WorldWideScience

Sample records for plasma welding process

  1. The variable polarity plasma arc welding process: Characteristics and performance

    Science.gov (United States)

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

    1991-01-01

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

  2. Process characteristics of fibre-laser-assisted plasma arc welding

    OpenAIRE

    Mahrle, A; SCHNICK, M; Rose, S; Demuth, C; Beyer, E.; Füssel, U

    2011-01-01

    Abstract Experimental and theoretical investigations on fibre-laser assisted plasma arc welding (LAPW) have been performed. Welding experiments were carried out on aluminium and steel sheets. In case of a highly focused laser beam and a separate arrangement of plasma torch and laser beam, high-speed video recordings of the plasma arc and corresponding measurements of the time-dependent arc voltage revealed differences in the process behaviour for both materials. In case of aluminium weldin...

  3. Process characteristics of fibre-laser-assisted plasma arc welding

    Energy Technology Data Exchange (ETDEWEB)

    Mahrle, A; Schnick, M; Rose, S; Demuth, C; Beyer, E; Fuessel, U, E-mail: achim.mahrle@iws.fraunhofer.de [Dresden University of Technology, Institute of Surface and Manufacturing Technology, PO Box, D-01062 Dresden (Germany)

    2011-08-31

    Experimental and theoretical investigations on fibre-laser-assisted plasma arc welding (LAPW) were performed. Welding experiments were carried out on aluminium and steel sheets. In the case of a highly focused laser beam and a separate arrangement of plasma torch and laser beam, high-speed video recordings of the plasma arc and corresponding measurements of the time-dependent arc voltage revealed differences in the process behaviour for both materials. In the case of aluminium welding, a sharp decline in arc voltage and stabilization and guiding of the anodic arc root was observed whereas in steel welding the arc voltage was slightly increased after the laser beam was switched on. However, significant improvement of the melting efficiency with the combined action of plasma arc and laser beam was achieved for both types of material. Theoretical results of additional numerical simulations of the arc behaviour suggest that the properties of the arc plasma are mainly influenced not by a direct interaction with the laser radiation but by the laser-induced evaporation of metal. Arc stabilization with increased current densities is predicted for moderate rates of evaporated metal only whereas metal vapour rates above a certain threshold causes a destabilization of the arc and reduced current densities along the arc axis.

  4. Research progress of laser welding process dynamic monitoring technology based on plasma characteristics signal

    Directory of Open Access Journals (Sweden)

    Teng WANG

    2017-02-01

    Full Text Available During the high-power laser welding process, plasmas are induced by the evaporation of metal under laser radiation, which can affect the coupling of laser energy and the workpiece, and ultimately impact on the reliability of laser welding quality and process directly. The research of laser-induced plasma is a focus in high-power deep penetration welding field, which provides a promising research area for realizing the automation of welding process quality inspection. In recent years, the research of laser welding process dynamic monitoring technology based on plasma characteristics is mainly in two aspects, namely the research of plasma signal detection and the research of laser welding process modeling. The laser-induced plasma in the laser welding is introduced, and the related research of laser welding process dynamic monitoring technology based on plasma characteristics at home and abroad is analyzed. The current problems in the field are summarized, and the future development trend is put forward.

  5. Welding arc plasma physics

    Science.gov (United States)

    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.

  6. Welding processes handbook

    CERN Document Server

    Weman, Klas

    2011-01-01

    Offers an introduction to the range of available welding technologies. This title includes chapters on individual techniques that cover principles, equipment, consumables and key quality issues. It includes material on such topics as the basics of electricity in welding, arc physics, and distortion, and the weldability of particular metals.$bThe first edition of Welding processes handbook established itself as a standard introduction and guide to the main welding technologies and their applications. This new edition has been substantially revised and extended to reflect the latest developments. After an initial introduction, the book first reviews gas welding before discussing the fundamentals of arc welding, including arc physics and power sources. It then discusses the range of arc welding techniques including TIG, plasma, MIG/MAG, MMA and submerged arc welding. Further chapters cover a range of other important welding technologies such as resistance and laser welding, as well as the use of welding techniqu...

  7. Comparison of Plasma, Metal Inactive Gas (MIG) and Tungsten Inactive Gas (TIG) Processes for Laser Hybrid Welding (302)

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove

    2003-01-01

    source, ignition and running torch stability, weld phase transformation and change in ductility and overall weld quality are described. The results show that all three processes can successfully be integrated with a CO2 laser beam for hybrid welding. Due to the pilot arc in plasma welding, this process......, the MIG process is more difficult to control than laser/plasma and laser/TIG processes. All three types of secondary heat sources enable an increased ductility of the weld as compared to pure laser welding when welding 1.8 mm GA 260 with a TIG torch and 2.13 mm CMn steel with a plasma arc or MIG......In this paper, TIG, plasma, and MIG processes have been individually combined with a 2.6 kW CO2 laser. In a number of systematic laboratory tests, the general benefits and drawbacks of each process have been individually assessed and compared. Aspects such as ease of integration with a CO2 laser...

  8. Comparison of Plasma, Metal Inactive Gas (MIG) and Tungsten Inactive Gas (TIG) Processes for Laser Hybrid Welding (302)

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove

    2003-01-01

    In this paper, TIG, plasma, and MIG processes have been individually combined with a 2.6 kW CO2 laser. In a number of systematic laboratory tests, the general benefits and drawbacks of each process have been individually assessed and compared. Aspects such as ease of integration with a CO2 laser...... source, ignition and running torch stability, weld phase transformation and change in ductility and overall weld quality are described. The results show that all three processes can successfully be integrated with a CO2 laser beam for hybrid welding. Due to the pilot arc in plasma welding, this process......, the MIG process is more difficult to control than laser/plasma and laser/TIG processes. All three types of secondary heat sources enable an increased ductility of the weld as compared to pure laser welding when welding 1.8 mm GA 260 with a TIG torch and 2.13 mm CMn steel with a plasma arc or MIG...

  9. Study on the correlation between plasma electron temperature and penetration depth in laser welding processes

    NARCIS (Netherlands)

    Sibillano, T.; Ancona, A.; Rizzi, D.; Saludes Rodil, S.; Rodriguez Nieto, J.; Konuk, A.R.; Aarts, R.G.K.M.; Huis in 't Veld, A.J.

    2010-01-01

    The plasma electron temperature has been estimated starting from the spectroscopic analysis of the optical emission of the lasergenerated plasma plume during quite diverse stainless steel welding procedures (c.w. CO2 and pulsed Nd:YAG). Although the optical emissions present different spectral featu

  10. KEYHOLE IMAGE PROCESSING OF VARIABLE POLARITY PLASMA ARC WELDING BASED ON WAVELET TRANSFORM

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    In order to realize the feedback control for variable polarity plasma arc welding (VPPAW) formation in the welding process, the geometrical sizes of the keyhole image must be extracted. With the properties of multiscale edge through the wavelet theory, the edge points were detected by getting the maximum modules of the gradient vector in the dircetion towards which the gradient vector points in the image plane. At coarse scales, the local maxima of modules have different positions and only detected the sharp edge. At fine scale, there are many maxima created by the image noise. The best scale where the edges are well discriminated from noises is discussed by the multiscale transform. At last, a new method of peak analysis for threshold selection is provided. It is based on the wavelet transform which provides a multiscale analysis of the information of the histogram. Many experiments show these ways are effective for the keyhole image to get the geometry parameters of the keyhole in the real-time VPPAW image processing.

  11. Plasma Bursts in Deep Penetration Laser Welding

    Science.gov (United States)

    Mrňa, L.; Šarbort, M.

    We present an experimental study of the deep penetration laser welding process which aims to analyze the plasma plume oscillations on a short time scale. Using the high-speed camera we show that the plasma comes out of the keyhole in the form of short bursts rather than the continuous flow. We detect these bursts as the short-time intensity oscillations of light emissions coming from the plasma plume. We determine the period of bursts using the statistical signal processing methods and the short-time frequency analysis. Finally, we compare the characteristics of plasma bursts and the geometry of resulting welds carried out on a 2 kW Yb:YAG laser welding machine for the steel workpiece and various welding parameters settings.

  12. In-line process control for laser welding of titanium by high dynamic range ratio pyrometry and plasma spectroscopy

    Science.gov (United States)

    Lempe, B.; Taudt, C.; Baselt, T.; Rudek, F.; Maschke, R.; Basan, F.; Hartmann, P.

    2014-02-01

    The production of complex titanium components for various industries using laser welding processes has received growing attention in recent years. It is important to know whether the result of the cohesive joint meets the quality requirements of standardization and ultimately the customer requirements. Erroneous weld seams can have fatal consequences especially in the field of car manufacturing and medicine technology. To meet these requirements, a real-time process control system has been developed which determines the welding quality through a locally resolved temperature profile. By analyzing the resulting weld plasma received data is used to verify the stability of the laser welding process. The determination of the temperature profile is done by the detection of the emitted electromagnetic radiation from the material in a range of 500 nm to 1100 nm. As detectors, special high dynamic range CMOS cameras are used. As the emissivity of titanium depends on the wavelength, the surface and the angle of radiation, measuring the temperature is a problem. To solve these a special pyrometer setting with two cameras is used. That enables the compensation of these effects by calculating the difference between the respective pixels on simultaneously recorded images. Two spectral regions with the same emissivity are detected. Therefore the degree of emission and surface effects are compensated and canceled out of the calculation. Using the spatially resolved temperature distribution the weld geometry can be determined and the laser process can be controlled. The active readjustment of parameters such as laser power, feed rate and inert gas injection increases the quality of the welding process and decreases the number of defective goods.

  13. Robotic Variable Polarity Plasma Arc (VPPA) Welding

    Science.gov (United States)

    Jaffery, Waris S.

    1993-01-01

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

  14. Plasma heating effects during laser welding

    Science.gov (United States)

    Lewis, G. K.; Dixon, R. D.

    Laser welding is a relatively low heat input process used in joining precisely machined components with minimum distortion and heat affects to surrounding material. The CO2 (10.6 (MU)m) and Nd-YAG (1.06 (MU)m) lasers are the primary lasers used for welding in industry today. Average powers range up to 20 kW for CO2 and 400 W for Nd-YAG with pulse lengths of milliseconds to continuous wave. Control of the process depends on an understanding of the laser-plasma-material interaction and characterization of the laser beam being used. Inherent plasma formation above the material surface and subsequent modulation of the incident laser radiation directly affect the energy transfer to the target material. The temporal and spatial characteristics of the laser beam affect the available power density incident on the target, which is important in achieving repeatability in the process. Other factors such as surface texture, surface contaminants, surface chemistry, and welding environment affect plasma formation which determines the weld penetration. This work involves studies of the laser-plasma-material interaction process and particularly the effect of the plasma on the coupling of laser energy to a material during welding. A pulsed Nd-YAG laser was used with maximum average power of 400 W.

  15. Welding processes handbook

    CERN Document Server

    Weman, Klas

    2003-01-01

    Deals with the main commercially significant and commonly used welding processes. This title takes the student or novice welder through the individual steps involved in each process in an easily understood way. It covers many of the requirements referred to in European Standards including EN719, EN 729, EN 729 and EN 287.$bWelding processes handbook is a concise, explanatory guide to the main commercially significant and commonly-used welding processes. It takes the novice welder or student through the individual steps involved in each process in a clear and easily understood way. It is intended to provide an up-to-date reference to the major applications of welding as they are used in industry. The contents have been arranged so that it can be used as a textbook for European welding courses in accordance with guidelines from the European Welding Federation. Welding processes and equipment necessary for each process are described so that they can be applied to all instruction levels required by the EWF and th...

  16. Thermal stir welding process

    Science.gov (United States)

    Ding, R. Jeffrey (Inventor)

    2012-01-01

    A welding method is provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

  17. Plasma ARC keyhole welding of aluminum

    Science.gov (United States)

    Fostervoll, H.

    1993-02-01

    An increasing and more advanced use of aluminum as a construction material make higher demands to the effectiveness and quality in aluminum joining. Furthermore, if the advantages of aluminum shall be exploited in the best possible way, it is necessary to use the best processes available for the certain application. Today, the most widely used processes of aluminum welding are gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW). Plasma arc welding (PAW) is another interesting process, which is rather newly adopted for aluminum welding. However, up to now the use is limited and most of the users are within the space industry in USA (NASA); also the new space industry in Europe has adopted the process. The reason for the great interest for PAW in the space industry is, according to NASA, higher weld quality and less repair costs, less heat distortion, and less groove preparations costs. Of these reasons, PAW should also be of interest for the aluminum industry in Scandinavia. The aim of the project is to focus on the possibilities and to some extent testing the PAW process.

  18. Laser forming and welding processes

    CERN Document Server

    Yilbas, Bekir Sami; Shuja, Shahzada Zaman

    2013-01-01

    This book introduces model studies and experimental results associated with laser forming and welding such as laser induced bending, welding of sheet metals, and related practical applications. The book provides insight into the physical processes involved with laser forming and welding. The analytical study covers the formulation of laser induced bending while the model study demonstrates the simulation of bending and welding processes using the finite element method. Analytical and numerical solutions for laser forming and welding problems are provided.

  19. Closed-loop control of weld penetration in keyhole plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    陈强; 孙振国; 孙久文; 王耀文

    2004-01-01

    To improve the penetrating ability and the welding quality of keyhole plasma arc welding, a novel penetration closed-loop control system was established. In the system, welding current and plasma gas flow rate were selected as adjusting variables. The wavelet method was used to detect penetration status from welding arc voltage in real-time. The control strategy of one-keyhole-per-pulse was adapted to fulfill stable and high quality welding process. Experimental results show that the developed system can apparently increase the penetrating force of plasma arc and keyhole plasma arc welding is realized successfully in stainless steel with 10 mm in thickness. Moreover,the disturbances of gradual change and break change from 3 mm to 6 mm in thickness are come over due to the good response property of the developed system.

  20. Thermal plasma properties for Ar-Al, Ar-Fe and Ar-Cu mixtures used in welding plasmas processes: I. Net emission coefficients at atmospheric pressure

    Science.gov (United States)

    Cressault, Y.; Gleizes, A.

