Development and Testing

    DTIC Science & Technology

    2010-09-01

    2 Welding The material used in this study was quenched and tempered martensitic HY80 steel which conforms to MIL-S-1621 [2]. The testing...Journal, 1977. [4] AWS, D1.6 in Structural Welding Code Stainless Steel . 2007, American Welding Society: Miami Florida. [5] DefStan, 02-770 Part 2...Canada Fibre Laser Welding of HY-80 Steel Proceedure Development and Testing Christopher Bayley DLP Neil Aucoin DLP Xinjin Cao NRC IAR AMTC Technical

  17. 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.

  18. Growth and microstructure formation of isothermally-solidified Zircaloy-4 joints brazed by a Zr-Ti-Cu-Ni amorphous alloy ribbon

    NASA Astrophysics Data System (ADS)

    Kim, K. H.; Lim, C. H.; Lee, J. G.; Lee, M. K.; Rhee, C. K.

    2013-10-01

    The microstructure and growth characteristics of Zircaloy-4 joints brazed by a Zr48Ti16Cu17Ni19 (at.%) amorphous filler metal have been investigated with regard to the controlled isothermal solidification and intermetallic formation. Two typical joints were produced depending on the isothermal brazing temperature: (1) a dendritic growth structure including bulky segregation in the central zone (at 850 °C), and (2) a homogeneous dendritic structure throughout the joint without segregation (at 890 °C). The primary α-Zr phase was solidified isothermally, nucleating to grow into a joint with a cellular or dendritic structure. Also, the continuous Zr2Ni and particulate Zr2Cu phases were formed in the segregated center zone and at the intercellular region, respectively, owing to the different solubility and atomic mobility of the solute elements (Ti, Cu, and Ni) in the α-Zr matrix. A disappearance of the central Zr2Ni phase was also rate-controlled by the outward diffusion of the Cu and Ni elements. When the detrimental Zr2Ni intermetallic phase was eliminated by a complete isothermal solidification at 890 °C, the strengths of the joints were high enough to cause yielding and fracture in the base metal, exceeding those of the bulk Zircaloy-4, at room temperature as well as at elevated temperatures (up to 400 °C).

  19. 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.

  20. Welding Course Curriculum.

    ERIC Educational Resources Information Center

    Genits, Joseph C.

    This guide is intended for use in helping students gain a fundamental background on the major aspects of the welding trade. The course emphasis is on mastery of the manipulative skills necessary to develop successful welding techniques and on acquisition of an understanding of the specialized tools and equipment used in welding. The first part…

  1. On post-weld heat treatment cracking in tig welded superalloy ATI 718Plus

    NASA Astrophysics Data System (ADS)

    Asala, G.; Ojo, O. A.

    The susceptibility of heat affected zone (HAZ) to cracking in Tungsten Inert Gas (TIG) welded Allvac 718Plus superalloy during post-weld heat treatment (PWHT) was studied. Contrary to the previously reported case of low heat input electron beam welded Allvac 718Plus, where HAZ cracking occurred during PWHT, the TIG welded alloy is crack-free after PWHT, notwithstanding the presence of similar micro-constituents that caused cracking in the low input weld. Accordingly, the formation of brittle HAZ intergranular micro-constituents may not be a sufficient factor to determine cracking propensity, the extent of heat input during welding may be another major factor that influences HAZ cracking during PWHT of the aerospace superalloy Allvac 718Plus.

  2. 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.

  3. 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.

  4. Weld radiograph enigmas

    NASA Technical Reports Server (NTRS)

    Jemian, Wartan A.

    1986-01-01

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

  5. Laser weld jig. [Patent application

    DOEpatents

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

    1980-12-05

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

  6. Optical sensor for real-time weld defect detection

    NASA Astrophysics Data System (ADS)

    Ancona, Antonio; Maggipinto, Tommaso; Spagnolo, Vincenzo; Ferrara, Michele; Lugara, Pietro M.

    2002-04-01

    In this work we present an innovative optical sensor for on- line and non-intrusive welding process monitoring. It is based on the spectroscopic analysis of the optical VIS emission of the welding plasma plume generated in the laser- metal interaction zone. Plasma electron temperature has been measured for different chemical species composing the plume. Temperature signal evolution has been recorded and analyzed during several CO2-laser welding processes, under variable operating conditions. We have developed a suitable software able to real time detect a wide range of weld defects like crater formation, lack of fusion, excessive penetration, seam oxidation. The same spectroscopic approach has been applied for electric arc welding process monitoring. We assembled our optical sensor in a torch for manual Gas Tungsten Arc Welding procedures and tested the prototype in a manufacturing industry production line. Even in this case we found a clear correlation between the signal behavior and the welded joint quality.

  7. Numerical modeling of keyhole dynamics in laser welding

    NASA Astrophysics Data System (ADS)

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

    2003-03-01

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

  8. Design Considerations for Remotely Operated Welding in Space: Task Definition and Visual Weld Monitoring Experiment

    DTIC Science & Technology

    1993-05-01

    processes [48] ................ 91 Figure 4.14 Energy effectiveness comparison between EBW, GMAW , and PAW [48...1 10 Figure 5.2 The spectrum of control modes [76] ................. 112 Figure 5.3 Levels of control for GMAW [26...vehicular activity FTS Flight Telerobotic Servicer GMAW Gas metal arc welding GTAW Gas tungsten arc welding LEO Low-earth orbit NDT Non-destructive test

  9. Welding, Bonding and Fastening, 1984

    NASA Technical Reports Server (NTRS)

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

    1985-01-01

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

  10. The characteristics of welded joints for air conditioning application

    NASA Astrophysics Data System (ADS)

    Weglowski, M. St.; Weglowska, A.; Miara, D.; Kwiecinski, K.; Błacha, S.; Dworak, J.; Rykala, J.; Pikula, J.; Ziobro, G.; Szafron, A.; Zimierska-Nowak, P.; Richert, M.; Noga, P.

    2017-10-01

    In the paper the results of metallographic examination of welded joints for air-conditioning elements are presented. The European directives 2006/40/EC on the greenhouse gasses elimination demand to stop using traditional refrigerant and to change it to R744 (CO2) medium in air conditioning installation. The R744 refrigerant is environmental friendly medium if compared with standard solution such as R12, R134a or R1234yf and safer for passengers than R1234yf. The non-standard thermodynamic parameters of the R744 which translate into high pressure and high temperature require specific materials to develop the shape and to specify the technology of manufacturing for the particular elements of the conduits and moreover the technologies of joining for the whole structure, which would meet the exploitation requirements of the new air-conditioning system. To produce the test welded joints of stainless steels four different joining technologies were applied: laser welding, plasma welding, electron beam welding as well as high speed rotation welding. This paper describes the influence of the selected welding process on the macrostructure and microstructure of welded joints of AISI 304 and AISI 316L steels. The results indicated that plasma welding laser welding and electron beam welding technologies guaranty the proper quality of welded joints and can be used for the air conditioning application in automotive industry. However, high speed rotation welding not guarantee the good quality of welded joints and cannot be used for above application.

  11. Welding Experiments of Aluminum Alloy by Space GHTA Welding in the ISS Orbital Pressure

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

    As a feasible welding method in space, the authors have previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. The space GHTA welding with high frequency power source for the arc starting may cause the electro-magnetic noise problems of computer equipments placed on the ISS. Therefore, in this paper the welding experiments of aluminum alloy by the space GHTA welding with DC high voltage power source for the arc starting was carried out in the ISS orbital pressure 10-5Pa. It is made clear that there is the shifting phenomenon in which the spark discharge changes to the glow or arc discharge at starting phenomenon of the space GHTA welding in high vacuum condition, and the features of those starting phenomenon are demonstrated. And the space GHTA welding with DC high voltage power source can be used for welding in the ISS orbital pressure.

  12. Laser beam welding of Waspaloy: Characterization and corrosion behavior evaluation

    NASA Astrophysics Data System (ADS)

    Shoja Razavi, Reza

    2016-08-01

    In this work, a study on Nd:YAG laser welding of Waspaloy sheets has been made. Microstructures, phase changes and hardness of the laser joint were investigated using optical microscopy, scanning electron microscopy (SEM), field emission scanning electron microscopy (FESEM), energy dispersive spectroscopy (EDS), X-ray diffraction analysis (XRD) and vickers microhardness (HV0.3). Corrosion behavior of the weldment at low temperature in 3.5%wt NaCl solution at room temperature was also investigated using open circuit potential and cyclic potentiodynamic polarization tests. Hot corrosion studies were conducted on samples in the molten salt environment (Na2SO4-60%V2O5) at 900 °C for 50 h. Results indicated that the microstructure of weld zone was mainly dendritic grown epitaxially in the direction perpendicular to the weld boundary and heat transfer. Moreover, the Ti-Mo carbide particles were observed in the structure of the weld zone and base metal. The average size of carbides formed in the base metal (2.97±0.5 μm) was larger than that of the weld zone (0.95±0.2 μm). XRD patterns of the weld zone and base metal showed that the laser welding did not alter the phase structure of the weld zone, being in γ-Ni(Cr) single phase. Microhardness profile showed that the hardness values of the weld zone (210-261 HV) were lower than that of the base metal (323-330 HV). Electrochemical and hot corrosion tests indicated that the corrosion resistance of the weld metal was greater than the base metal in both room and high temperatures.

  13. 30 CFR 250.110 - What must I include in my welding plan?

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 2 2010-07-01 2010-07-01 false What must I include in my welding plan? 250.110... must I include in my welding plan? You must include all of the following in the Welding Plan that you... qualified personnel weld; (c) Practices and procedures for safe welding that address: (1) Welding in...