    2013-10-01

    This article is devoted to the calculation of the net emission coefficient (NEC) of Ar-Al, Ar-Fe and Ar-Cu mixtures at atmospheric pressure for arc welding processes. The results are given in data tables for temperatures between 3 kK and 30 kK, for five plasma thicknesses (0, 0.5, 1, 2, 5 mm) and ten concentrations of metallic vapours (pure gas, 0.01%, 0.1%, 1%, 5%, 10%, 25%, 50%, 75% and pure metal vapours in mass proportions). The results are in good agreement with most of the works published on the subject for such mixtures. They highlight the influence of three parameters on the radiation of the plasma: the NEC is directly related to temperature and inversely related to plasma radius and is highly sensitive to the presence of metal vapours. Finally, numerical data are supplied in tables in order to develop accurate computational modelling of welding arc and to estimate both qualitatively and quantitatively the influence of each metallic vapour on the size and on the shape of the weld pool.

  1. Characterization of duplex stainless steel weld metals obtained by hybrid plasma-gas metal arc welding

    Directory of Open Access Journals (Sweden)

    Koray Yurtisik

    2013-09-01

    Full Text Available Despite its high efficiency, autogenous keyhole welding is not well-accepted for duplex stainless steels because it causes excessive ferrite in as-welded duplex microstructure, which leads to a degradation in toughness and corrosion properties of the material. Combining the deep penetration characteristics of plasma arc welding in keyhole mode and metal deposition capability of gas metal arc welding, hybrid plasma - gas metal arc welding process has considered for providing a proper duplex microstructure without compromising the welding efficiency. 11.1 mm-thick standard duplex stainless steel plates were joined in a single-pass using this novel technique. Same plates were also subjected to conventional gas metal arc and plasma arc welding processes, providing benchmarks for the investigation of the weldability of the material. In the first place, the hybrid welding process enabled us to achieve less heat input compared to gas metal arc welding. Consequently, the precipitation of secondary phases, which are known to be detrimental to the toughness and corrosion resistance of duplex stainless steels, was significantly suppressed in both fusion and heat affected zones. Secondly, contrary to other keyhole techniques, proper cooling time and weld metal chemistry were achieved during the process, facilitating sufficient reconstructive transformation of austenite in the ferrite phase.

  2. Fundamental Laser Welding Process Investigations

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove

    1998-01-01

    In a number of systematic laboratory investigations the fundamental behavior of the laser welding process was analyzed by the use of normal video (30 Hz), high speed video (100 and 400 Hz) and photo diodes. Sensors were positioned to monitor the welding process from both the top side and the rear...... side of the specimen.Special attention has been given to the dynamic nature of the laser welding process, especially during unstable welding conditions. In one series of experiments, the stability of the process has been varied by changing the gap distance in lap welding. In another series...

  3. Plasma ARC Welding of High-Performance-Ship Materials

    Science.gov (United States)

    1979-05-01

    the work piece dur- ing welding. During the course of development by industry of the plasma arc process as a welding tool, v&rious orifice...point for the intended keyhole weld although, of course , minor modification to the travel speed may have to be made. The curves may be used to estimate...8217 : ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. TABLE 2 - TENSILE TEST RESULTS SpOC imun Ytlld Strounth T’n mil• StrIe lngth I|loniinttirol Lwait IL’ ,i ifr pin

  4. Unique variable polarity plasma arc welding for space shuttle

    Science.gov (United States)

    Schwinghamer, R. J.

    1985-01-01

    Since the introduction of the Plasma Arc Torch in 1955 and subsequent to the work at Boeing in the 1960's, significant improvements crucial to success have been made in the Variable Polarity Plasma Arc (VPPA) Process at the Marshall Space Flight Center. Several very important advantages to this process are given, and the genesis of PA welding, the genesis of VPPA welding, special equiment requirements, weld property development, results with other aluminum alloys, and the eventual successful VPPA transition to production operations are discussed.

  5. Simultaneous observation of keyhole and weld pool in plasma arc welding with a single cost-effective sensor

    Institute of Scientific and Technical Information of China (English)

    张国凯; 武传松; 刘新锋; 张晨

    2014-01-01

    The dynamic behaviors ofthe keyhole and weld pool are coupled together in plasma arc welding,and the geometric variations ofboth the keyhole and the weld pool determine the weld quality.It is ofgreat significance to simultaneously sense and monitor the keyhole and the weld pool behaviors by using a single low-cost vision sensor in plasma arc welding process.In this study,the keyhole and weld pool were observed and measured under different levels ofwelding current by using the near infrared sensing technology and the charge coupled device (CCD)sensing system.The shapes and relative position ofweld pool and keyhole under different conditions were compared and analyzed.The observation results lay solid foundation for controlling weld quality and understanding the underlying process mechanisms.

  6. Sensor integration for robotic laser welding processes

    NARCIS (Netherlands)

    Iakovou, Dimitrios; Aarts, Ronald; Meijer, Johan

    2005-01-01

    The use of robotic laser welding is increasing among industrial applications, because of its ability to weld objects in three dimensions. Robotic laser welding involves three sub-processes: seam detection and tracking, welding process control, and weld seam inspection. Usually, for each sub-process,

  7. Unified model to the Tungsten inert Gas welding process including the cathode, the plasma and the anode; Modele couple cathode-plasma-piece en vue de la simulation du procede de soudage a l'arc TIG

    Energy Technology Data Exchange (ETDEWEB)

    Brochard, M.

    2009-06-15

    During this work, a 2D axially symmetric model of a TIG arc welding process had been developed in order to predict for given welding parameters, the needed variables for a designer of welded assembly: the heat input on the work piece, the weld pool geometry,... The developed model, using the Cast3M finite elements software, deals with the physical phenomena acting in each part of the process: the cathode, the plasma, the work piece with a weld pool, and the interfaces between these parts. To solve this model, the thermohydraulics equations are coupled with the electromagnetic equations that are calculated in part using the least squares finite element method. The beginning of the model validation consisted in comparing the results obtained with the ones available in the scientific literature. Thus, this step points out the action of each force in the weld pool, the contribution of each heat flux in the energy balance. Finally, to validate the model predictiveness, experimental and numerical sensitivity analyses were conducted using a design of experiments approach. The effects of the process current, the arc gap and the electrode tip angle on the weld pool geometry and the energy transferred to the work piece and the arc efficiency were studied. The good agreement obtained by the developed model for these outputs shows the good reproduction of the process physics. (author)

  8. Plasma spot welding of ferritic stainless steels

    Directory of Open Access Journals (Sweden)

    Lešnjak, A.

    2002-06-01

    Full Text Available Plasma spot welding of ferritic stainless steels is studied. The study was focused on welding parameters, plasma and shielding gases and the optimum welding equipment. Plasma-spot welded overlap joints on a 0.8 mm thick ferritic stainless steel sheet were subjected to a visual examination and mechanical testing in terms of tension-shear strength. Several macro specimens were prepared. Plasma spot welding is suitable to use the same gas as shielding gas and as plasma gas, i.e., a 98 % Ar/2 % H 2 gas mixture. Tension-shear strength of plasma-spot welded joints was compared to that of resistance-spot welded joints. It was found that the resistance welded joints withstand a somewhat stronger load than the plasma welded joints due to a larger weld spot diameter of the former. Strength of both types of welded joints is approximately the same.

    El artículo describe el proceso de soldeo de aceros inoxidables ferríticos por puntos con plasma. La investigación se centró en el establecimiento de los parámetros óptimos de la soldadura, la definición del gas de plasma y de protección más adecuado, así como del equipo óptimo para la realización de la soldadura. Las uniones de láminas de aceros inoxidables ferríticos de 0,8 mm de espesor, soldadas a solape por puntos con plasma, se inspeccionaron visualmente y se ensayaron mecánicamente mediante el ensayo de cizalladura por tracción. Se realizaron macro pulidos. Los resultados de la investigación demostraron que la solución más adecuada para el soldeo por puntos con plasma es elegir el mismo gas de plasma que de protección. Es decir, una mezcla de 98 % de argón y 2 % de hidrógeno. La resistencia a la cizalladura por tracción de las uniones soldadas por puntos con plasma fue comparada con la resistencia de las uniones soldadas por resistencia por puntos. Se llegó a la conclusión de que las uniones soldadas por resistencia soportan una carga algo mayor que la uniones

  9. Sensing controlled pulse key-holing condition in plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    JIA Chuan-bao; WU Chuan-song; ZHANG Yu-ming

    2009-01-01

    According to the strategy of controlled pulse key-holing, a new sensing and control system was developed for monitoring and controlling the keyhole condition during plasma arc welding (PAW). Through sensing and processing the efflux plasma voltage signals, the quantitative relationship among the welding current, efflux plasma voltage and backside weld width of the weld was established. PAW experiments show that the efflux plasma voltage can reflect the state of keyhole and backside weld width accurately. The closed-loop control tests validate the stability and reliability of the developed keyhole PAW system.

  10. Modeling of plasma and thermo-fluid transport in hybrid welding

    Science.gov (United States)

    Ribic, Brandon D.

    Hybrid welding combines a laser beam and electrical arc in order to join metals within a single pass at welding speeds on the order of 1 m min -1. Neither autonomous laser nor arc welding can achieve the weld geometry obtained from hybrid welding for the same process parameters. Depending upon the process parameters, hybrid weld depth and width can each be on the order of 5 mm. The ability to produce a wide weld bead increases gap tolerance for square joints which can reduce machining costs and joint fitting difficulty. The weld geometry and fast welding speed of hybrid welding make it a good choice for application in ship, pipeline, and aerospace welding. Heat transfer and fluid flow influence weld metal mixing, cooling rates, and weld bead geometry. Cooling rate affects weld microstructure and subsequent weld mechanical properties. Fluid flow and heat transfer in the liquid weld pool are affected by laser and arc energy absorption. The laser and arc generate plasmas which can influence arc and laser energy absorption. Metal vapors introduced from the keyhole, a vapor filled cavity formed near the laser focal point, influence arc plasma light emission and energy absorption. However, hybrid welding plasma properties near the opening of the keyhole are not known nor is the influence of arc power and heat source separation understood. A sound understanding of these processes is important to consistently achieving sound weldments. By varying process parameters during welding, it is possible to better understand their influence on temperature profiles, weld metal mixing, cooling rates, and plasma properties. The current literature has shown that important process parameters for hybrid welding include: arc power, laser power, and heat source separation distance. However, their influence on weld temperatures, fluid flow, cooling rates, and plasma properties are not well understood. Modeling has shown to be a successful means of better understanding the influence of

  11. Development of procedure using plasma welding process to produce {sup 125}I seeds; Desenvolvimento de procedimento utilizando processo de soldagem plasma para confeccao de sementes de {sup 125}I

    Energy Technology Data Exchange (ETDEWEB)

    Feher, Anselmo

    2006-07-01

    The prostate cancer, which is the second cause of death by cancer in men, overcome only by lung cancer, is a problem of public health in Brazil. Brachytherapy is among the possible available treatments for prostate cancer, in which small seeds containing {sup 125}I radioisotope are implanted in the prostate. The seed consists of a titanium sealed capsule with 0.8 mm external diameter and 4.5 mm length, containing a central silver wire with adsorbed {sup 125}I. The plasma arc welding is one of the viable techniques for the sealing process. The equipment used in this technique is less costly than in other processes. The main objective of this work was the development and the validation of the welding procedure using plasma welding process and the elaboration of a sealing routine according to Good Manufacturing Practices. The development of this work has presented the following phases: cut and cleaning of the titanium material, determination of the welding parameters, development of a device for holding the titanium tube during the welding process, validation of sealed sources according to ISO 2919 Sealed Radioactive Sources - General Requirements and Classification, leakage test according to ISO 9978 Sealed Radioactive Sources - Leakage Test Methods and metallographic assays. The developed procedure, to seal {sup 125}I seeds using plasma welding process, has shown to be efficient, satisfying all the established requirements of ISO 2919. The results obtained in this work have given the possibility to establish a routine production process according to the orientations presented in resolution RDC number 59 - Good Manufacturing Practices do Medical Products of the ANVISA - Brazilian Nacional Agency of Sanitary Surveillance. (author)

  12. Experimental determination of the weld penetration evolution in keyhole plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    Hu Qingxian; Wu Chuansong; Zhang Yuming

    2007-01-01

    Keyhole plasma arc welding experiments are conducted to measure the weld geometry and penetration at different moments during the initial phase from igniting arc to quasi-steady state. Indirect information on keyhole formation and evolution in plasma arc welding can be extracted based on the weld macrophotograph at cross section. It has laid foundation to verify the mathematical models of keyhole plasma arc welding.

  13. Plasma Arc Augmented CO2 laser welding

    DEFF Research Database (Denmark)

    Bagger, Claus; Andersen, Mikkel; Frederiksen, Niels

    2001-01-01

    In order to reduce the hardness of laser beam welded 2.13 mm medium strength steel CMn 250, a plasma arc has been used simultaneously with a 2.6 kW CO2 laser source. In a number of systematic laboratory tests, the plasma arc current, plasma gas flow and distance to the laser source were varied...... with all laser parameters fixed. The welds were quality assessed and hardness measured transversely to the welding direction in the top, middle and root of the seam. In the seams welded by laser alone, hardness values between 275 and 304 HV1 were measured, about the double of the base material, 150 HV1...

  14. Study of Dynamic Features of Surface Plasma in High-Power Disk Laser Welding

    Institute of Scientific and Technical Information of China (English)

    王腾; 高向东; Katayatna SEIJI; 金小莉

    2012-01-01

    High-speed photography was used to obtain the dynamic changes in the surface plasma during a high-power disk laser welding process. A color space clustering algorithm to extract the edge information of the surface plasma region was developed in order to improve the accuracy of image processing. With a comparative analysis of the plasma features, i.e., area and height, and the characteristics of the welded seam, the relationship between the surface plasma and the stability of the laser welding process was characterized, which provides a basic understanding for the real-time monitoring of laser welding.

  15. A Plasma Control and Gas Protection System for Laser Welding of Stainless Steel

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove

    1997-01-01

    A prototype shield gas box with different plasma control nozzles have been investigated for laser welding of stainless steel (AISI 316). Different gases for plasma control and gas protection of the weld seam have been used. The gas types, welding speed and gas flows show the impact on process...... stability and protection against oxidation. Also oxidation related to special conditions at the starting edge has been investigated. The interaction between coaxial and plasma gas flow show that the coaxial flow widens the band in which the plasma gas flow suppresses the metal plasma. In this band the welds...

  16. ARc Welding (Industrial Processing Series).

    Science.gov (United States)

    ARC WELDING , *BIBLIOGRAPHIES), (*ARC WELDS, BIBLIOGRAPHIES), ALUMINUM ALLOYS, TITANIUM ALLOYS, CHROMIUM ALLOYS, METAL PLATES, SPOT WELDING , STEEL...INERT GAS WELDING , MARAGING STEELS, MICROSTRUCTURE, HEAT RESISTANT ALLOYS, HEAT RESISTANT METALS, WELDABILITY, MECHANICAL PROPERTIES, MOLYBDENUM ALLOYS, NICKEL ALLOYS, RESISTANCE WELDING

  17. Pre-Industry-Optimisation of the Laser Welding Process

    DEFF Research Database (Denmark)

    Gong, Hui

    This dissertation documents the investigations into on-line monitoring the CO2 laser welding process and optimising the process parameters for achieving high quality welds. The requirements for realisation of an on-line control system are, first of all, a clear understanding of the dynamic...... phenomena of the laser welding process including the behaviour of the keyhole and plume, and the correlation between the adjustable process parameters: laser power, welding speed, focal point position, gas parameters etc. and the characteristics describing the quality of the weld: seam depth and width......, porosity etc. Secondly, a reliable monitoring system for sensing the laser-induced plasma and plume emission and detecting weld defects and process parameter deviations from the optimum conditions. Finally, an efficient control system with a fast signal processor and a precise feed-back controller...

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

    Science.gov (United States)

    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.

  19. Repair welding process of friction stir welding groove defect

    Institute of Scientific and Technical Information of China (English)

    LIU Hui-jie; ZHANG Hui-jie

    2009-01-01

    The groove defect formed in the friction stir welding dramatically deteriorates weld appearances and mechanical properties of the joints owing to its larger size and penetration. Therefore, the friction stir repair welding was utilized to remove such a groove defect, and the focus was placed on the mechanical properties and microstructural characteristics of the repair joints so as to obtain an optimum repair welding process. The experimental results indicate that the groove defect can be removed by friction stir repair welding, and the offset repair welding process is superior to the symmetrical repair welding process. In the symmetrical repair welding process, a large number of fine cavity defects and an obvious aggregation of hard-brittle phase Al2Cu occur, accordingly the mechanical properties of the repair joint are weakened, and the fracture feature of repair joint is partially brittle and partially plastic. A good-quality repair joint can be obtained by the offset repair welding process, and the repair joint is fractured near the interface between the weld nugget zone and thermal-mechanically affected zone.

  20. Modelling of the plasma-MIG welding temperature field

    Institute of Scientific and Technical Information of China (English)

    Bai Yan; Gao Hongming; Wu Lin; Shi Lei

    2006-01-01

    A three-dimensional simulation model for the plasma-MIG welding process, which takes the interaction between the plasma arc and MIG arc into account, is presented and the quasi-steady temperature fields on the workpiece are calculated with the model. The 10 mm-5A06 aluminum alloy is welded and the temperature fields are measured with the thermoelectric couple. The simulation results and measured results show that the biggest deviation of peak temperature between them is below 20 ℃ , which indicates good coincidence between the simulation and measurement.

  1. Deconvoluting the Friction Stir Weld Process for Optimizing Welds

    Science.gov (United States)

    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.

  2. Possibilities in optical monitoring of laser welding process

    Science.gov (United States)

    Horník, Petr; Mrňa, Libor; Pavelka, Jan

    2016-11-01

    Laser welding is a modern, widely used but still not really common method of welding. With increasing demands on the quality of the welds, it is usual to apply automated machine welding and with on-line monitoring of the welding process. The resulting quality of the weld is largely affected by the behavior of keyhole. However, its direct observation during the welding process is practically impossible and it is necessary to use indirect methods. At ISI we have developed optical methods of monitoring the process. Most advanced is an analysis of radiation of laser-induced plasma plume forming in the keyhole where changes in the frequency of the plasma bursts are monitored and evaluated using Fourier and autocorrelation analysis. Another solution, robust and suitable for industry, is based on the observation of the keyhole inlet opening through a coaxial camera mounted in the welding head and the subsequent image processing by computer vision methods. A high-speed camera is used to understand the dynamics of the plasma plume. Through optical spectroscopy of the plume, we can study the excitation of elements in a material. It is also beneficial to monitor the gas flow of shielding gas using schlieren method.

  3. Plasma Control and Gas Protection System for Laser Welding of Stainless Steel

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove; Petersen, Kaj

    1997-01-01

    An integrated plasma nozzle and a shield gas box have been investigated for laser welding of 2 mm stainless steel sheets. Different gases for plasma control and gas protection of the weld seam have been used. The gas types, welding speed and coaxial and plasma flow show the impact on process...... stability and protection against oxidation. Also oxidation related to special conditions at the starting edge has been investigated. The interaction between coaxial and plasma gas flow show that the coaxial flow widens the band in which the plasma gas flow suppresses the metal plasma. In this band the welds...... are oxide free. With 2.7 kW power welds have been performed at 3000 mm/min with Ar / He (70%/30%) as coaxial, plasma and shield gas....

  4. Relationship between sound signal and weld pool status in plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    The sound features of the weld pool status in plasma arc welding were systematically investigated after the sound signal was collected with a microphone. The results show that it is difficult to extract information about the weld pool status directly in time domain although the sound signal varies with the weld pool behaviors to some extent. The frequency spectra of the sound signal contain plenty of information about the weld pool behaviors. It is shown from the analysis of the sound generation mechanism that the sound signal of plasma arc welding is mainly caused by the weld pool oscillation, the power source fluctuation and so on. RS algorithm is designed to determine the weld pool status, and it is able to offer the feedback information for the closed-loop control of the penetration quality of plasma arc welding.

  5. A study of processes for welding pipelines

    Energy Technology Data Exchange (ETDEWEB)

    Weston, J. (ed.)

    1991-07-01

    A review was made of exisiting and potential processes for welding pipelines: fusion welding (arc, electron beam, laser, thermit) and forge welding (friction, flash, magnetically impelled arc butt, upset butt, explosive, shielded active gas, gas pressure). Consideration of J-lay operations gave indications that were reflections of the status of the processes in terms of normal land and offshore S-lay operation: forge welding processes, although having promise require considerable development; fusion welding processes offer several possibilities (mechanized GMA welding likely to be used in 1991-2); laser welding requires development in all pipeline areas: a production machine for electron beam welding will involve high costs. Nondestructive testing techniques are also reviewed. Demand for faster quality assessment is being addressed by speeding radiographic film processing and through the development of real time radiography and automatic ultrasonic testing. Conclusions on most likely future process developments are: SMAW with cellulosic electrodes is best for tie-ins, short pip runs; SMAW continues to be important for small-diameter lines, although mechanized GMA could be used, along with mechanical joining, MIAB, radial fraction, and flash butt; mechanized GMA welding is likely to predominate for large diameter lines and probably will be used for the first J-lay line (other techniques could be used too); and welding of piping for station facilities involves both shop welding of sub-assemblies and on-site welding of pipe and sub-assemblies to each other (site welding uses both SMAW and GMAW). Figs, tabs.

  6. A Plasma Control and Gas Protection System for Laser Welding of Stainless Steel

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove

    1997-01-01

    A prototype shield gas box with different plasma control nozzles have been investigated for laser welding of stainless steel (AISI 316). Different gases for plasma control and gas protection of the weld seam have been used. The gas types, welding speed and gas flows show the impact on process...... stability and protection against oxidation. Also oxidation related to special conditions at the starting edge has been investigated. The interaction between coaxial and plasma gas flow show that the coaxial flow widens the band in which the plasma gas flow suppresses the metal plasma. In this band the welds...... are oxide free. With 2.7 kW power welds have been performed at 4000 mm/min with Ar / He (70%/30%) as coaxial, plasma and shield gas....

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

    Science.gov (United States)

    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.

  8. Analysis of keyhole geometry in plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    Hu Qingxian; Wu Chuansong

    2006-01-01

    The key problem for numerical simulation of plasma arc welding (PAW) process is to develop a suitable and adaptive volumetric heat source mode which reflects the physical characteristics of keyhole PAW. To this end, the keyhole geometry under different PAW process conditions must be predicted. In this paper, a mathematical model for determining the keyhole shape is developed with considering the mass and momentum conservation of the in-keyhole plasma jet as well as the pressure equilibrium at the plasma jet/liquid metal boundary. A suitable heat source model related to the keyhole shape is applied to the calculation of PAW weld dimensions. The predicted results are in good agreement with the experimental ones.

  9. Development of Temper Bead Welding Process for Weld Overlay of Dissimilar Welds

    Energy Technology Data Exchange (ETDEWEB)

    Byeon, J. G.; Park, K. S.; Kim, Y. J. [Doosan Heavy Industries and Construction Co., Ltd., Seoul (Korea, Republic of)

    2008-10-15

    In recent years, the dissimilar weld metal used to connect stainless steel piping and low alloy steel or carbon steel components have experienced cracking in nuclear reactor piping systems. The cracking has been observed in several Pressurized Water Reactors in overseas. In Several cases, the cracking was repaired using structural weld overlays, a repair technique that has been in use in the U.S. in Boiling Water Reactors for over twenty years. Although weld overlays have been used primarily as a repair for flawed piping, they can also be applied at locations that have not yet exhibited any cracking, but are considered susceptible to cracking. The purpose of this research is to develop the temper bead weld process for the weld overlay of the dissimilar weld pipe. We developed equipment for the overlay system, applied Procedure Qualification(PQ) for the temper bead welding process.

  10. CO2 laser-micro plasma arc hybrid welding for galvanized steel sheets

    Institute of Scientific and Technical Information of China (English)

    C. H. KIM; Y. N. AHN; J. H. KIM

    2011-01-01

    A laser lap welding process for zinc-coated steel has a well-known unsolved problem-porosity formation. The boiling temperature of coated zinc is lower than the melting temperature of the base metal. which is steel. In the autogenous laser welding,the zinc vapor generates from the lapped surfaces expels the molten pool and the expulsion causes numerous weld defects, such as spatters and blow holes on the weld surface and porosity inside the welds. The laser-arc hybrid welding was suggested as an alternative method for the laser lap welding because the arc can preheat or post-heat the weldment according to the arrangement of the laser beam and the arc. CO2 laser-micro plasma hybrid welding was applied to the lap welding of zinc-coated steel with zero-gap.The relationships among the weld quality and process parameters of the laser-arc arrangement, and the laser-arc interspacing distance and arc current were investigated using a full-factorial experimental design. The effect of laser-arc arrangement is dominant because the leading plasma arc partially melts the upper steel sheets and vaporizes or oxidizes the coated zinc on the lapped surfaces.Compared with the result from the laser-TIG hybrid welding, the heat input from arc can be reduced by 40%.

  11. Friction Stir Welding and Processing

    Energy Technology Data Exchange (ETDEWEB)

    Hovanski, Yuri; Carsley, John; Clarke, Kester D.; Krajewski, Paul E.

    2015-05-01

    With nearly twenty years of international research and collaboration in friction stir welding (FSW) and processing industrial applications have spread into nearly every feasible market. Currently applications exist in aerospace, railway, automotive, personal computers, technology, marine, cutlery, construction, as well as several other markets. Implementation of FSW has demonstrated diverse opportunities ranging from enabling new materials to reducing the production costs of current welding technologies by enabling condensed packaging solutions for traditional fabrication and assembly. TMS has sponsored focused instruction and communication in this technology area for more than fifteen years, with leadership from the Shaping and Forming Committee, which organizes a biannual symposium each odd year at the annual meeting. A focused publication produced from each of these symposia now comprises eight volumes detailing the primary research and development activities in this area over the last two decades. The articles assembled herein focus on both recent developments and technology reviews of several key markets from international experts in this area.

  12. Variable-Polarity Plasma Arc Welding Of Alloy 2219

    Science.gov (United States)

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

    1989-01-01

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

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

    Science.gov (United States)

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

    2017-03-01

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

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

    Science.gov (United States)

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

    2017-01-01

    This work is dedicated to optimization of carbide particle system in a weld bead deposited by PTAW technique over D2 tool steel with high chromium content. The paper reports partial melting of the original carbide grains of the Ni-based filling powder, and growing of the secondary carbide phase (Cr, Ni)_3 W_3 C in the form of dendrites with wide branches that enhanced mechanical properties of the weld. The optimization of bead parameters was made with design of experiment methodology complemented by a complex sample characterization including SEM, EDXS, XRD, and nanoindentation measurements. It was shown that the preheat of the substrate to a moderate temperature 523 K (250° C) establishes linear pattern of metal flow in the weld pool, resulting in the most homogeneous distribution of the primary carbides in the microstructure of weld bead.

  15. Effect of pulsed current micro plasma arc welding process parameters on fusion zone grain size and ultimate tensile strength of Inconel 625 sheets

    Institute of Scientific and Technical Information of China (English)

    Kondapalli Siva Prasad; Chalamalasetti Srinivasa Rao; Damera Nageswara Rao

    2012-01-01

    The paper focuses on developing mathematical models to predict grain size and ultimate tensile strength of pulsed current micro plasma arc welded Inconel 625 nickel alloy.Four factors,five levels,central composite rotatable design matrix is used to optimize the number of experiments.The mathematical models have been developed by response surface method.The adequacy of the models is checked by analysis of variance technique.By using the developed mathematical models,grain size and ultimate tensile strength of the joints can be predicted with 99%0 confidence level.Contour plots are drawn to study the interaction effect of pulsed current micro plasma arc welding parameters on fusion zone grain size and ultimate tensile strength of Inconel 625 weld ioints.

  16. Gas arc constriction for plasma arc welding

    Science.gov (United States)

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

    1994-01-01

    A welding torch for plasma arc welding apparatus has an inert gas applied circumferentially about the arc column externally of the constricting nozzle so as to apply a constricting force on the arc after it has exited the nozzle orifice and downstream of the auxiliary shielding gas. The constricting inert gas is supplied to a plenum chamber about the body of the torch and exits through a series of circumferentially disposed orifices in an annular wall forming a closure at the forward end of the constricting gas plenum chamber. The constricting force of the circumferential gas flow about the arc concentrates and focuses the arc column into a more narrow and dense column of energy after exiting the nozzle orifice so that the arc better retains its energy density prior to contacting the workpiece.