  14. Aviation Maintenance Technology. Airframe. A204. Aircraft Welding. Instructor Material.

    ERIC Educational Resources Information Center

    Oklahoma State Board of Vocational and Technical Education, Stillwater. Curriculum and Instructional Materials Center.

    This teacher's guide is designed to aid teachers in leading students through a module on aircraft welding on airframes. The module contains four units that cover the following topics: (1) gas welding and cutting; (2) brazing and soldering; (3) shielded metal arc welding; and (4) gas tungsten arc welding. Each unit follows a standardized format…

  15. Modern Methods of Rail Welding

    NASA Astrophysics Data System (ADS)

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

    2017-10-01

    Existing methods of rail welding, which are enable to get continuous welded rail track, are observed in this article. Analysis of existing welding methods allows considering an issue of continuous rail track in detail. Metallurgical and welding technologies of rail welding and also process technologies reducing aftereffects of temperature exposure are important factors determining the quality and reliability of the continuous rail track. Analysis of the existing methods of rail welding enable to find the research line for solving this problem.

  16. Optimization of process parameters in welding of dissimilar steels using robot TIG welding

    NASA Astrophysics Data System (ADS)

    Navaneeswar Reddy, G.; VenkataRamana, M.

    2018-03-01

    Robot TIG welding is a modern technique used for joining two work pieces with high precision. Design of Experiments is used to conduct experiments by varying weld parameters like current, wire feed and travelling speed. The welding parameters play important role in joining of dissimilar stainless steel SS 304L and SS430. In this work, influences of welding parameter on Robot TIG Welded specimens are investigated using Response Surface Methodology. The Micro Vickers hardness tests of the weldments are measured. The process parameters are optimized to maximize the hardness of the weldments.

  17. GTA welding and heat treating of high purity aluminum. [-452/sup 0/F

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

    Voigt, R.C.; Loper, C.R. Jr.

    1979-01-01

    Gas tungsten arc welding is a suitable way to join high purity aluminum with only small increases in the electrical resistivity at 4.2 K (i.e., -269 C or -452 F) if proper welding procedures are used. High purity aluminum weld zone properties, useful for the design of cryogenic superconducting devices, are now available. The additional electrical resistivity caused by welding is independent of original base metal resistivity and can be decreased significantly by heat treatments as low as 260 C (500 F) for 30 minutes. Tungsten contamination caused from welding is small (on the order of 0.2 ppM) but itmore » is a significant contribution to weld zone resistivity. This suggests that other welding techniques such as laser welding or electron beam welding may be successful alternatives. Additional GTA welding tests for various welding conditions and welding procedures would lead to a greater understanding of the tungsten emission levels during welding. Perturbations during GTA welding such as electrode spitting or electrode contact with the weld metal must be eliminated to successfully weld high purity aluminum. Improper welding techniques causing arc instabilities, for any reason, cause highly resistive welds that must be properly repaired.« less

  18. Metallography of Battery Resistance Spot Welds

    NASA Technical Reports Server (NTRS)

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

    2015-01-01

    Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically

  19. 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.

  20. Acoustic-Emission Weld-Penetration Monitor

    NASA Technical Reports Server (NTRS)

    Maram, J.; Collins, J.

    1986-01-01

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

  1. Fundamental metallurgical aspects of axial splitting in zircaloy cladding

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

    Chung, H. M.

    Fundamental metallurgical aspects of axial splitting in irradiated Zircaloy cladding have been investigated by microstructural characterization and analytical modeling, with emphasis on application of the results to understand high-burnup fuel failure under RIA situations. Optical microscopy, SEM, and TEM were conducted on BWR and PWR fuel cladding tubes that were irradiated to fluence levels of 3.3 x 10{sup 21} n cm{sup {minus}2} to 5.9 x 10{sup 21} n cm{sup {minus}2} (E > 1 MeV) and tested in hot cell at 292--325 C in Ar. The morphology, distribution, and habit planes of macroscopic and microscopic hydrides in as-irradiated and posttest claddingmore » were determined by stereo-TEM. The type and magnitude of the residual stress produced in association with oxide-layer growth and dense hydride precipitation, and several synergistic factors that strongly influence axial-splitting behavior were analyzed. The results of the microstructural characterization and stress analyses were then correlated with axial-splitting behavior of high-burnup PWR cladding reported for simulated-RIA conditions. The effects of key test procedures and their implications for the interpretation of RIA test results are discussed.« less

  2. Evaluating the SCC resistance of underwater welds in sodium tetrathionate

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

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

    1997-12-01

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

  3. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, Donald W.; Johnson, John A.; Smartt, Herschel B.

    1987-01-01

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  4. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1985-09-04

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  5. Control of arc length during gas metal arc welding

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

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

    1994-12-31

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

  6. Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

    DOE PAGES

    Emery, John M.; Field, Richard V.; Foulk, James W.; ...

    2015-05-26

    Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not bemore » efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.« less

  7. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers

    PubMed Central

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-01-01

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2’-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m3 increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation. PMID:27641436

  8. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers.

    PubMed

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-09-19

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2'-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m(3) increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation.

  9. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers

    NASA Astrophysics Data System (ADS)

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-09-01

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2’-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m3 increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation.

  10. Performance evaluation and post-irradiation examination of a novel LWR fuel composed of U0.17ZrH1.6 fuel pellets bonded to Zircaloy-2 cladding by lead bismuth eutectic

    NASA Astrophysics Data System (ADS)

    Balooch, Mehdi; Olander, Donald R.; Terrani, Kurt A.; Hosemann, Peter; Casella, Andrew M.; Senor, David J.; Buck, Edgar C.

    2017-04-01

    A novel light water reactor fuel has been designed and fabricated at the University of California, Berkeley; irradiated at the Massachusetts Institute of Technology Reactor; and examined within the Radiochemical Processing Laboratory at the Pacific Northwest National Laboratory. This fuel consists of U0.17ZrH1.6 fuel pellets core-drilled from TRIGA reactor fuel elements that are clad in Zircaloy-2 and bonded with lead-bismuth eutectic. The performance evaluation and post irradiation examination of this fuel are presented here.

  11. Infrared Thermography For Welding

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2017-01-01

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

  13. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1987-12-15

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder is disclosed. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws. 5 figs.

  14. Tailor-welded blanks and their production

    NASA Astrophysics Data System (ADS)

    Yan, Qi

    2005-01-01

    Tailor welded blanks had been widely used in the automobile industry. A tailor welded blank consists of several flat sheets that were laser welded together before stamping. A combination of different materials, thickness, and coatings could be welded together to form a blank for stamping car body panels. As for the material for automobile industry, this technology was one of the development trend for automobile industry because of its weight reduction, safety improvement and economical use of materials. In this paper, the characters and production of tailor welded blanks in the market were discussed in detail. There had two major methods to produce tailor welded blanks. Laser welding would replace mesh seam welding for the production of tailor welded blanks in the future. The requirements on the edge preparation of unwelded blanks for tailor welded blanks were higher than the other steel processing technology. In order to produce the laser welded blank, there had the other process before the laser welding in the factory. In the world, there had three kinds of patterns for the large volume production of tailor welded blanks. In China, steel factory played the important role in the promotion of the application of tailor welded blanks. The competition for the supply of tailor welded blanks to the automobile industry would become fierce in the near future. As a result, the demand for the quality control on the production of tailor welded blanks would be the first priority concern for the factory.

  15. 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

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

    NASA Astrophysics Data System (ADS)

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

    2010-11-01

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

  17. 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.

  18. 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.

  19. Proposed GTA welding specification and acceptance criteria for the MC4163

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

    Kwiatkowski, J.J.

    1991-04-12

    This specification documents the gas tungsten arc (GTA) welding process and production weld acceptance criteria requirements for the MC4163. This document is written specifically to apply to the welds on the MC4163 and is not to be used as a general gas tungsten arc welding specification. All sections of this specification must be complied with unless specifically exempted in writing. There are a total of five welds with three different joint designs required to fabricate the MC4163. In the order of fabrication they are (1) initiator closure disc, (2) nozzle to case girth welds, two and, (3) nozzle closure discmore » welds, two. This specification will only address the nozzle to case girth welds and the nozzle closure disc welds.« less

  20. U-Groove Aluminum Weld Strength Improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1997-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. One is the source of peaking in which the extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe angular distortion that induces bending under uniaxial loading. The other is the filler strain hardening decreasing with increasing filler pass sequences, producing the weakest welds on the last weld pass side. Both phenomena are governed by weld pass sequences. Many industrial welding schedules unknowingly compound these effects, which reduce the weld strength. A depeaking index model was developed to select filler pass thickness, pass numbers, and sequences to improve depeaking in the welding process. The result was to select the number and sequence of weld passes to reverse the peaking angle such as to combine the strongest weld pass side with the peaking induced bending tension component side to provide a more uniform stress and stronger weld under axial tensile loading.

  1. Residual-stress measurement in socket welded joints by neutron diffraction

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

    Hayashi, M.; Ishiwata, M.; Minakawa, N.

    1994-12-31

    Neutron diffraction measurements of lattice strains provide spatial maps of residual stress near welds in ferritic steel socket joints. The highest tensile stresses in the welds are found in axial, radial and hoop direction at the weld root. However, the highest tensile stress in the axial direction is about 110MPa. Balancing compressive stresses are found near the surface of the socket weld fusion zone. Heat treatment at 600 C for 2 hours is sufficient to relieve residual stress in socket welds.

  2. 46 CFR 109.573 - Riveting, welding, and burning operations.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 4 2010-10-01 2010-10-01 false Riveting, welding, and burning operations. 109.573... DRILLING UNITS OPERATIONS Miscellaneous § 109.573 Riveting, welding, and burning operations. Except as..., welding, or burning— (1) In a fuel tank; (2) On the boundary of a fuel tank; (3) On pipelines, heating...

  3. Enhanced diffusion welding

    NASA Technical Reports Server (NTRS)

    Holko, K. H.; Moore, T. J. (Inventor)

    1973-01-01

    Surfaces of unrecrystallized alloys are sanded and polished. This is followed by a two-step welding process by which the strength of the parent metal is retained at the weld joint. The first step forces the surfaces into intimate contact at a temperature where the metal still has good ductility. The second step causes diffusion, recrystallization, and grain growth across the original weld interface.

  4. Mars Atmosphere Effects on Arc Welds: Phase 1

    NASA Technical Reports Server (NTRS)

    Courtright, Z. S.

    2016-01-01

    NASA has been unprecedented in achieving its goals related to space exploration and furthering the understanding of our solar system. In keeping with this trend, NASA's current mission is to land a team of astronauts on Mars and return them safely to Earth. In addition to comprising much of the structure and life support systems that will be brought to Mars for the habitat and vehicle, titanium and aluminum can be found and mined on Mars and may be used when building structures.Where metals are present, there will be a need for welding capabilities. For welds that need to be made quickly and are located far from heavy resistance or solid state welding machinery, there will be a need for basic arc welding. Arc welding has been a major cornerstone of manufacturing throughout the 20th century, and the portability and capability of gas tungsten arc welding (GTAW) will be necessary for repair, manufacturing, and survival on Mars. The two primary concerns for welding on Mars are that the Martian atmosphere contains high levels of carbon dioxide (CO2), and the atmospheric pressure is much lower than it is on Earth. The high levels of CO2 in the Martian atmosphere may dissociate and produce oxygen in the arc and therefore increase the risk of oxidation. For simplification, atmospheric pressure will not be taken into account for this experiment. For survival on Mars during this mission, the life support and water filtration systems must be kept operational at all times. In order to ensure that water filtration systems can be repaired in the event of an emergency, it is very important to have the capability to weld. The Orion capsule and Mars lander must also remain operational throughout the duration of the mission to ensure the safe return of the astronauts on the mission to Mars. A better understanding of welding in a Mars environment is important to ensure that repair welds are possible if the Orion capsule/Mars lander or water filtration system is damaged at any point

  5. Effect of Pulse Parameters on Weld Quality in Pulsed Gas Metal Arc Welding: A Review

    NASA Astrophysics Data System (ADS)

    Pal, Kamal; Pal, Surjya K.

    2011-08-01

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

  6. Sensors control gas metal arc welding

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

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

    1997-04-01

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

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

    DOEpatents

    Heiple, C.R.; Burgardt, P.

    1984-03-13

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

  8. 30 CFR 250.112 - What standards must my welding equipment meet?

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 2 2014-07-01 2014-07-01 false What standards must my welding equipment meet... Performance Standards § 250.112 What standards must my welding equipment meet? Your welding equipment must meet the following requirements: (a) All engine-driven welding equipment must be equipped with spark...

  9. 30 CFR 250.112 - What standards must my welding equipment meet?

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 2 2012-07-01 2012-07-01 false What standards must my welding equipment meet... Performance Standards § 250.112 What standards must my welding equipment meet? Your welding equipment must meet the following requirements: (a) All engine-driven welding equipment must be equipped with spark...

  10. 30 CFR 250.112 - What standards must my welding equipment meet?

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 2 2013-07-01 2013-07-01 false What standards must my welding equipment meet... Performance Standards § 250.112 What standards must my welding equipment meet? Your welding equipment must meet the following requirements: (a) All engine-driven welding equipment must be equipped with spark...

  11. 30 CFR 250.112 - What standards must my welding equipment meet?

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 2 2011-07-01 2011-07-01 false What standards must my welding equipment meet... SHELF General Performance Standards § 250.112 What standards must my welding equipment meet? Your welding equipment must meet the following requirements: (a) All engine-driven welding equipment must be...

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

    NASA Astrophysics Data System (ADS)

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

    2013-10-01

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

  13. 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.

  14. Development of Welding Fumes Health Index (WFHI) for Welding Workplace’s Safety and Health Assessment

    PubMed Central

    HARIRI, Azian; PAIMAN, Nuur Azreen; LEMAN, Abdul Mutalib; MD. YUSOF, Mohammad Zainal

    2014-01-01

    Abstract Background This study aimed to develop an index that can rank welding workplace that associate well with possible health risk of welders. Methods Welding Fumes Health Index (WFHI) were developed based on data from case studies conducted in Plant 1 and Plant 2. Personal sampling of welding fumes to assess the concentration of metal constituents along with series of lung function tests was conducted. Fifteen metal constituents were investigated in each case study. Index values were derived from aggregation analysis of metal constituent concentration while significant lung functions were recognized through statistical analysis in each plant. Results The results showed none of the metal constituent concentration was exceeding the permissible exposure limit (PEL) for all plants. However, statistical analysis showed significant mean differences of lung functions between welders and non-welders. The index was then applied to one of the welding industry (Plant 3) for verification purpose. The developed index showed its promising ability to rank welding workplace, according to the multiple constituent concentrations of welding fumes that associates well with lung functions of the investigated welders. Conclusion There was possibility that some of the metal constituents were below the detection limit leading to ‘0’ value of sub index, thus the multiplicative form of aggregation model was not suitable for analysis. On the other hand, maximum or minimum operator forms suffer from compensation issues and were not considered in this study. PMID:25927034

  15. In situ high temperature oxidation analysis of Zircaloy-4 using acoustic emission coupled with thermogravimetry

    NASA Astrophysics Data System (ADS)

    Omar, Al Haj; Véronique, Peres; Eric, Serris; François, Grosjean; Jean, Kittel; François, Ropital; Michel, Cournil

    2015-06-01

    Zircaloy-4 oxidation behavior at high temperature (900 °C), which can be reached in case of severe accidental situations in nuclear pressurised water reactor, was studied using acoustic emission analysis coupled with thermogravimetry. Two different atmospheres were used to study the oxidation of Zircaloy-4: (a) helium and pure oxygen, (b) helium and oxygen combined with slight addition of air. The experiments with 20% of oxygen confirm the dependence on oxygen anions diffusion in the oxide scale. Under a mixture of oxygen and air in helium, an acceleration of the corrosion was observed due to the detrimental effect of nitrogen. The kinetic rate increased significantly after a kinetic transition (breakaway). This acceleration was accompanied by an acoustic emission activity. Most of the acoustic emission bursts were recorded after the kinetic transition (post-transition) or during the cooling of the sample. The characteristic features of the acoustic emission signals appear to be correlated with the different populations of cracks and their occurrence in the ZrO2 layer or in the α-Zr(O) layer. Acoustic events were recorded during the isothermal dwell time at high temperature under air. They were associated with large cracks in the zirconia porous layer. Acoustic events were also recorded during cooling after oxidation tests both under air or oxygen. For the latter, cracks were observed in the oxygen enriched zirconium metal phase and not in the dense zirconia layer after 5 h of oxidation.

  16. High Temperature Corrosion and Characterization Studies in Flux Cored Arc Welded 2.25Cr-1Mo Power Plant Steel

    NASA Astrophysics Data System (ADS)

    Kumaresh Babu, S. P.; Natarajan, S.

    2010-07-01

    Higher productivity is registered with Flux cored arc welding (FCAW) process in many applications. Further, it combines the characteristics of shielded metal arc welding (SMAW), gas metal arc welding (GMAW), and submerged arc welding (SAW) processes. This article describes the experimental work carried out to evaluate and compare corrosion and its inhibition in SA 387 Gr.22 (2.25Cr-1Mo) steel weldments prepared by FCAW process with four different heat inputs exposed to hydrochloric acid medium at 0.1, 0.5, and 1.0 M concentrations. The parent metal, weld metal, and heat-affected zone are chosen as regions of exposure for the study carried out at 100 °C. Electrochemical polarization techniques such as Tafel line extrapolation (Tafel) and linear polarization resistance (LPR) have been used to measure the corrosion current. The role of hexamine and mixed inhibitor (thiourea + hexamine in 0.5 M HCl), each at 100 ppm concentration is studied in these experiments. Microstructural observation, hardness survey, surface characterization, and morphology using scanning electron microscope (SEM) and x-ray diffraction (XRD) have been made on samples to highlight the nature and extent of film formation. The film is found to contain Fe2Si, FeSi2, FeMn3, Fe7Mo3, Fe3O4, FeO, FeCr, AlO7Fe3SiO3, and KFe4Mn77Si19.

  17. Acute decrease in HDL cholesterol associated with exposure to welding fumes.

    PubMed

    Rice, Mary Berlik; Cavallari, Jenn; Fang, Shona; Christiani, David

    2011-01-01

    To investigate acute changes in circulating lipids after exposure to relatively high levels of particulate matter through welding. Using a repeated measures panel study, lipid levels before and after welding and personal exposures to fine particulate matter (PM2.5) were measured in 36 male welders over 63 exposure and/or control days. There was a trend toward decrease in HDL (-2.3 mg/dL, P = 0.08) 18 hours after welding. This effect became significant (-2.6 mg/dL, P = 0.05) after adjustment for possible confounders. The effect was strongest (-4.3 mg/dL, P = 0.02) among welders who did not weld the day before the study. There were no significant changes in other lipids associated with welding or PM2.5 exposure. Welding exposure was associated with an acute decrease in circulating HDL, which may relate to the inflammatory and proatherosclerotic effects of fine particle exposure.