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

    Science.gov (United States)

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

    2015-03-01

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

  18. Effects of welding wire composition and welding process on the weld metal toughness of submerged arc welded pipeline steel

    Institute of Scientific and Technical Information of China (English)

    De-liang Ren; Fu-ren Xiao; Peng Tian; Xu Wang; Bo Liao

    2009-01-01

    The effects of alloying elements in welding wires and submerged arc welding process on the microstructures and low-temperature impact toughness of weld metals have been investigated.The results indicate that the optimal contents of alloying elements in welding wires can improve the low-temperature impact toughness of weld metals because the proentectoid ferrite and bainite formations can be suppressed,and the fraction of acicular ferrite increases.However,the contents of alloying elements need to vary along with the welding heat input.With the increase in welding heat input,the contents of alloying elements in welding wires need to be increased accordingly.The microstructures mainly consisting of acicular ferrite can be obtained in weld metals after four-wire submerged arc welding using the wires with a low carbon content and appropriate contents of Mn,Mo,Ti-B,Cu,Ni,and RE,resulting in the high low-temperature impact toughness of weld metals.

  19. Welding of titanium and nickel alloy by combination of explosive welding and spark plasma sintering technologies

    Energy Technology Data Exchange (ETDEWEB)

    Malyutina, Yu. N., E-mail: iuliiamaliutina@gmail.com; Bataev, A. A., E-mail: bataev@adm.nstu.ru; Shevtsova, L. I., E-mail: edeliya2010@mail.ru [Novosibirsk State Technical University, Novosibirsk, 630073 (Russian Federation); Mali, V. I., E-mail: vmali@mail.ru; Anisimov, A. G., E-mail: anis@hydro.nsc.ru [Lavrentyev Institute of Hydrodynamics SB RAS, Novosibirsk, 630090 (Russian Federation)

    2015-10-27

    A possibility of titanium and nickel-based alloys composite materials formation using combination of explosive welding and spark plasma sintering technologies was demonstrated in the current research. An employment of interlayer consisting of copper and tantalum thin plates makes possible to eliminate a contact between metallurgical incompatible titanium and nickel that are susceptible to intermetallic compounds formation during their interaction. By the following spark plasma sintering process the bonding has been received between titanium and titanium alloy VT20 through the thin powder layer of pure titanium that is distinguished by low defectiveness and fine dispersive structure.

  20. Welding of titanium and nickel alloy by combination of explosive welding and spark plasma sintering technologies

    Science.gov (United States)

    Malyutina, Yu. N.; Bataev, A. A.; Mali, V. I.; Anisimov, A. G.; Shevtsova, L. I.

    2015-10-01

    A possibility of titanium and nickel-based alloys composite materials formation using combination of explosive welding and spark plasma sintering technologies was demonstrated in the current research. An employment of interlayer consisting of copper and tantalum thin plates makes possible to eliminate a contact between metallurgical incompatible titanium and nickel that are susceptible to intermetallic compounds formation during their interaction. By the following spark plasma sintering process the bonding has been received between titanium and titanium alloy VT20 through the thin powder layer of pure titanium that is distinguished by low defectiveness and fine dispersive structure.

  1. Development of a comprehensive weld process model

    Energy Technology Data Exchange (ETDEWEB)

    Radhakrishnan, B.; Zacharia, T.; Paul, A.

    1997-05-01

    This cooperative research and development agreement (CRADA) between Concurrent Technologies Corporation (CTC) and Lockheed Martin Energy Systems (LMES) combines CTC`s expertise in the welding area and that of LMES to develop computer models and simulation software for welding processes. This development is of significant impact to the industry, including materials producers and fabricators. The main thrust of the research effort was to develop a comprehensive welding simulation methodology. A substantial amount of work has been done by several researchers to numerically model several welding processes. The primary drawback of most of the existing models is the lack of sound linkages between the mechanistic aspects (e.g., heat transfer, fluid flow, and residual stress) and the metallurgical aspects (e.g., microstructure development and control). A comprehensive numerical model which can be used to elucidate the effect of welding parameters/conditions on the temperature distribution, weld pool shape and size, solidification behavior, and microstructure development, as well as stresses and distortion, does not exist. It was therefore imperative to develop a comprehensive model which would predict all of the above phenomena during welding. The CRADA built upon an already existing three-dimensional (3-D) welding simulation model which was developed by LMES which is capable of predicting weld pool shape and the temperature history in 3-d single-pass welds. However, the model does not account for multipass welds, microstructural evolution, distortion and residual stresses. Additionally, the model requires large resources of computing time, which limits its use for practical applications. To overcome this, CTC and LMES have developed through this CRADA the comprehensive welding simulation model described above.

  2. [The Spectral Analysis of Laser-Induced Plasma in Laser Welding with Various Protecting Conditions].

    Science.gov (United States)

    Du, Xiao; Yang, Li-jun; Liu, Tong; Jiao, Jiao; Wang, Hui-chao

    2016-01-01

    The shielding gas plays an important role in the laser welding process and the variation of the protecting conditions has an obvious effect on the welding quality. This paper studied the influence of the change of protecting conditions on the parameters of laser-induced plasma such as electron temperature and electron density during the laser welding process by designing some experiments of reducing the shielding gas flow rate step by step and simulating the adverse conditions possibly occurring in the actual Nd : YAG laser welding process. The laser-induced plasma was detected by a fiber spectrometer to get the spectral data. So the electron temperature of laser-induced plasma was calculated by using the method of relative spectral intensity and the electron density by the Stark Broadening. The results indicated that the variation of protecting conditions had an important effect on the electron temperature and the electron density in the laser welding. When the protecting conditions were changed, the average electron temperature and the average electron density of the laser-induced plasma would change, so did their fluctuation range. When the weld was in a good protecting condition, the electron temperature, the electron density and their fluctuation were all low. Otherwise, the values would be high. These characteristics would have contribution to monitoring the process of laser welding.

  3. Laser Shock Processing of Metal Sheet and Welded Joints

    Institute of Scientific and Technical Information of China (English)

    ZOU Shi-kun; TAN Yong-sheng; ZHANG Xiao-bin; LIU Fang-jun

    2004-01-01

    In order to study the application of laser shock processing(LSP) as a post weld treatment technology and a strengthening technology, a series experiments and analysis were taken in this paper. The hardness of the laser shock processed zone of Al-Li alloy was measured, and the microstructure and mechanical properties of the welded joints of the Ni-based superalloy GH30 and the Austenitic stainless steel 1Cr18Ni9Ti were compared with those without LSP in this paper. The results showed that the size of strengthened zone was similar to that of laser spot and strengthened layer was about 1mm deep, and the high intense dislocations and twins produced in the shocked zone. Plastic strain also gained surface residual compress stress, which is benefit for the fatigue properties of welded zones. In this test, the surface hardness of welding zone of the superalloy GH30 improved obviously and tensile strength increased by 12%, but the improvement of fatigue life was not obvious; Martensite phase is formed in plasma welding 1Cr18Ni9Ti, which reduced the effect of strain deformation martensite induced by laser shock processing, but the surface residual compress stress gained by laser shock processing can obviously improve the fatigue life of 1Cr1 8Ni9Ti welded joints.

  4. Laser Shock Processing of Metal Sheet and Welded Joints

    Institute of Scientific and Technical Information of China (English)

    ZOUShi-kun; TANYong-sheng; ZHANGXiao-bin; LIUFang-jun

    2004-01-01

    In order to study the application of laser shock processing(LSP) as a post weld treatment technology and a strengthening technology, a series experiments and analysis were taken in this paper. The hardness of the laser shock processed zone of A1-Li alloy was measured, and the microstructure and mechanical properties of the welded joints of the Ni-based superalloy GH30 and the Austenitic stainless steel 1Crl8Ni9Ti were compared with those without LSP in this paper. The results showed that the size of strengthened zone was similar to that of laser spot and strengthened layer was about lmm deep, and the high intense dislocations and twins produced in the shocked zone. Plastic strain also gained surface residual compress stress, which is benefit for the fatigue properties of welded zones. In this test, the surface hardness of welding zone of the superalloy GH30 improved obviously and tensile strength increased by 12%, but the improvement of fatigue life was not obvious; Martensite phase is formed in plasma welding 1Crl8Ni9Ti, which reduced the effect of strain deformation martensite induced by laser shock processing, but the surface residual compress stress gained by laser shock processing can obviously improve the fatigue life of 1Crl 8Ni9Ti welded joints.

  5. Laser guided and stabilized gas metal arc welding processes (LGS-GMA)

    Science.gov (United States)

    Hermsdorf, Jörg; Barroi, Alexander; Kaierle, Stefan; Overmeyer, Ludger

    2013-05-01

    The demands of the industry are cheap and fast production of highly sophisticated parts without compromises in product quality. To realize this requirement, we have developed a laser guided and stabilized gas metal arc process (LGS-GMA welding). The new welding process is based on a gas metal arc process using low power laser radiation for stabilization. The laser stabilization of gas metal arcs welding is applied to joint welding and cladding. With only 400 W laser power and a focal spot of 1.6 mm the laser radiation is mainly interacting with the arc plasma in order to guide and stabilize it. In joint welding up to 100% increase in welding speed is possible, at equal penetration depth. The guidance effect also enables the process to weld in challenging situations like different sheet thicknesses. Used for cladding, the enhanced process stability allows low penetration depth with dilutions of only 3%. Coatings with up to 63 HRC were achieved.

  6. Numerical analysis of transient keyhole shape in pulsed current plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    孙俊华; 武传松

    2014-01-01

    Based on the characteristics of“one keyhole in a pulse”in pulsed current plasma arc welding (PAW),the transient variation process ofweld pool in a pulse cycle is simulated through the establishment ofcorresponding heat source model.And considering the effects ofgravitational force,plasma arc pressure and surface tension on the weld pool surface,the dynamic change features of the keyhole shape in a pulse cycle are calculated by using surface deformation equation. Experiments are conducted and validate that the calculated weld fusion line is in good agreement with the experimental results.

  7. Spectral diagnostics of a vapor-plasma plume produced during welding titanium with a high-power ytterbium fiber laser

    Science.gov (United States)

    Uspenskiy, S. A.; Petrovskiy, V. N.; Bykovskiy, D. P.; Mironov, V. D.; Prokopova, N. M.; Tret'yakov, E. V.

    2015-03-01

    This work is devoted to the research of welding plume during high power ytterbium fiber laser welding of a titanium alloy in the Ar shielding gas environment. High speed video observation of a vapor-plasma plume for visualization of processes occurring at laser welding was carried out. The coefficient of the inverse Bremsstrahlung absorption of laser radiation is calculated for a plasma welding plume by results of spectrometer researches. The conclusion deals with the impact of plasma on a high-power fiber laser radiation.

  8. Optimization of underwater wet welding process parameters using neural network

    National Research Council Canada - National Science Library

    Omajene, Joshua Emuejevoke; Martikainen, Jukka; Wu, Huapeng; Kah, Paul

    2014-01-01

    .... The soundness of a weld can be predicted from the weld bead geometry.This paper illustrates the application of artificial neural network approach in the optimization of the welding process parameter and the influence of the water environment...

  9. Improvement of bonding properties of laser transmission welded, dissimilar thermoplastics by plasma surface treatment

    Energy Technology Data Exchange (ETDEWEB)

    Hopmann, Ch.; Weber, M.; Schöngart, M.; Sooriyapiragasam, S.; Behm, H.; Dahlmann, R. [Institute of Plastics Processing (IKV), RWTH Aachen University, Pontstrasse 49, 52062 Aachen (Germany)

    2015-05-22

    Compared to different welding methods such as ultrasonic welding, laser transmission welding is a relatively new technology to join thermoplastic parts. The most significant advantages over other methods are the contactless energy input which can be controlled very precisely and the low mechanical loads on the welded parts. Therefore, laser transmission welding is used in various areas of application, for example in medical technology or for assembling headlights in the automotive sector. However, there are several challenges in welding dissimilar thermoplastics. This may be due to different melting points on the one hand and different polarities on the other hand. So far these problems are faced with the intermediate layer technique. In this process a layer bonding together the two components is placed between the components. This means that an additional step in the production is needed to apply the extra layer. To avoid this additional step, different ways of joining dissimilar thermoplastics are investigated. In this regard, the improvement in the weldability of the dissimilar thermoplastics polyamide 6 (PA 6) and polypropylene (PP) by means of plasma surface modification and contour welding is examined. To evaluate the influence of the plasma surface modification process on the subsequent welding process of the two dissimilar materials, the treatment time as well as the storage time between treatment and welding are varied. The treatment time in pulsed micro wave excited oxygen plasmas with an electron density of about 1x10{sup 17} m{sup −3} is varied from 0.5 s to 120 s and the time between treatment and welding is varied from a few minutes up to a week. As reference, parts being made of the same polymer (PP and PA 6) are welded and tested. For the evaluation of the results of the welding experiments, short-time tensile tests are used to determine the bond strength. Without plasma treatment the described combination of PA 6/PP cannot be welded with

  10. Development of a Comprehensive Weld Process Model

    Energy Technology Data Exchange (ETDEWEB)

    Radhakrishnan, B.; Zacharia, T.

    1997-05-01

    This cooperative research and development agreement (CRADA) between Concurrent Technologies Corporation (CTC) and Lockheed Martin Energy Systems (LMES) combines CTC's expertise in the welding area and that of LMES to develop computer models and simulation software for welding processes. This development is of significant impact to the industry, including materials producers and fabricators. The main thrust of the research effort was to develop a comprehensive welding simulation methodology. A substantial amount of work has been done by several researchers to numerically model several welding processes. The primary drawback of most of the existing models is the lack of sound linkages between the mechanistic aspects (e.g., heat transfer, fluid flow, and residual stress) and the metallurgical aspects (e.g., microstructure development and control). A comprehensive numerical model which can be used to elucidate the effect of welding parameters/conditions on the temperature distribution, weld pool shape and size, solidification behavior, and microstructure development, as well as stresses and distortion, does not exist. It was therefore imperative to develop a comprehensive model which would predict all of the above phenomena during welding. The CRADA built upon an already existing three- dimensional (3-D) welding simulation model which was developed by LMES which is capable of predicting weld pool shape and the temperature history in 3-d single-pass welds. However, the model does not account for multipass welds, microstructural evolution, distortion and residual stresses. Additionally, the model requires large resources of computing time, which limits its use for practical applications. To overcome this, CTC and LMES have developed through this CRADA the comprehensive welding simulation model described above. The following technical tasks have been accomplished as part of the CRADA. 1. The LMES welding code has been ported to the Intel Paragon parallel computer at

  11. EMAT weld inspection and weld machine diagnostic system for continuous coil processing lines

    Science.gov (United States)

    Latham, Wayne M.; MacLauchlan, Daniel T.; Geier, Dan P.; Lang, Dennis D.