  18. Acute Decrease in HDL Cholesterol Associated With Exposure to Welding Fumes

    PubMed Central

    Rice, Mary Berlik; Cavallari, Jenn; Fang, Shona; Christiani, David

    2011-01-01

    Objective To investigate acute changes in circulating lipids after exposure to relatively high levels of particulate matter through welding. Methods Using a repeated measures panel study, lipid levels before and after welding and personal exposures to fine particulate matter (PM2.5) were measured in 36 male welders over 63 exposure and/or control days. Results There was a trend toward decrease in HDL (−2.3 mg/dL, P = 0.08) 18 hours after welding. This effect became significant (−2.6 mg/dL, P = 0.05) after adjustment for possible confounders. The effect was strongest (−4.3 mg/dL, P = 0.02) among welders who did not weld the day before the study. There were no significant changes in other lipids associated with welding or PM2.5 exposure. Conclusion Welding exposure was associated with an acute decrease in circulating HDL, which may relate to the inflammatory and proatherosclerotic effects of fine particle exposure. PMID:21187793

  19. Automatic welding of stainless steel tubing

    NASA Technical Reports Server (NTRS)

    Clautice, W. E.

    1978-01-01

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

  20. Laser skin welding using water absorption and heat management

    NASA Astrophysics Data System (ADS)

    Halder, Rabindra K.; Katz, Alvin; Savage, Howard E.; Kartazayev, Vladimir; McCormick, Steven A.; Budansky, Yury; Paul, Misu; Rosen, Richard B.; Alfano, Robert R.

    2005-04-01

    Laser skin welding (LSW) is being pursued for scarless wound healing. We present a new LSW approach using a contact glass slide over the sample and rapid scanning of the laser beam around the area to be welded. This led to dramatic improvement in welding efficacy. A 400 mW beam at 1455 nm with a focused spot diameter of 80 μm in air was scanned at a rate of 5mm/second over a 5mm line of incision in 5 mm x 20 mm human skin samples. Histological analysis of the welded samples using hematoxyline and eosin under unpolarized light showed full-thickness full-length weld, and that with picrosirius red F3BA stain under polarized light revealed that there was no appreciable damage. Measured tensile strength of 2.1 kg/cm2 is markedly greater than our previous LSW results of 1.05 +/- 0.19 kg/cm2, which is greater than the typical values of 0.4 kg/cm2 obtained using sutures.

  1. Final Report of Project Curriculum Development: Pulsed Tig Welding, 1978-1979.

    ERIC Educational Resources Information Center

    Atlantic County Area Vocational-Technical School, NJ.

    Designed to help unemployed and disadvantaged workers find new career opportunities, this curriculum provides vocational students with a basic course of instruction in pulsed tungsten inert gas (TIG) welding. The first of four sections provides a general background of welding, the welding industry, and welding processes. Section 2 focuses on…

  2. 30 CFR 250.113 - What procedures must I follow when welding?

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 2 2010-07-01 2010-07-01 false What procedures must I follow when welding? 250....113 What procedures must I follow when welding? (a) Before you weld, you must move any equipment containing hydrocarbons or other flammable substances at least 35 feet horizontally from the welding area...

  3. 30 CFR 250.111 - Who oversees operations under my welding plan?

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 2 2011-07-01 2011-07-01 false Who oversees operations under my welding plan... SHELF General Performance Standards § 250.111 Who oversees operations under my welding plan? A welding supervisor or a designated person in charge must be thoroughly familiar with your welding plan. This person...

  4. Defense Waste Processing Facility Canister Closure Weld Current Validation Testing

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

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

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

  5. 78 FR 40200 - Duke Energy Carolinas, LLC, Oconee Nuclear Station Units 1, 2, and 3; Independent Spent Fuel...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-07-03

    ... breaches.'' Zircaloy is a type of zirconium alloy which includes both Zircaloy-2 and Zircaloy-4 cladding, but does not include M5 cladding. The M5 is a different type of zirconium alloy, which does not... ``zirconium alloy'' clad spent fuel assemblies in the 24PHB DSC, which would include both the ``zircaloy clad...

  6. Welding, a risk factor of lung cancer: the ICARE study.

    PubMed

    Matrat, Mireille; Guida, Florence; Mattei, Francesca; Cénée, Sylvie; Cyr, Diane; Févotte, Joëlle; Sanchez, Marie; Menvielle, Gwenn; Radoï, Loredana; Schmaus, Annie; Woronoff, Anne-Sophie; Luce, Danièle; Stücker, Isabelle

    2016-04-01

    We investigated the relationship between lung cancer and occupational exposure to welding activity in ICARE, a population-based case-control study. Analyses were restricted to men (2276 cases, 2780 controls). Welding exposure was assessed through detailed questionnaires, including lifelong occupational history. ORs were computed using unconditional logistic regression, adjusted for lifelong cigarette smoking and occupational exposure to asbestos. Among the regular welders, welding was associated with a risk of lung cancer (OR=1.7, 95% CI 1.1 to 2.5), which increased with the duration (OR=2.0, 95% CI 1.0 to 3.9 when duration >10 years), and was maximum 10-20 years since last welding. The risk was more pronounced in case of gas welding (OR=2.0, 95% CI 1.2 to 3.3), when the workpiece was covered by paint, grease, or other substances (OR=2.0, 95% CI 1.2 to 3.4) and when it was cleaned with chemical substances before welding. No statistically significant increase in lung cancer risk was observed among occasional welders. Although these results should be confirmed, we showed that type of welding and mode of workpiece preparation are important determinants of the lung cancer risk in regular welders. Published by the BMJ Publishing Group Limited. For permission to use (where not already granted under a licence) please go to http://www.bmj.com/company/products-services/rights-and-licensing/

  7. Fiber laser welding of nickel based superalloy Inconel 625

    NASA Astrophysics Data System (ADS)

    Janicki, Damian M.

    2013-01-01

    The paper describes the application of single mode high power fiber laser (HPFL) for the welding of nickel based superalloy Inconel 625. Butt joints of Inconel 625 sheets 0,8 mm thick were laser welded without an additional material. The influence of laser welding parameters on weld quality and mechanical properties of test joints was studied. The quality and mechanical properties of the joints were determined by means of tensile and bending tests, and micro hardness tests, and also metallographic examinations. The results showed that a proper selection of laser welding parameters provides non-porous, fully-penetrated welds with the aspect ratio up to 2.0. The minimum heat input required to achieve full penetration butt welded joints with no defect was found to be 6 J/mm. The yield strength and ultimate tensile strength of the joints are essentially equivalent to that for the base material.

  8. Inspection of thick welded joints using laser-ultrasonic SAFT.

    PubMed

    Lévesque, D; Asaumi, Y; Lord, M; Bescond, C; Hatanaka, H; Tagami, M; Monchalin, J-P

    2016-07-01

    The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing. Crown Copyright © 2016. Published by Elsevier B.V. All rights reserved.

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

    NASA Astrophysics Data System (ADS)

    Rezaei Ashtiani, Hamid Reza; Zarandooz, Roozbeh

    2015-09-01

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

  10. 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

  11. Welding technology. [technology transfer of NASA developments to commercial organizations

    NASA Technical Reports Server (NTRS)

    1974-01-01

    Welding processes which have been developed during NASA space program activities are discussed. The subjects considered are: (1) welding with an electron gun, (2) technology of welding special alloys, and (3) welding shop techniques and equipment. The material presented is part of the combined efforts of NASA and the Small Business Administration to provide technology transfer of space-related developments to the benefit of commercial organizations.

  12. High-Powered, Ultrasonically Assisted Thermal Stir Welding

    NASA Technical Reports Server (NTRS)

    Ding, Robert

    2013-01-01

    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.

  13. Research on Wheel Steel Welding Cracks Caused by Quenching Stress

    NASA Astrophysics Data System (ADS)

    Guan-nan, Li

    Wheel steel products of Han Steel occurred welding cracking when using in a wheel factory, by analyzing the crack in the wheel steel weld cracking with microstructure analysis and spectrum analysis, test results showed the grain in heat affect zone serious grow, and the user at the end of the flash-butt quenched from a high temperature to room temperature at welding seam, larger cooling rate to generate sufficiently large quenching stress, increased the risk of cracking along the grain boundary. When the stress reaches a certain level, there will be a greater area of the grain cracks at the location of welding seam, eventually leading to weld cracking. We develop measures for improvement to solving this problem, we suggest that the cooling mode at welding seam should be slow cooling or air cooling after the rim welding process, welding current range is 7800 9500 amps, upsetting time is 0.2 seconds, these measures can improve the welding quality of wheel steel products and reduce the risk of welding cracks.

  14. Introduction and Validation of Chromium-Free Consumables for Welding Stainless Steels. Version 2

    DTIC Science & Technology

    2015-04-14

    12 4.3 Site-related Permits and Regulations .......................................................................... 13 TEST DESIGN ...109 Appendix K: X-ray Report on ENiCuRu Weld Test Assembly...60 Table 6.24 Radiographic Test Report on Baseline E308L-16 and Test ENiCuRu Weld Assemblies

  15. Weld failure detection

    DOEpatents

    Pennell, William E.; Sutton, Jr., Harry G.

    1981-01-01

    Method and apparatus for detecting failure in a welded connection, particrly applicable to not readily accessible welds such as those joining components within the reactor vessel of a nuclear reactor system. A preselected tag gas is sealed within a chamber which extends through selected portions of the base metal and weld deposit. In the event of a failure, such as development of a crack extending from the chamber to an outer surface, the tag gas is released. The environment about the welded area is directed to an analyzer which, in the event of presence of the tag gas, evidences the failure. A trigger gas can be included with the tag gas to actuate the analyzer.

  16. [The effects of different welding wires on the mechanical properties of laser welding joints].

    PubMed

    Huang, Qing-feng; Zhang, Jian-zhong; Jiang, Wei-dong; Li, Quan; Yu, Jin-xing

    2006-08-01

    To evaluate the mechanical properties and microstructure of laser-welded joints with different welding wires for clinical use of welding wire. The standard tensile test and three-point bending test rods were made from Co-Cr and Ni-Cr alloy, and were laser-welded with different welding wire (commercially welding wire and casting wire). Then the tensile rods were tested for the ultimate tensile strength (UTS), and the bending rods for the ultimate bending strength (UBS). The results was analyzed by one-way ANOVA. The tensile fracture surface were examined by scanning electron microscopy (SEM). Metallurgical analysis were also performed on polished longitudinal sectioned samples. For Co-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (606.40+/-82.53)MPa and (693.61+/-47.68)MPa; the UBS was respectively (997.95+/-88.89)MPa and (1160.76+/-91.59)MPa. ANOVA showed a significant difference of UTS and UBS between the two groups at the 0.05 level (P<0.05). For Ni-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (558.14+/-46.75)MPa and (582.32+/-35.43)MPa; the UBS was respectively (1084.75+/-46.02)MPa and (1078.29+/-36.25)MPa. There was no significant difference between the two groups (P>0.05). SEM and metallurgical examination showed the welded zone exhibiting more cracks in the casting wire group than in the commercially welding wire group. It would be advisable to work with commercially welding wire for the joints that need better strength.

  17. Blue-Light Hazard From Gas Metal Arc Welding of Aluminum Alloys.

    PubMed

    Nakashima, Hitoshi; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

    2017-10-01

    The objective was to quantify the blue-light hazard from gas metal arc welding (GMAW) of aluminum alloys. The exposure level is expected to depend on the welding conditions. Therefore, it is important to identify the blue-light hazard under various welding conditions. We experimentally conducted GMAW of aluminum alloys under various welding conditions and measured the spectral radiance of the arcs. The effective blue-light radiance, which the American Conference of Governmental Industrial Hygienists has defined to quantify the exposure level of blue light, was calculated from the measured spectral radiance. The maximum acceptable exposure duration per 10000 s for this effective blue-light radiance was calculated. The effective blue-light radiance measured in this study was in the range of 2.9-20.0 W cm-2·sr. The corresponding maximum acceptable exposure duration per 10000 s was only 5.0-34 s, so it is hazardous to view the welding arc. The effective blue-light radiance was higher at higher welding currents than at lower welding currents, when pulsed welding currents were used rather than steady welding currents, and when magnesium was included in the welding materials. It is very hazardous to view the arcs in GMAW of aluminum alloys. Welders and their helpers should use appropriate eye protection in arc-welding operations. They should also avoid direct light exposure when starting an arc-welding operation. © The Author 2017. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

  18. Method for welding beryllium

    DOEpatents

    Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

    1997-01-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

  19. Method for welding beryllium

    DOEpatents

    Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

    1997-04-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

  20. 30 CFR 250.112 - What standards must my welding equipment meet?

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 2 2010-07-01 2010-07-01 false What standards must my welding equipment meet... § 250.112 What standards must my welding equipment meet? Your welding equipment must meet the following requirements: (a) All engine-driven welding equipment must be equipped with spark arrestors and drip pans; (b...

  1. 30 CFR 250.111 - Who oversees operations under my welding plan?

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 2 2010-07-01 2010-07-01 false Who oversees operations under my welding plan... § 250.111 Who oversees operations under my welding plan? A welding supervisor or a designated person in charge must be thoroughly familiar with your welding plan. This person must ensure that each welder is...

  2. 30 CFR 250.111 - Who oversees operations under my welding plan?

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 2 2012-07-01 2012-07-01 false Who oversees operations under my welding plan... Performance Standards § 250.111 Who oversees operations under my welding plan? A welding supervisor or a designated person in charge must be thoroughly familiar with your welding plan. This person must ensure that...

  3. 30 CFR 250.111 - Who oversees operations under my welding plan?

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 2 2014-07-01 2014-07-01 false Who oversees operations under my welding plan... Performance Standards § 250.111 Who oversees operations under my welding plan? A welding supervisor or a designated person in charge must be thoroughly familiar with your welding plan. This person must ensure that...

  4. 30 CFR 250.111 - Who oversees operations under my welding plan?

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 2 2013-07-01 2013-07-01 false Who oversees operations under my welding plan... Performance Standards § 250.111 Who oversees operations under my welding plan? A welding supervisor or a designated person in charge must be thoroughly familiar with your welding plan. This person must ensure that...

  5. Elevated-temperature flow strength, creep resistance and diffusion welding characteristics of Ti-gAl-2Nb-1Ta-0.8Mo

    NASA Technical Reports Server (NTRS)

    Whittenberger, J. D.; Moore, T. J.

    1977-01-01

    A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo was conducted. Two mill-processed forms of this alloy were examined. The forged material was essentially processed above the beta transus while the rolled form was subjected to considerable work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

  6. EB welding of launch vehicles

    NASA Astrophysics Data System (ADS)

    Szabo, Attila

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

  7. Welding III.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

    Instructional objectives and performance requirements are outlined in this course guide for Welding III, an advanced course in arc welding offered at the Community College of Allegheny County to provide students with the proficiency necessary for industrial certification. The course objectives, which are outlined first, specify that students will…

  8. SLI Complex Curvature Friction Stir Weld Risk Reduction Program

    NASA Technical Reports Server (NTRS)

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

    2003-01-01

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

  9. Mathematical Modeling of Optical Radiation Emission as a Function of Welding Power during Gas Shielded Metal Arc Welding.

    PubMed

    Bauer, Stefan; Janßen, Marco; Schmitz, Martin; Ott, Günter

    2017-11-01

    Arc welding is accompanied by intense optical radiation emission that can be detrimental not only for the welder himself but also for people working nearby or for passersby. Technological progress advances continuously in the field of joining, so an up-to-date radiation database is necessary. Additionally, many literature irradiance data have been measured for a few welding currents or for parts of the optical spectral region only. Within this paper, a comprehensive study of contemporary metal active gas, metal inert gas, and cold metal transfer welding is presented covering optical radiation emission from 200 up to 2,700 nm by means of (spectro-) radiometric measurements. The investigated welding currents range from 70 to 350 A, reflecting values usually applied in industry. Based upon these new irradiance data, three mathematical models were derived in order to describe optical radiation emission as a function of welding power. The linear, exponential, and sigmoidal emission models depend on the process variant (standard or pulsed) as well as on the welding material (mild and stainless steel, aluminum). In conjunction with the corresponding exposure limit values for incoherent optical radiation maximum permissible exposure durations were calculated as a function of welding power. Typical times are shorter than 1 s for the ultraviolet spectral region and range from 1 to 10 s for visible radiation. For the infrared regime, exposure durations are of the order of minutes to hours. Finally, a validation of the metal active gas emission models was carried out with manual arc welding.

  10. Physics of Fusion Welding

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.

    1986-01-01

    Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

  11. Effect of thermal exposure, forming, and welding on high-temperature, dispersion-strengthened aluminum alloy: Al-8Fe-1V-2Si

    NASA Technical Reports Server (NTRS)

    Kennedy, J. R.; Gilman, P. S.; Zedalis, M. S.; Skinner, D. J.; Peltier, J. M.

    1991-01-01

    The feasibility of applying conventional hot forming and welding methods to high temperature aluminum alloy, Al-8Fe-1V-2Si (FVS812), for structural applications and the effect of thermal exposure on mechanical properties were determined. FVS812 (AA8009) sheet exhibited good hot forming and resistance welding characteristics. It was brake formed to 90 deg bends (0.5T bend radius) at temperatures greater than or equal to 390 C (730 F), indicating the feasibility of fabricating basic shapes, such as angles and zees. Hot forming of simple contoured-flanged parts was demonstrated. Resistance spot welds with good static and fatigue strength at room and elevated temperatures were readily produced. Extended vacuum degassing during billet fabrication reduced porosity in fusion and resistance welds. However, electron beam welding was not possible because of extreme degassing during welding, and gas-tungsten-arc welds were not acceptable because of severely degraded mechanical properties. The FVS812 alloy exhibited excellent high temperature strength stability after thermal exposures up to 315 C (600 F) for 1000 h. Extended billet degassing appeared to generally improve tensile ductility, fatigue strength, and notch toughness. But the effects of billet degassing and thermal exposure on properties need to be further clarified. The manufacture of zee-stiffened, riveted, and resistance-spot-welded compression panels was demonstrated.

  12. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

  13. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

  14. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

  15. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

  16. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

  17. 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.

  18. U-Groove aluminum weld strength improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1996-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking, which induces bending under uniaxial loading. The filler strain-hardening decreased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A depeaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve depeaking in the welding process. The intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

  19. Laser Beam Welding of Nitride Steel Components

    NASA Astrophysics Data System (ADS)

    Gu, Hongping; Yin, Guobin; Shulkin, Boris

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

  20. Microstructure and Mechanical Properties of Laser Welded Titanium 6Al-4V

    NASA Astrophysics Data System (ADS)

    Mazumder, J.; Steen, W. M.

    1982-05-01

    Laser butt welds were fabricated in a titanium alloy (Ti-6A1-4V, AMS 4911-Tal0 BSS, annealed) using a Control Laser 2 kW CW CO2 laser. The relationships between the weld microstructure and mechanical properties are described and compared to the theoretical thermal history of the weld zone as calculated from a three-dimensional heat transfer model of the process. The structure of the weld zone was examined by radiography to detect any gross porosity as well as by both optical and electron microscopy in order to identify the microstructure. The oxygen pick-up during gas shielded laser welding was analyzed to correlate further with the observed mechanical properties. It was found that optimally fabricated laser welds have a very good combination of weld microstructure and mechanical properties, ranking this process as one which can produce high quality welds.