    1996-11-01

    Weld breaks of steel coil during cold rolling and continuous pickling operations are a significant source of lost productivity and product yield. Babcock and Wilcox Innerspec Technologies has developed a weld process control system which monitors the key variables of the welding process and determines the quality of the welds generated by flash butt welding equipment. This system is known as the Temate 2000 Automated Flash Butt Weld Inspection and Weld Machine Diagnostic System. The Temate 2000 system utilizes electro- magnetic acoustic transducer (EMAT) technology as the basis for performing on-line, real-time, nondestructive weld quality evaluation. This technique accurately detects voids, laps, misalignment and over/under trim conditions in the weld. Results of the EMAT weld inspection are immediately presented to the weld machine operator for disposition. Welding process variables such as voltage, current, platen movements and upset pressures are monitored and collected with the high speed data acquisition system. This data is processed and presented in real-time display to indicate useful welding process information such as platen crabbing, upset force, peak upset current, and many others. Alarming for each variable is provided and allows detailed maintenance reports and summary information to be generated. All weld quality and process parameter data are stored, traceable to each unique weld, and available for post process evaluation. Installation of the Temate 2000 system in a major flat rolled steel mill has contributed to near elimination of weld breakage and increased productivity at this facility.

  12. Comparative study on interactions between laser and arc plasma during laser-GTA welding and laser-GMA welding

    Science.gov (United States)

    Chen, Minghua; Xu, Jiannan; Xin, Lijun; Zhao, Zuofu; Wu, Fufa

    2016-10-01

    This paper describes an investigation on differences in interactions between laser and arc plasma during laser-gas tungsten arc (LT) welding and laser-gas metal arc (LM) welding. The characteristics of LT heat source and LM heat source, such as plasma behavior, heat penetration ability and spectral information were comparably studied. Based on the plasma discharge theory, the interactions during plasma discharge were modeled and analyzed. Results show that in both LT and LM welding, coupling discharge between the laser keyhole plasma and arc happens, which strongly enhance the arc. But, the enhancing effect in LT welding is much more sensitive than that in LM welding when parameters are adjusted.

  13. Novel Process Revolutionizes Welding Industry

    Science.gov (United States)

    2008-01-01

    Glenn Research Center, Delphi Corporation, and the Michigan Research Institute entered into a research project to study the use of Deformation Resistance Welding (DRW) in the construction and repair of stationary structures with multiple geometries and dissimilar materials, such as those NASA might use on the Moon or Mars. Traditional welding technologies are burdened by significant business and engineering challenges, including high costs of equipment and labor, heat-affected zones, limited automation, and inconsistent quality. DRW addresses each of those issues, while drastically reducing welding, manufacturing, and maintenance costs.

  14. Laser weld process monitoring and control using chromatic filtering of thermal radiation from a weld pool

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Cheol Jung; Kim, Min Suk; Baik, Sung Hoon; Chung, Chin Man

    2000-06-01

    The application of high power Nd: YAG lasers for precision welding in industry has been growing quite fast these days in diverse areas such as the automobile, the electronics and the aerospace industries. These diverse applications also require the new developments for the precise control and the reliable process monitoring. Due to the hostile environment in laser welding, a remote monitoring is required. The present development relates in general to weld process monitoring techniques, and more particularly to improved methods and apparatus for real-time monitoring of thermal radiation of a weld pool to monitor a size variation and a focus shift of the weld pool for weld process control, utilizing the chromatic aberration of focusing lens or lenses. The monitoring technique of the size variation and the focus shift of a weld pool is developed by using the chromatic filtering of the thermal radiation from a weld pool. The monitoring of weld pool size variation can also be used to monitor the weld depth in a laser welding. Furthermore, the monitoring of the size variation of a weld pool is independent of the focus shift of a weld pool and the monitoring of the focus shift of a weld pool is independent of the size variation of a weld pool.

  15. Investigation on the stepping arc stud welding process

    Institute of Scientific and Technical Information of China (English)

    Chi Qiang; Zhang Jianxun; Fu Jifei; Zhang Youquan

    2005-01-01

    Through the investigation on traditional arc stud welding process, a new welding gun and its control system were developed in this paper. The stepping arc stud welding gun was mainly made by a stepping motor as actuating unit and a screw-driven device as moving unit. A control system with a MCS-51 single-chip microcomputer as main control component was used to realize the new stud welding procedure. This new welding process with stepping stud welding gun is named as stepping arc stud welding. In the new welding process, the stud action can be looked as constituted by some micro steps. The setting and adjusting of the stepping arc welding gun behavior parameters are accomplished independently. It is indicated from the results of process tests and bending test that the stepping arc stud welding process is practicable.

  16. Quality status display for a vibration welding process

    Energy Technology Data Exchange (ETDEWEB)

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

    2017-03-28

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

  17. [Plasma temperature calculation and coupling mechanism analysis of laser-double wire hybrid welding].

    Science.gov (United States)

    Zheng, Kai; Li, Huan; Yang, Li-Jun; Gu, Xiao-Yan; Gao, Ying

    2013-04-01

    The plasma radiation of laser-double wire hybrid welding was collected by using fiber spectrometer, the coupling mechanism of arc with laser was studied through high-speed photography during welding process, and the temperature of hybrid plasma was calculated by using the method of Boltzmann plot. The results indicated that with laser hybrid, luminance was enhanced; radiation intensity became stronger; arc was attracted to the laser point; cross section contracted and arc was more stable. The laser power, welding current and arc-arc distance are important factors that have great influence on electron temperature. Increase in the laser power, amplification of welding current and reduction of arc-arc distance can all result in the rise of temperature.

  18. Real-time monitoring of weld penetration quality in roboticarc welding process

    Institute of Scientific and Technical Information of China (English)

    Wu Chuansong; Jia Chuanbao; Duan Xiaoning

    2008-01-01

    It is of great significance to develop an intelligent monitoring system for weld penetration defects such as incomplete penetration and burn-through in real-time during robotic arc welding process. In this paper, robotic gas metal arc welding experiments are carried out on the mild steel test pieces with Vee-type groove. Through-the-arc sensing method is used to capture the transient values of the welding voltage and current. The raw data of the captured welding current and voltage are processed statistically, and the feature vector S10 is extracted to correlate the welding conditions to the weld penetration information. It lays foundation for intelligent monitoring of weld quality in robotic arc welding.

  19. Weld pool vision sensing and image processing for GMAW

    Institute of Scientific and Technical Information of China (English)

    YUE Jianfeng; LI Liangyu; FAN Fanglei; WU Baolin

    2009-01-01

    It is difficult to acquire satisfied weld pool image by CCD sensor during gas metal arc welding(GMAW), for arc disturbs violently, welding current is great and working frequeacy is high. By using CMOS vision sensor to GMA W process, the vivid weld pool image is collected at any time, furthermore, whose gray compression ratio is controllable by sensor hardware circuit developed. Acquired weld pool image is firstly pre-processed by using Wiener filter and Ostu threshold segmentation algorithm. Subsequently separation between weld pool intage and cathode mist region is conducted by means of mathematical morphological algorithm, and the edge of weld pool image is extracted by using Prewitt algorithm.

  20. Duplex 2209 Weld Overlay by ESSC Process

    Directory of Open Access Journals (Sweden)

    Er. Manoj Kumar

    2017-03-01

    Full Text Available In the modern world of industrialization the wear is eating metal assets worth millions of dollars per year. The wear is in the form of corrosion, erosion, abrasion etc. which occur in the process industries like oil & gas, refineries, cement plants, steel plants, shipping and offshore working structures. The equipments like pressure vessels, heat exchangers, hydro processing reactors which very often work at elevated temperatures face corrosion in the internal diameter. Duplex 2209 weld overlay on ferrous material is developed for high corrosion resistance properties and having high productivity by Electroslag strip cladding process due to its less dilution ~10% as compared to SMAW , GTAW or FCAW process. Because of Low Dilution ~10% undiluted chemistry can be achieved with single layer as compared to other weld overlay processes. The facility was developed inhouse to carry out weld overlay by ESSC and Testing

  1. Mechanical behaviour of Astm A 297 grade Hp joints welded using different processes; Comportamento mecanico de juntas de aco ASTM A297 grau HP soldadas por diferentes processos

    Energy Technology Data Exchange (ETDEWEB)

    Emygdio, Paulo Roberto Oliveira; Zeemann, Annelise [Tecmetal Consultoria S/C Ltda (Brazil); Almeida, Luiz Henrique de [Universidade Federal, Rio de Janeiro, RJ (Brazil). Coordenacao dos Programas de Pos-graduacao de Engenharia

    1996-12-31

    The influence of different arc welding processes on mechanical behaviour was studied for cast heat resistant stainless steel welded joints, in the as welded conditions. ASTM A 297 grade HP with niobium and niobium/titanium additions were welded following three different welding procedures, using shielded metal arc welding gas tungsten arc welding and plasma arc welding, in six welded joints. The welded joint mechanical behaviour was evaluated by ambient temperature and 870 deg C tensile tests; and creep tests at 900 deg C and 50 MPa. Mechanical test results showed that the welding procedure qualification following welding codes is not suitable for high temperature service applications. (author) 7 refs., 2 figs., 8 tabs.

  2. Virtual Welded - Joint Design Integrating Advanced Materials and Processing Technology

    Energy Technology Data Exchange (ETDEWEB)

    Yang, Zhishang; Ludewig, Howard W.; Babu, S. Suresh

    2005-06-30

    Virtual Welede-Joint Design, a systematic modeling approach, has been developed in this project to predict the relationship of welding process, microstructure, properties, residual stress, and the ultimate weld fatique strength. This systematic modeling approach was applied in the welding of high strength steel. A special welding wire was developed in this project to introduce compressive residual stress at weld toe. The results from both modeling and experiments demonstrated that more than 10x fatique life improvement can be acheived in high strength steel welds by the combination of compressive residual stress from the special welding wire and the desired weld bead shape from a unique welding process. The results indicate a technology breakthrough in the design of lightweight and high fatique performance welded structures using high strength steels.

  3. Spectral diagnostics of a vapor-plasma plume produced during welding with a high-power ytterbium fiber laser

    Science.gov (United States)

    Uspenskiy, S. A.; Shcheglov, P. Yu.; Petrovskiy, V. N.; Gumenyuk, A. V.; Rethmeier, M.

    2013-07-01

    We have conducted spectroscopic studies of the welding plasma formed in the process of welding with an ytterbium fiber laser delivering output power of up to 20 kW. The influence of shielding gases (Ar, He) on different parts of the welding plume is investigated. The absorption coefficient of the laser radiation by the welding-plume plasma is estimated. Scattering of 532-nm probe radiation from particles of the condensed metal vapor within the caustic of a high-power fiber laser beam is measured. Based on the obtained results, conclusions are made on the influence of the plasma formation and metal vapor condensation on the radiation of the high-power fiber laser and the stability of the welding process.

  4. Evaluation of the Low Heat Input Process for Weld Repair of Nickel-Base Superalloys

    Science.gov (United States)

    Durocher, J.; Richards, N. L.

    2011-10-01

    The repair of turbine blades and vanes commonly involves gas tungsten arc welding or an equivalent process, but unfortunately these components are often susceptible to heat-affected zone (HAZ) cracking during the weld repair process. This is a major problem especially in cast alloys due to their coarse-grain size and where the (Al + Ti) contents is in excess of 3-4%; vacuum brazing is also used but mainly on low stress non-rotating components such as vanes. Micro-welding has the potential to deposit small amounts of filler at low heat input levels with minimum HAZ and thus is an attractive process for depositing a quality weld. As with conventional fusion processes, the filler alloy is deposited by the generation of a low power arc between a consumable electrode and the substrate. The low heat input of this process offers unique advantages over more common welding processes such as gas tungsten arc, plasma arc, laser, and electron beam welding. In this study, the low heat input characteristic of micro-welding has been used to simulate weld repair using Inconel (IN) (Inconel and IN are trademarks of INCO Alloys International) 625, Rene (Rene is a trademark of General Electric Company) 41, Nimonic (Nimonic is a trademark of INCO Alloys International) 105 and Inconel 738LC filler alloys, to a cast Inconel 738LC substrate. The effect of micro-welding process parameters on the deposition rate, coating quality, and substrate has been investigated.

  5. Process Model for Friction Stir Welding

    Science.gov (United States)

    Adams, Glynn

    1996-01-01

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

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

    Science.gov (United States)

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

    2014-04-01

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

  7. Control of surface defects on plasma-MIG hybrid welds in cryogenic aluminum alloys

    Directory of Open Access Journals (Sweden)

    Lee Hee-Keun

    2015-07-01

    Full Text Available Lately, high production rate welding processes for Al alloys, which are used as LNG FPSO cargo containment system material, have been developed to overcome the limit of installation and high rework rates. In particular, plasma-metal inert gas (MIG hybrid (PMH welding can be used to obtain a higher deposition rate and lower porosity, while facilitating a cleaning effect by preheating and post heating the wire and the base metal. However, an asymmetric undercut and a black-colored deposit are created on the surface of PMH weld in Al alloys. For controlling the surface defect formation, the wire feeding speed and nozzle diameter in the PMH weld was investigated through arc phenomena with high-speed imaging and metallurgical analysis.

  8. Plasma Charge Current for Controlling and Monitoring Electron Beam Welding with Beam Oscillation

    Directory of Open Access Journals (Sweden)

    Valeriy Shchavlev

    2012-12-01

    Full Text Available Electron beam welding (EBW shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process.

  9. Plasma charge current for controlling and monitoring electron beam welding with beam oscillation.

    Science.gov (United States)

    Trushnikov, Dmitriy; Belenkiy, Vladimir; Shchavlev, Valeriy; Piskunov, Anatoliy; Abdullin, Aleksandr; Mladenov, Georgy

    2012-12-14

    Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process.