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

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

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

    1995-12-31

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

  2. Diode laser welding of polypropylene: investigations of the microstructures in the welded seam

    NASA Astrophysics Data System (ADS)

    Abed, S.; Laurens, Patricia; Carretero, C.; Deschamps, J. R.; Duval, C.

    2003-03-01

    Laser welding of thermoplastic polymers is a non-contact process especially efficient for joining thermoplastic polymers. This innovative technology is already used for industrial series production in different sectors (automobile, packaging,...). The majority of the basic research concerns the weld strength depending on polymer nature, optical properties, butt design and process parameters. Nevertheless, a lack of knowledge concerning the influence of thermal history of the weld seam on morphology of semicrystalline polymer still exists, when this parameter strongly influences the strength of the weld. Actual results of diode laser transmission welding (LTW) experiments on polypropylene, a semicrystalline polymer widely used in industry, could contribute to a better understanding of the process itself and to success in practical applications.

  3. Hydrogen mitigation in submerged arc welding

    NASA Astrophysics Data System (ADS)

    Klimowicz, Steven

    removes the moisture that is added by the water based binder. The second phase of the project was to modify the flux with fluoride additions to remove hydrogen from the arc while welding. The introduction of fluorine into the arc would lower the amount of hydrogen that may be absorbed as diffusible hydrogen by the weld metal. To select the fluorides a series of thermodynamic calculations were performed as well as simple tests to determine the fluorides behavior in a welding arc and flux. From these tests the following fluorides were selected to be used to be added to EM12K flux as oneweight percent additions: SrF 2, K2TiF6, K2SiF6, and LiF. Welds were then run with the experimental fluxes according to AWS A4.3 standard for diffusible hydrogen testing. From these tests it was found that none experimental fluxes were able to achieve a diffusible hydrogen content lower than the original EM12K flux. It was also found that fluoride reduction in a simple flux is a better predictor of fluoride effectiveness than decomposition temperature.

  4. Thermoplastic welding apparatus and method

    DOEpatents

    Matsen, Marc R.; Negley, Mark A.; Geren, William Preston; Miller, Robert James

    2017-03-07

    A thermoplastic welding apparatus includes a thermoplastic welding tool, at least one tooling surface in the thermoplastic welding tool, a magnetic induction coil in the thermoplastic welding tool and generally encircling the at least one tooling surface and at least one smart susceptor in the thermoplastic welding tool at the at least one tooling surface. The magnetic induction coil is adapted to generate a magnetic flux field oriented generally parallel to a plane of the at least one smart susceptor.

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

    NASA Astrophysics Data System (ADS)

    Macwan, A.; Chen, D. L.

    2016-04-01

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

  6. Method and apparatus for assessing weld quality

    DOEpatents

    Smartt, Herschel B.; Kenney, Kevin L.; Johnson, John A.; Carlson, Nancy M.; Clark, Denis E.; Taylor, Paul L.; Reutzel, Edward W.

    2001-01-01

    Apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

  7. 73rd American Welding Society annual meeting

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

    Not Available

    1992-01-01

    The volume includes the abstracts of papers presented at the 73rd American Welding Society Annual Meeting. Detailed summaries are given for 118 technical sessions papers discussing computer and control applications in welding, stainless steel, nickel and nickel alloys, weld metal microstructure, shipbuilding, consumables, structural welding, investigations in arc welding and cutting, arc welding processes, weldability testing, piping and tubing, high energy beam welding processes, welding metallurgy of structural steels, new applications, weld metal behavior, NDT certification, aluminum welding, submerged arc welding, modeling studies, resistance welding, friction welding, and safety and health. The 23rd International AWS Brazing and Soldering Conference wasmore » also held during this meeting. The topics presented in 24 papers included recent developments in soldering technology, brazing of stainless steel, brazing of ceramics and nickel material, filler metal developments for torch brazing, and developments in diffusion and induction brazing.« less

  8. Galvanic Corrosion Behavior of Microwave Welded and Post-weld Heat-Treated Inconel-718 Joints

    NASA Astrophysics Data System (ADS)

    Bansal, Amit; Sharma, Apurbba Kumar; Kumar, Pradeep

    2017-05-01

    In the present study, corrosion behavior of microwave welded Inconel-718 at various conditions was investigated. Welding of Inconel-718 in 980 °C solution-treated condition was performed using microwave hybrid heating technique. The microwave welds were subjected to post-heat treatment for improving its microstructure and mechanical properties by solubilizing the Nb-enriched Laves phase. The microstructural features of the fabricated welds at various conditions were investigated through scanning electron microscopy. The electrochemical testing results revealed that Inconel-718 welds were galvanic corroded when they were anodically polarized in 3.5 wt.% NaCl solution at 28 °C. The difference in the corrosion potentials between the base metal (BM) and fusion zone (FZ) in an Inconel-718 weld was the main factor for galvanic corrosion. The highest corrosion was occurred in the as-welded/aged weldments, followed by 980 °C solution-treated and aged weldments, as-welded specimen, and 1080 °C solution-treated and aged (1080STA) weldments. The least galvanic corrosion was occurred in the 1080STA specimens due to almost uniform microstructure developed in the weldment after the treatment. Thus, it was possible to minimize the galvanic corrosion in the microwave welded Inconel-718 by 1080STA treatment which resulted in reducing the difference in corrosion potentials between the BM and the FZ.

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

    NASA Astrophysics Data System (ADS)

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

    2016-01-01

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

  10. Chemical and microstructural characterization of a 9 cycle Zircaloy-2 cladding using EPMA and FIB tomography

    NASA Astrophysics Data System (ADS)

    Baris, A.; Restani, R.; Grabherr, R.; Chiu, Y.-L.; Evans, H. E.; Ammon, K.; Limbäck, M.; Abolhassani, S.

    2018-06-01

    A high burn-up Zircaloy-2 cladding is characterised in order to correlate its microstructure and composition to the change of oxidation and hydrogen uptake behaviour during long term service in the reactor. After 9 cycle of service, the chemical analysis of the cladding segment shows that most secondary phase particles (SPPs) have dissolved into the matrix. Fe and Ni are distributed homogenously in the metal matrix. Cr-containing clusters, remnants of the original Zr(Fe, Cr)2 type precipitates, are still present. Hydrides are observed abundantly in the metal side close to the metal-oxide interface. These hydrides have lower Fe and Ni concentration than that in the metal matrix. The three-dimensional (3D) reconstruction of the oxide and the metal-oxide interface obtained by Focused Ion Beam (FIB) tomography shows how the oxide microstructure has evolved with the number of cycles. The composition and microstructural changes in the oxide and the metal can be correlated to the oxidation kinetics and the H-uptake. It is observed that there is an increase in the oxidation kinetics and in the H-uptake between the third and the fifth cycles, as well as during the last two cycles. At the same time the volume fraction of cracks in the oxide significantly increased. Many fine cracks and pores exist in the oxide formed in the last cycle. Furthermore, the EPMA results confirm that this oxide formed at the last cycle reflects the composition of the metal at the metal-oxide interface after the long residence time in the reactor.

  11. 30 CFR 250.113 - What procedures must I follow when welding?

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 2 2012-07-01 2012-07-01 false What procedures must I follow when welding? 250... Performance Standards § 250.113 What procedures must I follow when welding? (a) Before you weld, you must move... the welding area. You must move similar equipment on lower decks at least 35 feet from the point of...

  12. 30 CFR 250.113 - What procedures must I follow when welding?

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 2 2011-07-01 2011-07-01 false What procedures must I follow when welding? 250... Performance Standards § 250.113 What procedures must I follow when welding? (a) Before you weld, you must move... the welding area. You must move similar equipment on lower decks at least 35 feet from the point of...

  13. 30 CFR 250.113 - What procedures must I follow when welding?

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 2 2014-07-01 2014-07-01 false What procedures must I follow when welding? 250... Performance Standards § 250.113 What procedures must I follow when welding? (a) Before you weld, you must move... the welding area. You must move similar equipment on lower decks at least 35 feet from the point of...

  14. 30 CFR 250.113 - What procedures must I follow when welding?

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 2 2013-07-01 2013-07-01 false What procedures must I follow when welding? 250... Performance Standards § 250.113 What procedures must I follow when welding? (a) Before you weld, you must move... the welding area. You must move similar equipment on lower decks at least 35 feet from the point of...

  15. Method for welding chromium molybdenum steels

    DOEpatents

    Sikka, Vinod K.

    1986-01-01

    Chromium-molybdenum steels exhibit a weakening after welding in an area adjacent to the weld. This invention is an improved method for welding to eliminate the weakness by subjecting normalized steel to a partial temper prior to welding and subsequently fully tempering the welded article for optimum strength and ductility.

  16. Electron beam welding passes initial test

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

    de Sirvy, B.

    1979-11-01

    Once the new electron-beam welding process is coupled with vertical or J-curve pipelaying techniques, Total-Compagnie Francaise des Petroles (Gestion and Recherches) will be able to offer a system capable of laying up to 36-in. pipe in deep water (1000-9900 ft) at a pace competitive with the best performance of a shallow-water barge: 8200 ft in 24 hr. Electron-beam welding provides the fast, single-station joining needed to make J-curve laying economical. Tests recently demonstrated that this welding technique can join 1.25-in.-wall, 24-in. pipe in less than 3 min; conventional processes require 1-1 1/2 hr.