  10. INCREASE OF THE OPERATIONAL PROPERTIES OF WELD AND PLASMA COATINGS USING NANOPOWDERS

    Directory of Open Access Journals (Sweden)

    Andrii Chornyi

    2016-07-01

    Full Text Available In this work, studies concerning determination of the oxide nanoparticles effect on structure and performance of the welds and plasma coatings were conducted. Ways of introducing nanodisperse refractory powders to the weld pool and how to cover with the deactivation of nanoparticles powder were determined. Introducing of the nanoparticles in the molten pool during the deposition and the coating was carried out by preparing a powder mixture by mechano-chemical processing in special high-energy intensive planetary mills. Structural studies of welds with nanooxides additives in the weld pool showed the formation of milled dispersed structure with microhardness 264-304 MPa. Statistical mean value of the number of non-metallic inclusions was defined. Mechanical testing of welds showed growth of the yield as well as tensile strength, when titanium and aluminum nanooxides were introduced into the weld pool. The most significant effect on these parameters has aluminum nanooxide in an amount of 0.5 vol.%, increasing the yield strength by 49 % and the tensile strength by 23 %. The toughness is mostly affected by titanium oxide in an amount of 1 vol.%., increasing its value by about 2 times. In turn, the introduction of alumina nanopowder in quantity 1,5 vol.% into the plasma coatings allowed to reduce friction and increase wear resistance of coatings by 2-3 times.

  11. Plasma Plume Oscillations Monitoring during Laser Welding of Stainless Steel by Discrete Wavelet Transform Application

    Directory of Open Access Journals (Sweden)

    Teresa Sibillano

    2010-04-01

    Full Text Available The plasma optical radiation emitted during CO2 laser welding of stainless steel samples has been detected with a Si-PIN photodiode and analyzed under different process conditions. The discrete wavelet transform (DWT has been used to decompose the optical signal into various discrete series of sequences over different frequency bands. The results show that changes of the process settings may yield different signal features in the range of frequencies between 200 Hz and 30 kHz. Potential applications of this method to monitor in real time the laser welding processes are also discussed.

  12. Plasma Plume Oscillations Monitoring during Laser Welding of Stainless Steel by Discrete Wavelet Transform Application

    Science.gov (United States)

    Sibillano, Teresa; Ancona, Antonio; Rizzi, Domenico; Lupo, Valentina; Tricarico, Luigi; Lugarà, Pietro Mario

    2010-01-01

    The plasma optical radiation emitted during CO2 laser welding of stainless steel samples has been detected with a Si-PIN photodiode and analyzed under different process conditions. The discrete wavelet transform (DWT) has been used to decompose the optical signal into various discrete series of sequences over different frequency bands. The results show that changes of the process settings may yield different signal features in the range of frequencies between 200 Hz and 30 kHz. Potential applications of this method to monitor in real time the laser welding processes are also discussed. PMID:22319311

  13. Gas Tungsten Arc Welding and Plasma Arc Cutting. Teacher Edition.

    Science.gov (United States)

    Fortney, Clarence; And Others

    This welding curriculum guide treats two topics in detail: the care of tungsten electrodes and the entire concept of contamination control and the hafnium electrode and its importance in dual-air cutting systems that use compressed shop air for plasma arc cutting activities. The guide contains three units of instruction that cover the following…

  14. In-process discontinuity detection during friction stir welding

    Science.gov (United States)

    Shrivastava, Amber

    The objective of this work is to develop a method for detecting the creation of discontinuities (e.g., voids) during friction stir welding. Friction stir welding is inherently cost-effective, however, the need for significant weld inspection can make the process cost-prohibitive. A new approach to weld inspection is required -- where an in-situ characterization of weld quality can be obtained, reducing the need for post-process inspection. Friction stir welds with discontinuity and without discontinuity were created. In this work, discontinuities are generated by reducing the friction stir tool rotation frequency and increasing the tool traverse speed in order to create "colder" welds. During the welds, forces are measured. Discontinuity sizes for welds are measured by computerized tomography. The relationship between the force transients and the discontinuity sizes indicate that the force measurement during friction stir welding can be effectively used for detecting discontinuities in friction stir welds. The normalized force transient data and normalized discontinuity size are correlated to develop a criterion for discontinuity detection. Additional welds are performed to validate the discontinuity detection method. The discontinuity sizes estimated by the force measurement based method are in good agreement with the discontinuity sizes measured by computerized tomography. These results show that the force measurement based discontinuity detection model method can be effectively used to detect discontinuities during friction stir welding.

  15. Effects of the Process Parameters on Austenitic Stainless Steel by TIG-Flux Welding

    Institute of Scientific and Technical Information of China (English)

    Heryueh HUANG; Shengwen SHYU; Kuanghung TSENG; Changpin CHOU

    2006-01-01

    The effects of the process parameters of TIG (tungsten inset gas)-flux welding on the welds morphology,angular distortion, ferrite content and hot cracking in austenitic stainless steel were investigated. Autogenous TIG welding process was applied to the type 304 stainless steel through a thin layer of activating flux to produce a bead on plate welded joint. TiO2, SiO2, Fe2O3, Cr2O3, ZnO and MnO2 were used as the activating fluxes. The experimental results indicated that the TIG-flux welding can increase the weld depth/width ratio and reduce the HAZ (heat affected zone) range, and therefore the angular distortion of the weldment can be reduced. It was also found that the retained ferrite content within the TIG-flux welds is increased, and has a beneficial effect in reducing hot cracking tendency for stainless steels of the austenitic type weld metals. A plasma column constriction increases the current density at the anode spot and then a substantial increase in penetration of the TIG-flux welds can be obtained.

  16. NTWV-based sensing keyhole dimension in plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    Jia Chuanbao; Wu Chuansong; Zhang Yuming

    2008-01-01

    During stable keyhole plasma arc welding, the pilot arc and the transferred arc exist at the meantime, and the arcs can be considered as a composition of two parts inside and outside the nozzle, respectively. Under the mechanical constriction and thermal contraction effects, the inside arc has certain arc length, electron density and arc profile etc. Inducing constant tungsten-to-nozzle voltage. However, the arc outside the nozzle diverges at about 5 degrees and has certain characteristics similar to the free arcs. The nozzle-to-workpiece voltage (NTWV) depends mainly on the length of the arc, which gets bigger as increasing of the weld penetration and keyhole size. The NTWV sensor is developed for monitoring NTWV in real time. The welding experiments are designed to get different penetrations and keyhole sizes. It is found that as the weld penetration and the keyhole size increase, NTWV also increases linearly. The NTWV signals can be used as the feedback variable in automatic control of keyhole plasma arc welding.

  17. Closing the weld gap with laser/mig hybrid welding process

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove; Wiwe, Bjarne David

    2003-01-01

    In this article, laboratory tests are demonstrated that systematically accesses the critical gap distance when welding CMn 2.13 mm steel with a 2.6 kW CO2 laser, combined with a MIG energy source. In the work, the welding speed is varied at gap distances from 0 to 0.8 mm such that the limits...... for obtaining sound welds are identified. The welds are quality assessed according to ISO 13.919-1 and EN25817, transversal hardness measurements are made and the heat input to the workpiece is calculated. The results show that the critical gap is 0.1 mm for a laser weld alone. With hybrid welding, this can...... be increased to 0.6 mm, even at a welding speed of 3.5 m/min. The maximum welding speed with the hybrid process is comparable to laser welding alone, 4.5 m/min. The measured hardness is comparable to MIG welding, and this corresponds to a 33 percent reduction compared to laser welding alone. The heat input...

  18. Closing the weld gap with laser/mig hybrid welding process

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove; Wiwe, Bjarne David;

    2003-01-01

    In this article, laboratory tests are demonstrated that systematically accesses the critical gap distance when welding CMn 2.13 mm steel with a 2.6 kW CO2 laser, combined with a MIG energy source. In the work, the welding speed is varied at gap distances from 0 to 0.8 mm such that the limits...... for obtaining sound welds are identified. The welds are quality assessed according to ISO 13.919-1 and EN25817, transversal hardness measurements are made and the heat input to the workpiece is calculated. The results show that the critical gap is 0.1 mm for a laser weld alone. With hybrid welding, this can...... be increased to 0.6 mm, even at a welding speed of 3.5 m/min. The maximum welding speed with the hybrid process is comparable to laser welding alone, 4.5 m/min. The measured hardness is comparable to MIG welding, and this corresponds to a 33 percent reduction compared to laser welding alone. The heat input...

  19. Modeling of Arc Force in Plasma Arc Welding

    Institute of Scientific and Technical Information of China (English)

    GAO Zhonglin; HU Shengsun; YIN Fengliang; WANG Rui

    2008-01-01

    A three. dimensional mathematical model for the transferred-type argon arc was developed to describe arc force on the anode surface. The software ANSYS was employed to solve the model. The model includes a part of torch and tungsten electrode to achieve m ore reasonable results. The arc temperature and flow fields were derived. And the influences of welding parameters on arc force were also studied. The simulated results show that arc pressure at the anode are dependent on the welding current, plasma gas flow rate and electrode neck-in, while not sensitive to arc length.

  20. Optimization of vibratory welding process parameters using response surface methodology

    Energy Technology Data Exchange (ETDEWEB)

    Singh, Pravin Kumar; Kumar, S. Deepak; Patel, D.; Prasad, S. B. [National Institute of Technology Jamshedpur, Jharkhand (India)

    2017-05-15

    The current investigation was carried out to study the effect of vibratory welding technique on mechanical properties of 6 mm thick butt welded mild steel plates. A new concept of vibratory welding technique has been designed and developed which is capable to transfer vibrations, having resonance frequency of 300 Hz, into the molten weld pool before it solidifies during the Shielded metal arc welding (SMAW) process. The important process parameters of vibratory welding technique namely welding current, welding speed and frequency of the vibrations induced in molten weld pool were optimized using Taguchi’s analysis and Response surface methodology (RSM). The effect of process parameters on tensile strength and hardness were evaluated using optimization techniques. Applying RSM, the effect of vibratory welding parameters on tensile strength and hardness were obtained through two separate regression equations. Results showed that, the most influencing factor for the desired tensile strength and hardness is frequency at its resonance value, i.e. 300 Hz. The micro-hardness and microstructures of the vibratory welded joints were studied in detail and compared with those of conventional SMAW joints. Comparatively, uniform and fine grain structure has been found in vibratory welded joints.

  1. Variable polarity arc welding

    Science.gov (United States)

    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.

  2. Hybrid manufacturing processes for fusion welding and friction stir welding of aerospace grade aluminum alloys

    Science.gov (United States)

    Gegesky, Megan Alexandra

    Friction stir welding and processing can provide for joints in aerospace grade aluminum alloys that have preferable material properties as compared to fusion welding techniques. Aerospace grade aluminum alloys such as AA2024-T3 and AA7075-T6 are considered non-weldable by traditional fusion welding techniques. Improved mechanical properties over previously used techniques are usually preferable for aerospace applications. Therefore, by combining traditional fusion welding and friction stir processing techniques, it could be plausible to create more difficult geometries in manufactured parts instead of using traditional techniques. While this combination of fusion welding and friction stir processing is not a new technology, its introduction to aerospace grade aluminum alloys as well as non-weldable alloys, is new. This is brought about by a lowered required clamping force required by adding a fusion weld before a friction stir processing technique. The changes in properties associated with joining techniques include: microstructural changes, changes in hardness, tensile strength, and corrosion resistance. This thesis illustrates these changes for the non-weldable AA2024-T351 and AA7075-T651 as well as the weldable alloy AA5052-H32. The microhardness, tensile strength and corrosion resistance of the four processing states: base material, fusion welded material, friction stir welded material, and friction stir processed fusion welded material is studied. The plausibility of this hybrid process for the three different materials is characterized, as well as plausible applications for this joining technique.

  3. Non-destructive Real Time Monitoring of the Laser Welding Process

    Science.gov (United States)

    Sebestova, Hana; Chmelickova, Hana; Nozka, Libor; Moudry, Jiri

    2012-05-01

    Laser welding is a high power density technology of materials joining that has many advantages in comparison with conventional fusion welding methods, for example, high accuracy, flexibility, repeatability and especially very narrow heat-affected zone which results in minimal workpiece distortions. Since it is still quite expensive technology, minimal spoilage is required. Effective system of quality control and processing parameters optimization must be established to reduce total costs, which is particularly required in industrial production. In this article some results of pulsed Nd:YAG laser welding process monitoring based on the measurement of plasma electron temperature are presented. The ability of designed sensor to detect weld penetration depth has been demonstrated. Plasma spectral lines intensities measurement can discover gap instabilities as well as local sheet thickness reduction.

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

    Science.gov (United States)

    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. Effect of Autogenous Arc Welding Processes on Tensile and Impact Properties of Ferritic Stainless Steel Joints

    Institute of Scientific and Technical Information of China (English)

    A K Lakshminarayanan; K Shanmugam; V Balasubramanian

    2009-01-01

    The effect of autogeneous arc welding processes on tensile and impact properties of ferritic stainless steel conformed to AISI 409M grade is studied.Rolled plates of 4 mm thickness have been used as the base material for preparing single pass butt welded jointa.Tensile and impact properties,microhardness,microstructure,and fracture surface morphology of continuous current gas tungsten arc welding (CCGTAW),pulsed current gas tungsten arc welding (PCGTAW),and plasma arc welding (PAW) joints are evaluated and the results are compared.It is found that the PAW joints of ferritic stainless steel show superior tensile and impact properties when compared with CCGTAW and PCGTAW joints,and this is mainly due to lower heat input,finer fusion zone grain diameter,and higher fusion zone hardness.

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

    Institute of Scientific and Technical Information of China (English)

    Yanbin Chen; Zhenglong Lei; Liqun Li; Lin Wu

    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 thedroplet 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 stablehybrid welding, and the frequency of droplet transfer and the penetration depth increase significantly.

  7. Advantages of MAG-STT Welding Process for Root Pass Welding in the Oil and Gas Industry

    Directory of Open Access Journals (Sweden)

    Pandzic Adi

    2016-02-01

    Full Text Available This paper describesthe basics of modern MAG-STT welding process and its advantages for root pass welding of construction steels in oil and gas industry. MAG-STT welding process was compared with competitive arc welding processes (SMAW and TIG, which are also used for root pass welding on pipes and plates. After experimental tests, the obtained results are analyzed and presented in this paper

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

    Energy Technology Data Exchange (ETDEWEB)

    Murray, P.E.; Smartt, H.B.; Johnson, J.A. [Lockheed Martin Idaho Technologies, Idaho Falls, ID (United States)

    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 by 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.

  9. Characterization of the Micro-Welding Process for Repair of Nickel Base Superalloys

    Science.gov (United States)

    Durocher, J.; Richards, N. L.