  17. 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.

  18. 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.

  19. Design of Boiler Welding for Improvement of Lifetime and Cost Control.

    PubMed

    Thong-On, Atcharawadi; Boonruang, Chatdanai

    2016-11-03

    Fe-2.25Cr-1Mo a widely used material for headers and steam tubes of boilers. Welding of steam tube to header is required for production of boiler. Heat affected zone of the weld can have poor mechanical properties and poor corrosion behavior leading to weld failure. The cost of material used for steam tube and header of boiler should be controlled. This study propose a new materials design for boiler welding to improve the lifetime and cost control, using tungsten inert gas (TIG) welding of Fe-2.25Cr-1Mo tube to carbon steel pipe with chromium-containing filler. The cost of production could be reduced by the use of low cost material such as carbon steel pipe for boiler header. The effect of chromium content on corrosion behavior of the weld was greater than that of the microstructure. The lifetime of the welded boiler can be increased by improvement of mechanical properties and corrosion behavior of the heat affected zone.

  20. Design of Boiler Welding for Improvement of Lifetime and Cost Control

    PubMed Central

    Thong-On, Atcharawadi; Boonruang, Chatdanai

    2016-01-01

    Fe-2.25Cr-1Mo a widely used material for headers and steam tubes of boilers. Welding of steam tube to header is required for production of boiler. Heat affected zone of the weld can have poor mechanical properties and poor corrosion behavior leading to weld failure. The cost of material used for steam tube and header of boiler should be controlled. This study propose a new materials design for boiler welding to improve the lifetime and cost control, using tungsten inert gas (TIG) welding of Fe-2.25Cr-1Mo tube to carbon steel pipe with chromium-containing filler. The cost of production could be reduced by the use of low cost material such as carbon steel pipe for boiler header. The effect of chromium content on corrosion behavior of the weld was greater than that of the microstructure. The lifetime of the welded boiler can be increased by improvement of mechanical properties and corrosion behavior of the heat affected zone. PMID:28774014

  1. Clinical Cold Welding of the Modular Total Hip Arthroplasty Prosthesis.

    PubMed

    Whittaker, Robert K; Zaghloul, Ahmed M; Hothi, Harry S; Siddiqui, Imran A; Blunn, Gordon W; Skinner, John A; Hart, Alister J

    2017-02-01

    A head that is "clinically cold welded" to a stem is one of the commonest reasons for unplanned removal of the stem. It is not clear which hip designs are at greatest risk of clinical cold welding. This was a case-control study of consecutively received hip implant retrievals; we chose the design of hip that had the greatest number of truly cold-welded heads (n = 11). For our controls, we chose retrieved hips of the same design but without cold welding of the head (n = 35). We compared the clinical variables between these 2 groups using nonparametric Mann-Whitney tests to investigate the significance of differences between the cold-welded and non-cold-welded groups. The design that most commonly caused cold welding was a combination of a Ti stem and Ti taper: 11 out of 48 (23%) were truly cold welded. Comparison of the clinical data showed that no individual factor could be used to predict this preoperatively with none of the 4 predictors tested showing any significance: (1) time to revision (P = .687), (2) head size (P = .067), (3) patient age at primary (P = .380), and (4) gender (P = .054). We have shown that clinical cold welding is most prevalent in Ti-Ti combinations of the stem and taper; approximately 25% of cases received at our center were cold welded. Analysis of clinical variables showed that it is not possible to predict which will be cold welded preoperatively. Surgeons should be aware of this potential complication when revising a Ti-Ti stem/head junction. Copyright © 2016 Elsevier Inc. All rights reserved.

  2. 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.

  3. Vacuum Gas Tungsten Arc Welding

    NASA Technical Reports Server (NTRS)

    Weeks, J. L.; Todd, D. T.; Wooten, J. R.

    1997-01-01

    A two-year program investigated vacuum gas tungsten arc welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. After a vacuum chamber and GTAW power supply were modified, several difficult-to-weld materials were studied and key parameters developed. Finally, Incoloy 903 weld overlays were produced without microfissures.

  4. Variable polarity arc welding

    NASA Technical Reports Server (NTRS)

    Bayless, E. O., Jr.

    1991-01-01

    Technological advances generate within themselves dissatisfactions that lead to further advances in a process. A series of advances in welding technology which culminated in the Variable Polarity Plasma Arc (VPPA) Welding Process and an advance instituted to overcome the latest dissatisfactions with the process: automated VPPA welding are described briefly.

  5. Laser Welding in Space

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.; Kaukler, William F.

    1989-01-01

    Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and $914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

  6. Automatic programming of arc welding robots

    NASA Astrophysics Data System (ADS)

    Padmanabhan, Srikanth

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

  7. Elevated temperature flow strength, creep resistance and diffusion welding characteristics of Ti-6Al-2Nb-1Ta-0.8Mo

    NASA Technical Reports Server (NTRS)

    Whittenberger, J. D.; Moore, T. J.

    1979-01-01

    A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo has been conducted. Two mill-processed forms of this alloy were examined. The forged material had been processed above the beta transus (approximately 1275 K) while the rolled form had been subjected to work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

  8. Hybrid welding of hollow section beams for a telescopic lifter

    NASA Astrophysics Data System (ADS)

    Jernstroem, Petteri

    2003-03-01

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

  9. Factors affecting the strength of multipass low-alloy steel weld metal

    NASA Technical Reports Server (NTRS)

    Krantz, B. M.

    1972-01-01

    The mechanical properties of multipass high-strength steel weld metals depend upon several factors, among the most important being: (1) The interaction between the alloy composition and weld metal cooling rate which determines the as-deposited microstructure; and (2) the thermal effects of subsequent passes on each underlying pass which alter the original microstructure. The bulk properties of a multipass weld are therefore governed by both the initial microstructure of each weld pass and its subsequent thermal history. Data obtained for a high strength low alloy steel weld metal confirmed that a simple correlation exists between mechanical properties and welding conditions if the latter are in turn correlated as weld cooling rate.

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

  11. Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

    NASA Technical Reports Server (NTRS)

    Russell, C.

    2001-01-01

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

  12. Report Summarizing the Effort Required to Initiate Welding of Irradiated Materials within the Welding Cubicle

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

    Frederick, Greg; Sutton, Benjamin J.; Tatman, Jonathan K.

    The advanced welding facility within a hot cell at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory (ORNL), which has been jointly funded by the U.S. Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability Program and the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, is in the final phase of development. Research and development activities in this facility will involve direct testing of advanced welding technologies on irradiated materials in order to address the primary technical challenge of helium induced cracking that can arise when conventionalmore » fusion welding techniques are utilized on neutron irradiated stainless steels and nickel-base alloys. This report details the effort that has been required since the beginning of fiscal year 2017 to initiate welding research and development activities on irradiated materials within the hot cell cubicle, which houses welding sub-systems that include laser beam welding (LBW) and friction stir welding (FSW) and provides material containment within the hot cell.« less

  13. Effect of joint design and welding type on the flexural strength and weld penetration of Ti-6Al-4V alloy bars.

    PubMed

    Simamoto Júnior, Paulo Cézar; Resende Novais, Veridiana; Rodrigues Machado, Asbel; Soares, Carlos José; Araújo Raposo, Luís Henrique

    2015-05-01

    Framework longevity is a key factor for the success of complete-arch prostheses and commonly depends on the welding methods. However, no consensus has been reached on the joint design and welding type for improving framework resistance. The purpose of this study was to assess the effect of different joint designs and welding methods with tungsten inert gas (TIG) or laser to join titanium alloy bars (Ti-6Al-4V). Seventy titanium alloy bar specimens were prepared (3.18 mm in diameter × 40.0 mm in length) and divided into 7 groups (n=10): the C-control group consisting of intact specimens without joints and the remaining 6 groups consisting of specimens sectioned perpendicular to the long-axis and rejoined using an I-, X30-, or X45-shaped joint design with TIG welding (TI, TX30, and TX45) or laser welding (LI, LX30, and LX45). The specimens were tested with 3-point bending. The fracture surfaces were first evaluated with stereomicroscopy to measure the weld penetration area and then analyzed with scanning electron microscopy (SEM). The data were statistically analyzed with 2-way ANOVA and the Tukey post hoc test, 1-way ANOVA and the Dunnett test, and the Pearson correlation test (α=.05). Specimens from the X30 and X45 groups showed higher flexural strength (P<.05) and welded area (P<.05) than specimens from the I groups, regardless of the welding type. TIG welded groups showed significantly higher flexural strength than the laser groups (P<.05), regardless of the joint design. TIG welding also resulted in higher welded areas than laser welding for the I-shaped specimens. No significant differences were found for the weld penetration area in the X45 group, either for laser or TIG welding. SEM analysis showed more pores at the fracture surfaces of the laser specimens. Fracture surfaces indicative of regions of increased ductility were detected for the TIG specimens. TIG welding resulted in higher flexural strength for the joined titanium specimens than laser welding

  14. Welding wire selection critical to jet engine repair work

    NASA Astrophysics Data System (ADS)

    1992-11-01

    A review is provided of issues related to the selection of welding wire for aircraft gas-turbine engines emphasizing the importance of cleanliness in the welding wire product. A three-step metallurgical control process is described for the production of welding wire that is clean and suitable for turbine repair. The process is based on: (1) vacuum induction melting; (2) contamination-free processing of the wire; and (3) environmentally controlled packaging. Weld work on aerospace casting is shown to be useful and suitable for many alloy and superalloy materials with various filler materials.

  15. Welding and joining: A compilation

    NASA Technical Reports Server (NTRS)

    1975-01-01

    A compilation is presented of NASA-developed technology in welding and joining. Topics discussed include welding equipment, techniques in welding, general bonding, joining techniques, and clamps and holding fixtures.