    2007-12-01

    Micro-welding is a low-heat input process whereby a metal or cermet, is deposited by the generation of a low-power arc between a consumable electrode and a substrate. The low-heat input of this process offers unique advantages over more common welding processes such as gas tungsten arc, plasma arc, laser, and electron beam welding. At present, the repair of turbine blades and vanes commonly involves gas tungsten arc welding and these components are susceptible to heat affected zone cracking during the weld repair process; vacuum brazing is also used but mainly on low-stress components such as stators. In this study, the low-heat input characteristic of micro-welding has been utilized to simulate repair of Inconel (Trade Mark of Special Metals) 625, Inconel 718, and Inconel 722 filler alloys to a cast Inconel 738 substrate. The effect of micro-welding process parameters on the deposition rate, coating quality, and substrate has been investigated.

  10. Plasma diagnostics in gas metal arc welding by optical emission spectroscopy

    Energy Technology Data Exchange (ETDEWEB)

    Valensi, F; Pellerin, S; Zielinska, S [GREMI, Universite d' Orleans (Site de Bourges)/CNRS, BP 4043, 18028 Bourges cedex (France); Boutaghane, A [Universite des Sciences et de la Technologie Houari Boumediene, Alger (Algeria); Dzierzega, K [Marian Smoluchowski Institute of Physics, Jagellonian University, Krakow (Poland); Pellerin, N [CNRS, UPR3079 CEMHTI, 1D av. de la Recherche Scientifique, 45071 Orleans cedex 2 (France); Briand, F, E-mail: flavien.valensi@laplace.univ-tsle.f, E-mail: stephane.pellerin@univ-orleans.f, E-mail: aboutaghane@yahoo.f, E-mail: krzycho@netmail.if.uj.edu.p, E-mail: sylwia.zielinska@airliquide.co, E-mail: nadia.pellerin@univ-orleans.f, E-mail: francis.briand@airliquide.co [CTAS-Air Liquide Welding, Saint Ouen l' Aumone, 95315 Cergy-Pontoise cedex (France)

    2010-11-03

    The plasma column in a metal inert gas welding process is investigated by optical emission spectroscopy and high-speed imaging. The concentration and repartition of iron vapours are measured and correlated with the plasma and electrode geometric configuration. Plasma temperatures and electron densities are also measured for each studied position in the plasma. The temperatures are calculated using two different methods, allowing validation of the local thermodynamic equilibrium state of the plasma. The results show a maximum temperature of 12 500 K in the upper part of the arc, away from the arc axis. The iron concentration reaches a maximum of 0.3% close to the anode and strongly decreases along both the vertical and radial directions. The plasma thermophysical properties, calculated from this plasma composition, are then discussed regarding the metal transfer mode.

  11. Improvement of reliability of welding by in-process sensing and control (development of smart welding machines for girth welding of pipes). Final report

    Energy Technology Data Exchange (ETDEWEB)

    Hardt, D.E.; Masubuchi, K.; Paynter, H.M.; Unkel, W.C.

    1983-04-01

    Closed-loop control of the welding variables represents a promising, cost-effective approach to improving weld quality and therefore reducing the total cost of producing welded structures. The ultimate goal is to place all significant weld variables under direct closed-loop control; this contrasts with preprogrammed machines which place the welding equipment under control. As the first step, an overall strategy has been formulated and an investigation of weld pool geometry control for gas tungsten arc process has been completed. The research activities were divided into the areas of arc phenomena, weld pool phenomena, sensing techniques and control activities.

  12. OF PROCESSING PARAMETERS OF VIBRATION DURING WELDING ON THE PROPERTIES OF WELDED JOINTS

    Directory of Open Access Journals (Sweden)

    R. G. Rizvanov

    2012-01-01

    Full Text Available The researches of influence of vibrating processing regimes on mechanical and other properties of the welded joints received by fusion welding are carried out on the basis of the literary analysis of the works devoted to influence of vibrating oscillations on melted and crystallizing metal.

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    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

  15. Thermo-Mechanical Processing in Friction Stir Welds

    Science.gov (United States)

    Schneider, Judy

    2003-01-01

    Friction stir welding is a solid-phase joining, or welding process that was invented in 1991 at The Welding Institute (TWI). The process is potentially capable of joining a wide variety of aluminum alloys that are traditionally difficult to fusion weld. The friction stir welding (FSW) process produces welds by moving a non-consumable rotating pin tool along a seam between work pieces that are firmly clamped to an anvil. At the start of the process, the rotating pin is plunged into the material to a pre-determined load. The required heat is produced by a combination of frictional and deformation heating. The shape of the tool shoulder and supporting anvil promotes a high hydrostatic pressure along the joint line as the tool shears and literally stirs the metal together. To produce a defect free weld, process variables (RPM, transverse speed, and downward force) and tool pin design must be chosen carefully. An accurate model of the material flow during the process is necessary to guide process variable selection. At MSFC a plastic slip line model of the process has been synthesized based on macroscopic images of the resulting weld material. Although this model appears to have captured the main features of the process, material specific interactions are not understood. The objective of the present research was to develop a basic understanding of the evolution of the microstructure to be able to relate it to the deformation process variables of strain, strain rate, and temperature.

  16. Optimization of weld bead geometry in the activated GMA welding process via a grey-based Taguchi method

    Energy Technology Data Exchange (ETDEWEB)

    Lin, Hsuan Liang [National Kaohsiung Normal University, Kaohsiung (China); Yan, Jia Ching [National Chiao Tung University, Hsinchu (China)

    2014-08-15

    We optimized the weld bead geometry of 6061 aluminum alloy welds pre-coated with activating flux before gas metal arc (GMA) welding. In this activated GMA welding process, there were five single component fluxes used in the initial experiment to evaluate the penetration capability of bead-on-plate GMA welds. Based on the higher penetration of weld bead, two single component fluxes were selected to create mixed component flux in next stage. The grey-based Taguchi method was employed to obtain the optimal welding parameters that were considered with multiple quality characteristics such as penetration, depth-to-width ratio (DWR) and fusion area of GMA welds. The experimental procedure of the proposed approach not only increases penetration of 6061 aluminum alloy welds, but also improves the DWR and fusion area of GMA butt-joint welds simultaneously.

  17. Analysis of plasma characteristics and conductive mechanism of laser assisted pulsed arc welding

    Science.gov (United States)

    Liu, Shuangyu; Chen, Shixian; Wang, Qinghua; Li, Yanqing; Zhang, Hong; Ding, Hongtao

    2017-05-01

    This study aims to investigate the arc plasma shape and the spectral characteristics during the laser assisted pulsed arc welding process. The arc plasma shape was synchronously observed using a high speed camera, and the emission spectrum of plasma was obtained by spectrometer. The well-known Boltzmann plot method and Stark broadening were used to calculate the electron temperature and density respectively. The conductive mechanism of arc ignition in laser assisted arc hybrid welding was investigated, and it was found that the plasma current moved to the arc anode under the action of electric field. Thus, a significant parabolic channel was formed between the keyhole and the wire tip. This channel became the main method of energy transformation between the arc and the molten pool. The calculation results of plasma resistivity show that the laser plasma has low resistivity as the starting point of conductive channel formation. When the laser pulse duration increases, the intensity of the plasma radiation spectrum and the plasma electron density will increase, and the electron temperature will decrease.

  18. The algorithm of verification of welding process for plastic pipes

    Science.gov (United States)

    Rzasinski, R.

    2017-08-01

    The study analyzes the process of butt welding of PE pipes in terms of proper selection of connector parameters. The process was oriented to the elements performed as a series of types of pipes. Polymeric materials commonly referred to as polymers or plastics, synthetic materials are produced from oil products in the polyreaction compounds of low molecular weight, called monomers. During the polyreactions monomers combine to build a macromolecule material monomer named with the prefix poly polypropylene, polyethylene or polyurethane, creating particles in solid state on the order of 0,2 to 0,4 mm. Finished products from polymers of virtually any shape and size are obtained by compression molding, injection molding, extrusion, laminating, centrifugal casting, etc. Weld can only be a thermoplastic that softens at an elevated temperature, and thus can be connected via a clamp. Depending on the source and method of supplying heat include the following welding processes: welding contact, radiant welding, friction welding, dielectric welding, ultrasonic welding. The analysis will be welding contact. In connection with the development of new generation of polyethylene, and the production of pipes with increasing dimensions (diameter, wall thickness) is important to select the correct process.

  19. Effect of arc on radiation thermometry in welding process

    Institute of Scientific and Technical Information of China (English)

    李亮玉; 王燕; 武宝林

    2002-01-01

    The effect of arc on radiation thermometry is analyzed in a field close to the arc during the welding process, and the ratio of signal to noise and other factors are obtained for a small current arc .The method of the temperature measurement is feasible when the arc current is decreased to a smaller value in the welding process.

  20. Finite Element Simulation of Plasma Transferred ARC Welding [PTAW] of Structural Steel

    Directory of Open Access Journals (Sweden)

    PV Senthiil

    2014-10-01

    Full Text Available Plasma transferred Arc welding is one of the most widely used welding process, in which the metals are fused just above the melting point, and makes the metal to fuse. It is employed in many applications like tool die and metal casting, strip metal welding etc. This investigation is to analyze temperature distribution residual stress and distortion by varying the heat source parameter in SYSWELD, and compared the results with ANSYS. The simulation of Plasma Transferred Arc welding was of structural steel plate performed using a non-linear transient heat transfer analysis. Heat losses due to convection and variation of material properties with temperature were considered in this analysis. To incorporate the heat developed the Gaussian distribution was considered. Finite element simulations were performed using ANSYS Parametric Design Language (APDL code and using SYSWELD. The temperatures obtained were compared with experimental results for validation. It was found that the predicted values of temperature agree very well with the experimental values. Residual Stress and Distortion were also predicted for various heat Input. The effect of heat input on residual stress and distortion was investigated.

  1. Friction stir welding (FSW process of copper alloys

    Directory of Open Access Journals (Sweden)

    M. Miličić

    2016-01-01

    Full Text Available The present paper analyzes the structure of the weld joint of technically pure copper, which is realized using friction stir welding (FSW. The mechanism of thermo-mechanical processes of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Parameters of the FSW welding technology influencing the zone of the seam material and the mechanical properties of the resulting joint were analyzed. The physical joining consists of intense mixing the base material along the joint line in the “doughy” phase. Substantial plastic deformations immediately beneath the frontal surface of tool provide fine-grained structure and a good quality joint. The optimum shape of the tool and the optimum welding regime (pressure force, rotation speed and the traverse speed of the tool in the heat affected zone enable the achievement of the same mechanical properties as those of the basic material, which justifies its use in welding reliable structures.

  2. GMAW (Gas Metal Arc Welding) process development for girth welding of high strength pipelines

    Energy Technology Data Exchange (ETDEWEB)

    Rajan, Vaidyanath; Daniel, Joe; Quintana, Marie [The Lincoln Electric Company, Cleveland, OH (United States); Chen, Yaoshan [Center for Reliable Energy Systems (CRES), Dublin, OH (United States); Souza, Antonio [Lincoln Electric do Brasil, Guarulhos, SP (Brazil)

    2009-07-01

    This paper highlights some of the results and findings from the first phase of a consolidated program co-funded by US Department of Transportation Pipeline and Hazardous Materials Safety Administration (PHMSA) and Pipeline Research Council Inc (PRCI) to develop pipe weld assessment and qualification methods and optimize X 100 pipe welding technologies. One objective of the program is to establish the range of viable welding options for X 100 line pipe, and define the essential variables to provide welding process control for reliable and consistent mechanical performance of the weldments. In this first phase, a series of narrow gap girth welds were made with pulsed gas metal arc welding (GMAW), instrumented with thermocouples in the heat affected zone (HAZ) and weld metal to obtain the associated thermal profiles, and instrumented to measure true energy input as opposed to conventional heat input. Results reveal that true heat input is 16%-22% higher than conventional heat input. The thermal profile measurements correlate very well with thermal model predictions using true energy input data, which indicates the viability of treating the latter as an essential variable. Ongoing microstructural and mechanical testing work will enable validation of an integrated thermal-microstructural model being developed for these applications. Outputs from this model will be used to correlate essential welding process variables with weld microstructure and hardness. This will ultimately enable development of a list of essential variables and the ranges needed to ensure mechanical properties are achieved in practice, recommendations for controlling and monitoring these essential variables and test methods suitable for classification of welding consumables. (author)

  3. Unraveling the Processing Parameters in Friction Stir Welding

    Science.gov (United States)

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

    2005-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is translated along a weld seam, literally stirring the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path or paths is required. In this study, various markers are used to trace the flow paths of the metal. X-ray radiographs record the segmentation and position of the wire. Several variations in the trajectories can be differentiated within the weld zone.

  4. Numerical Analysis of Two-Way Interaction between Weld-Pool and Arc for GTA Welding Process

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    A mathematical model to describe the heat transfer and fluid flow in the mutually coupled weld pool and arc by an interactive free surface of the pool for a stationary gas tungsten arc welding (GTAW) is developed. The two sets of governing equations and auxiliary formulas, controlling the weld pool and plasma arc systems respectively, were solved by a finite difference method. A boundary-fitted coordinate system was adopted because the free surface has a curved and unknown shape during welding. The results of this work provide a fundamental basis for predicting the behavior of an integrated weld pool and arc system from first principles.

  5. Welding of AA1050 aluminum with AISI 304 stainless steel by rotary friction welding process

    OpenAIRE

    Chen Ying An; Francisco Piorino Neto; Eder Paduan Alves

    2010-01-01

    The purpose of this work was to assess the development of solid state joints of dissimilar material AA1050 aluminum and AISI 304 stainless steel, which can be used in pipes of tanks of liquid propellants and other components of the Satellite Launch Vehicle. The joints were obtained by rotary friction welding process (RFW), which combines the heat generated from friction between two surfaces and plastic deformation. Tests were conducted with different welding process parameters. The results we...

  6. Overview of advanced process control in welding within ERDA

    Energy Technology Data Exchange (ETDEWEB)

    Armstrong, R.E.

    1977-02-11

    The special kinds of demands placed on ERDA weapons and reactors require them to have very reliable welds. Process control is critical in achieving this reliability. ERDA has a number of advanced process control projects underway with much of the emphasis being on electron beam welding. These include projects on voltage measurement, beam-current control, beam focusing, beam spot tracking, spike suppression, and computer control. A general discussion of process control in welding is followed by specific examples of some of the advanced joining process control projects in ERDA.

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

    Science.gov (United States)

    Vasudevan, M.