  16. Health effects of welding.

    PubMed

    Antonini, James M

    2003-01-01

    Many of the epidemiology studies performed are difficult to compare because of differences in worker populations, industrial settings, welding techniques, duration of exposure, and other occupational exposures besides welding fumes. Some studies were conducted in carefully controlled work environments, others during actual workplace conditions, and some in laboratories. Epidemiology studies have shown that a large number of welders experience some type of respiratory illness. Respiratory effects seen in full-time welders have included bronchitis, airway irritation, lung function changes, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders. Although epidemiological studies have demonstrated an increase in pulmonary illness after exposure to welding fumes, little information of the causality, dose-response, and possible underlying mechanisms regarding the inhalation of welding fumes exists. Even less information is available about the neurological, reproductive, and dermal effects after welding fume exposure. Moreover, carcinogenicity and short-term and long-term toxicology studies of welding fumes in animals are lacing or incomplete. Therefore, an understanding of possible adverse health effects of exposure to welding fumes is essential to risk assessment and the development of prevention strategies and will impact a large population of workers.

  17. Pipeline welding goes mechanized

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

    Beeson, R.

    1999-11-01

    Spread four has bugs in the cornfield--but not to worry. The bug referred to here is a mechanized welding bug, specifically a single welding head, computer-aided gas metal arc (GMAW) system from CRC-Evans Automatic Welding powered by a Miller Electric XMT{reg{underscore}sign} 304 inverter-based welding machine. The bug operator and owner of 32 inverters is Welded Construction, L.P., of Perrysburgh, Ohio. Spread four is a 147-mile stretch of the Alliance Pipeline system (Alliance) cutting through the cornfields of northeast Iowa. While used successfully in Canada and Europe for onshore and offshore pipeline construction for 30 years, this is the first large-scalemore » use of mechanized welding in the US on a cross-country pipeline. On longer, larger-diameter and thicker-wall pipe projects--the Alliance mainline has 1,844 miles of pipe, most of it 36-in. diameter with a 0.622-in. wall thickness--mechanized GMAW offers better productivity than manual shielded metal arc welding (SMAW). In addition, high-strength steels, such as the API 5L Grade X70 pipe used on the Alliance, benefit from the low-hydrogen content of certain solid and tubular wire electrodes.« less

  18. 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.

  19. Spot-Welding Gun Is Easy To Use

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.; Nguyen, Francis H.

    1991-01-01

    Electrical-resistance spot-welding gun designed to produce more welds per unit time by decreasing technician's effort and fatigue. Vacuum cups on frame secure welding gun to workpiece while compressed air drives welding tip against workpiece to make spot resistance weld. When weld completed, vacuum in frame cups released so frame and gun moved to position of next spot weld.

  20. 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

  1. 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.

  2. Welding Development: Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Ding, Jeff

    2007-01-01

    This paper presents the basic understanding of the friction stir welding process. It covers process description, pin tool operation and materials, metal flow theory, mechanical properties, and materials welded using the process. It also discusses the thermal stir welding process and the differences between thermal stir and friction stir welding. MSFC weld tools used for development are also presented.

  3. 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.

  4. Assessment of the Biological Effects of Welding Fumes Emitted From Metal Active Gas and Manual Metal Arc Welding in Humans.

    PubMed

    Dewald, Eva; Gube, Monika; Baumann, Ralf; Bertram, Jens; Kossack, Veronika; Lenz, Klaus; Reisgen, Uwe; Kraus, Thomas; Brand, Peter

    2015-08-01

    Emissions from a particular welding process, metal inert gas brazing of zinc-coated steel, induce an increase in C-reactive protein. In this study, it was investigated whether inflammatory effects could also be observed for other welding procedures. Twelve male subjects were separately exposed to (1) manual metal arc welding fumes, (2) filtered air, and (3) metal active gas welding fumes for 6 hours. Inflammatory markers were measured in serum before, and directly, 1 and 7 days after exposure. Although C-reactive protein concentrations remained unchanged, neutrophil concentrations increased directly after exposure to manual metal arc welding fumes, and endothelin-1 concentrations increased directly and 24 hours after exposure. After exposure to metal active gas and filtered air, endothelin-1 concentrations decreased. The increase in the concentrations of neutrophils and endothelin-1 may characterize a subclinical inflammatory reaction, whereas the decrease of endothelin-1 may indicate stress reduction.

  5. Determination of GTA Welding Efficiencies

    DTIC Science & Technology

    1993-03-01

    continue on reverse if ncessary andidentify by block number) A method is developed for estimating welding efficiencies for moving arc GTAW processes...Dutta, Co-Advi r Department of Mechanical Engineering ii ABSTRACT A method is developed for estimating welding efficiencies for moving arc GTAW ...17 Figure 10. Miller Welding Equipment ............. ... 18 Figure 11. GTAW Torch Setup for Automatic Welding. . 19 Figure 12

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

    NASA Astrophysics Data System (ADS)

    Chen, Ying-Chun; Prangnell, Phil

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

  7. Method for enhanced control of welding processes

    DOEpatents

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

    2000-01-01

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

  8. Welding wire pressure sensor assembly

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

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

    NASA Technical Reports Server (NTRS)

    Querin, Joseph A.; Schneider, Judy A.

    2008-01-01

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

  10. Automated Variable-Polarity Plasma-Arc Welding

    NASA Technical Reports Server (NTRS)

    Numes, A. C., Jr.; Bayless, E. O., Jr.; Jones, S. C., III; Munafo, P.; Munafo, A.; Biddle, A.; Wilson, W.

    1984-01-01

    Variable-polarity plasma-arc methods produces better welds at lower cost than gas-shielded tungsten-arc welding in assemblies. Weld porosity very low and costs of joint preparation, depeaking, inspection, and weld repair minimized.

  11. Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel.

    PubMed

    Nakashima, Hitoshi; Utsunomiya, Akihiro; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

    2016-09-30

    Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO 2 and 100% CO 2 . The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm 2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO 2 is used as a shielding gas than when 100% CO 2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous.

  12. Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel

    PubMed Central

    Nakashima, Hitoshi; Utsunomiya, Akihiro; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

    2016-01-01

    Objectives: Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. Methods: We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO2 and 100% CO2. The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. Results: The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. Conclusions: The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO2 is used as a shielding gas than when 100% CO2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous. PMID:27488036

  13. 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

  14. Bronchial reactions to exposure to welding fumes.

    PubMed

    Contreras, G R; Chan-Yeung, M

    1997-11-01

    To study the airway response and its mechanism to welding fumes in six welders with respiratory symptoms. Methacholine and welding challenge tests were carried out. The concentration of welding fumes during the exposure test was measured. On two subjects who developed bronchoconstricition to welding challenge, additional tests were carried out including prick, patch, and inhalation challenges with metal salt solutions. Three subjects developed immediate bronchial reaction to exposure to welding fume; one to mild steel and stainless steel welding, another to mild steel and galvanised welding, and one only to galvanised welding. They all had a moderate to pronounced degree of non-specific bronchial hyperresponsiveness. The concentration of fumes during welding tests, particularly to galvanised welding, was high. An inhalation challenge test with zinc chloride salt solution in two subjects who reacted to galvanised welding was negative. Prick and patch tests with zinc chloride were also negative. The airway response to welding in these subjects is non-specific and is due to irritation rather than to sensitisation.

  15. Ultrasonic Welding of Hybrid Joints

    NASA Astrophysics Data System (ADS)

    Wagner, Guntram; Balle, Frank; Eifler, Dietmar

    2012-03-01

    A central research field of the Institute of Materials Science and Engineering at the University of Kaiserslautern (WKK), Germany, is the realization of innovative hybrid joints by ultrasonic metal welding. This article gives an overview of suitable ultrasonic welding systems as well as of essential machine and material parameters, which influence the quality of the welds. Besides the ultrasonic welding of dissimilar metals such as Al to Cu or Al to steels, the welds between newly developed materials like aluminum foam sandwiches or flat flexible cables also can be realized. Moreover, the joining of glass and ceramic to sheet metals is a point of interest at the WKK. By using the ultrasonic metal welding process, it is possible to realize metal/glass welds with tensile shear strengths of 50 MPa. For metal/ceramic joints, the shear strengths values up to 150 MPa were measured. Finally, selected results about the occurring bonding mechanisms will be discussed.

  16. 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.

  17. Parameters for good welding of copper to nickel

    NASA Technical Reports Server (NTRS)

    Hall, L. G.

    1969-01-01

    Quality in welding copper leads to nickel bus wires is obtained by the mass of nickel exceeding that of copper. Welding range 2ncreases proportionately with the increase in the nickel-to-copper mass ratio up to 4-to-1.

  18. 46 CFR 54.05-17 - Weld toughness test acceptance criteria.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 2 2010-10-01 2010-10-01 false Weld toughness test acceptance criteria. 54.05-17 Section 54.05-17 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING... impact tests the energy absorbed in both the weld metal and heat affected zone impact tests in weld...

  19. 46 CFR 54.05-17 - Weld toughness test acceptance criteria.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 2 2011-10-01 2011-10-01 false Weld toughness test acceptance criteria. 54.05-17 Section 54.05-17 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING... impact tests the energy absorbed in both the weld metal and heat affected zone impact tests in weld...

  20. 46 CFR 54.05-17 - Weld toughness test acceptance criteria.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 2 2012-10-01 2012-10-01 false Weld toughness test acceptance criteria. 54.05-17 Section 54.05-17 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING... impact tests the energy absorbed in both the weld metal and heat affected zone impact tests in weld...