    2017-03-01

    The specific activated flux has been developed for enhancing the penetration performance of TIG welding process for autogenous welding of type 304LN and 316LN stainless steels through systematic study. Initially single-component fluxes were used to study their effect on depth of penetration and tensile properties. Then multi-component activated flux was developed which was found to produce a significant increase in penetration of 10-12 mm in single-pass TIG welding of type 304LN and 316LN stainless steels. The significant improvement in penetration achieved using the activated flux developed in the present work has been attributed to the constriction of the arc and as well as reversal of Marangoni flow in the molten weld pool. The use of activated flux has been found to overcome the variable weld penetration observed in 316LN stainless steel with welds compared to that of the welds produced by conventional TIG welding on the contrary the transverse strength properties of the 304LN and 316LN stainless steel welds produced by A-TIG welding exceeded the minimum specified strength values of the base metals. Improvement in toughness values were observed in 316LN stainless steel produced by A-TIG welding due to refinement in the weld microstructure in the region close to the weld center. Thus, activated flux developed in the present work has greater potential for use during the TIG welding of structural components made of type 304LN and 316LN stainless steels.

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

    Science.gov (United States)

    Vasudevan, M.

    2017-02-01

    The specific activated flux has been developed for enhancing the penetration performance of TIG welding process for autogenous welding of type 304LN and 316LN stainless steels through systematic study. Initially single-component fluxes were used to study their effect on depth of penetration and tensile properties. Then multi-component activated flux was developed which was found to produce a significant increase in penetration of 10-12 mm in single-pass TIG welding of type 304LN and 316LN stainless steels. The significant improvement in penetration achieved using the activated flux developed in the present work has been attributed to the constriction of the arc and as well as reversal of Marangoni flow in the molten weld pool. The use of activated flux has been found to overcome the variable weld penetration observed in 316LN stainless steel with welds compared to that of the welds produced by conventional TIG welding on the contrary the transverse strength properties of the 304LN and 316LN stainless steel welds produced by A-TIG welding exceeded the minimum specified strength values of the base metals. Improvement in toughness values were observed in 316LN stainless steel produced by A-TIG welding due to refinement in the weld microstructure in the region close to the weld center. Thus, activated flux developed in the present work has greater potential for use during the TIG welding of structural components made of type 304LN and 316LN stainless steels.

  9. Process Simulation of Resistance Weld Bonding and Automotive Light-weight Materials

    DEFF Research Database (Denmark)

    Zhang, Wenqi; Chergui, Azeddine; Nielsen, Chris Valentin

    and predicting welding process window, for weld planning with optimal welding parameter settings, and for modeling microstructures and hardness distribution after welding. Latest developments have been made on simulation of resistance welding with nonconductive materials for applications in weld bonding......This paper presents the latest developments in numerical simulation of resistance welding especially with the new functions for simulation of microstructures, weld bonding and spot welding of new light-weight materials. The fundamental functions in SORPAS® are built on coupled modeling...... of mechanical, electrical, thermal and metallurgical processes, which are essential for simulation of resistance welding process to predict the welding results and evaluate the weldability of materials. These functions have been further extended with new functions for optimization of welding process parameters...

  10. Novel Optimization Methodology for Welding Process/Consumable Integration

    Energy Technology Data Exchange (ETDEWEB)

    Quintana, Marie A; DebRoy, Tarasankar; Vitek, John; Babu, Suresh

    2006-01-15

    Advanced materials are being developed to improve the energy efficiency of many industries of future including steel, mining, and chemical, as well as, US infrastructures including bridges, pipelines and buildings. Effective deployment of these materials is highly dependent upon the development of arc welding technology. Traditional welding technology development is slow and often involves expensive and time-consuming trial and error experimentation. The reason for this is the lack of useful predictive tools that enable welding technology development to keep pace with the deployment of new materials in various industrial sectors. Literature reviews showed two kinds of modeling activities. Academic and national laboratory efforts focus on developing integrated weld process models by employing the detailed scientific methodologies. However, these models are cumbersome and not easy to use. Therefore, these scientific models have limited application in real-world industrial conditions. On the other hand, industrial users have relied on simple predictive models based on analytical and empirical equations to drive their product development. The scopes of these simple models are limited. In this research, attempts were made to bridge this gap and provide the industry with a computational tool that combines the advantages of both approaches. This research resulted in the development of predictive tools which facilitate the development of optimized welding processes and consumables. The work demonstrated that it is possible to develop hybrid integrated models for relating the weld metal composition and process parameters to the performance of welds. In addition, these tools can be deployed for industrial users through user friendly graphical interface. In principle, the welding industry users can use these modular tools to guide their welding process parameter and consumable composition selection. It is hypothesized that by expanding these tools throughout welding industry

  11. Effect of Thermal and Diffusion Processes on Formation of the Structure of Weld Metal in Laser Welding of Dissimilar Materials

    Science.gov (United States)

    Turichin, G. A.; Klimova, O. G.; Babkin, K. D.; Pevzner, Ya. B.

    2014-01-01

    The thermal and diffusion processes in laser welding of dissimilar materials are simulated. The active LaserCAD model for welding of dissimilar materials is amended. The developed model is verified for the Fe - Cu system. The microstructure of a weld of tin bronze and low-carbon steel is studied and the elements in the diffusion zone are analyzed. The computed and experimental data for laser and electron-beam welding are shown to agree well.

  12. Optimization of Gas Metal Arc Welding Process Parameters

    Science.gov (United States)

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

    2016-09-01

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

  13. Hastelloy C-276Weld Overlay bySMAW Process

    National Research Council Canada - National Science Library

    Er. Rahul Sharma; Er. Manoj Kumar; Dr. Abhishek Kamboj

    2017-01-01

    ... diameter.Hastelloy C-276weld overlay on ferrous material is developed for outstanding resistance to wide variety of chemical process environments such as ferric and cupric chlorides, hot contaminated mineral...

  14. Novel welding image processing method based on fractal theory

    Institute of Scientific and Technical Information of China (English)

    陈强; 孙振国; 肖勇; 路井荣

    2002-01-01

    Computer vision has come into used in the fields of welding process control and automation. In order to improve precision and rapidity of welding image processing, a novel method based on fractal theory has been put forward in this paper. Compared with traditional methods, the image is preliminarily processed in the macroscopic regions then thoroughly analyzed in the microscopic regions in the new method. With which, an image is divided up to some regions according to the different fractal characters of image edge, and the fuzzy regions including image edges are detected out, then image edges are identified with Sobel operator and curved by LSM (Lease Square Method). Since the data to be processed have been decreased and the noise of image has been reduced, it has been testified through experiments that edges of weld seam or weld pool could be recognized correctly and quickly.

  15. 46 CFR 154.650 - Cargo tank and process pressure vessel welding.

    Science.gov (United States)

    2010-10-01

    ... 46 Shipping 5 2010-10-01 2010-10-01 false Cargo tank and process pressure vessel welding. 154.650... Equipment Construction § 154.650 Cargo tank and process pressure vessel welding. (a) Cargo tank and process pressure vessel welding must meet Subpart 54.05 and Part 57 of this chapter. (b) Welding consumables...

  16. Ultrasonic stir welding process and apparatus

    Science.gov (United States)

    Ding, R. Jeffrey (Inventor)

    2009-01-01

    An ultrasonic stir welding device provides a method and apparatus for elevating the temperature of a work piece utilizing at least one ultrasonic heater. Instead of relying on a rotating shoulder to provide heat to a workpiece an ultrasonic heater is utilized to provide ultrasonic energy to the workpiece. A rotating pin driven by a motor assembly performs the weld on the workpiece. A handheld version can be constructed as well as a fixedly mounted embodiment.

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

    Science.gov (United States)

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

    2017-03-01

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

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

    Science.gov (United States)

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

    2017-05-01

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

  19. Effect of process control mode on weld quality of friction stir welded plates

    Energy Technology Data Exchange (ETDEWEB)

    Shazly, Mostafa; Sorour, Sherif; Alian, Ahmed R. [Faculty of Engineering, The British University in Egypt, Cairo (Egypt)

    2016-01-15

    Friction stir welding (FSW) is a solid state welding process which requires no filler material where the heat input is generated by frictional energy between the tool and workpiece. The objective of the present work is to conduct a fully coupled thermomechanical finite element analysis based on Arbitrary Lagrangian Eulerian (ALE) formulation for both 'Force-Controlled' and 'Displacement-Controlled' FSW process to provide more detailed insight of their effect on the resulting joint quality. The developed finite element models use Johnson- Cook material model and temperature dependent physical properties for the welded plates. Efforts on proper modeling of the underlying process physics are done focusing on the heat generation of the tool/workpiece interface to overcome the shortcomings of previous investigations. Finite elements results show that 'Force-Controlled' FSW process provides better joint quality especially at higher traveling speed of the tool which comes to an agreement with published experimental results.

  20. Plasma processing for VLSI

    CERN Document Server

    Einspruch, Norman G

    1984-01-01

    VLSI Electronics: Microstructure Science, Volume 8: Plasma Processing for VLSI (Very Large Scale Integration) discusses the utilization of plasmas for general semiconductor processing. It also includes expositions on advanced deposition of materials for metallization, lithographic methods that use plasmas as exposure sources and for multiple resist patterning, and device structures made possible by anisotropic etching.This volume is divided into four sections. It begins with the history of plasma processing, a discussion of some of the early developments and trends for VLSI. The second section

  1. Welding Metallurgy and Processing Issues for Joining of Power Sources

    Energy Technology Data Exchange (ETDEWEB)

    Lienert, Thomas J. [Los Alamos National Laboratory; Reardon, Patrick T. [Los Alamos National Laboratory

    2012-08-14

    Weldability issues with the pertinent alloys have been reviewed and preliminary results of our work on Haynes 25 have been presented. Further results on the mechanical properties and metallography on the EB welds are imminent. Hot-ductility experiments will commence within a few weeks. Aging studies on the effects of heat treatment using the Gleeble are also planned. MST-6 has extensive background in the welding metallurgy of the pertinent alloys. We also have considerable experience with the various welding processes to be used.

  2. A Generalized Rough Set Modeling Method for Welding Process

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Modeling is essential, significant and difficult for the quality and shaping control of arc welding process. A generalized rough set based modeling method was brought forward and a dynamic predictive model for pulsed gas tungsten arc welding (GTAW) was obtained by this modeling method. The results show that this modeling method can well acquire knowledge in welding and satisfy the real life application. In addition, the results of comparison between classic rough set model and back-propagation neural network model respectively are also satisfying.

  3. SmartWeld/SmartProcess - intelligent model based system for the design and validation of welding processes

    Energy Technology Data Exchange (ETDEWEB)

    Mitchner, J.

    1996-04-01

    Diagrams are presented on an intelligent model based system for the design and validation of welding processes. Key capabilities identified include `right the first time` manufacturing, continuous improvement, and on-line quality assurance.

  4. Development of an encapsulation method using plasma arc welding to produce iodine-125 seeds for brachytherapy

    Energy Technology Data Exchange (ETDEWEB)

    Feher, Anselmo; Calvo, Wilson A.P.; Rostelato, Maria E.C.M.; Zeituni, Carlos A.; Somessari, Samir L.; Costa, Osvaldo L.; Moura, Joao A.; Moura, Eduardo S.; Souza, Carla D.; Rela, Paulo R., E-mail: afeher@ipen.b, E-mail: wapcalvo@ipen.b, E-mail: elisaros@ipen.b, E-mail: somessar@ipen.b, E-mail: olcosta@ipen.b, E-mail: esmoura@ipen.b, E-mail: cdsouza@ipen.b, E-mail: prela@ipen.b [Instituto de Pesquisas Energeticas e Nucleares (IPEN/CNEN-SP), Sao Paulo, SP (Brazil)

    2011-07-01

    The prostate cancer, which is the second cause of death by cancer in men, overcome only by lung cancer is public health problem in Brazil. Brachytherapy is among the possible available treatments for prostate cancer, in which small seeds containing Iodine-125 radioisotope are implanted into the prostate gland. The seed consists of a titanium sealed capsule with 0.8 mm external diameter and 4.5 mm length, containing a central silver wire with adsorbed Iodine-125. The Plasma Arc Welding (PAW) is one of the viable techniques for sealing process. The equipment used in this technique is less costly than in other processes, such as, Laser Beam Welding (LBW). The main purpose of this work was the development of an encapsulation method using PAW. The development of this work has presented the following phases: cutting and cleaning titanium tube, determination of the welding parameters, development of a titanium tube holding device for PAW, sealed sources validation according to ISO 2919 - Sealed Radioactive Sources - General Requirements and Classification, and metallographic assays. The developed procedure to seal Iodine-125 seeds using PAW has shown high efficiency, satisfying all the established requirements of ISO 2919. The results obtained in this work will give the possibility to establish a routine production process according to the orientations presented in resolution RDC 17 - Good Manufacturing Practices to Medical Products defined by the ANVISA - National Agency of Sanitary Surveillance. (author)

  5. Process Optimization for Friction-Stir-Welded Martensitic Steel

    Science.gov (United States)

    Ghosh, M.; Kumar, K.; Mishra, R. S.

    2012-06-01

    Advanced high-strength M190 steel sheets were joined by friction-stir welding under different tool rotational and traversing speeds. The optical microstructure of the joints exhibited complete martensite and partial martensite at the weld nugget depending on the cooling rate during welding. The first heat-affected zone outside of the weld nugget revealed ferrite-pearlite phase aggregate, and the second heat-affected zone showed a tempered martensitic structure. The interplay of process variables in terms of peak temperature and cooling rate was studied to observe their effect on joint efficiency under shear testing. The peak hardness at weld nugget was close to the parent alloy at an intermediate cooling rate of 294 to 313 K/s. The lowest hardness was observed at the first heat-affected zone for all welded joints. Joint efficiency was dependent on relative quantity of ferrite-pearlite at first heat-affected zone. In that respect, the intermediate temperature to the tune of ~1193 K to 1273 K (~920 °C to 1000 °C) at the weld nugget was found to be beneficial for obtaining an adequate quantity of pearlite at the first heat-affected zone to provide joint efficiency of more than 50 pct of that of parent alloy.

  6. Finite element analysis of keyhole plasma arc welding based on an adaptive heat source mode

    Institute of Scientific and Technical Information of China (English)

    Hu Qingxian; Wu Chuansong; Zhang Yuming

    2007-01-01

    An adaptive heat source mode is proposed to account for the keyhole effect and the characteristics of volumetric distribution along the direction of the workpiece thickness. Finite element analysis of the temperature field in keyhole plasma arc welding is conducted and the weld geometry is obtained. The predicted results are in agreement with the measured ones.

  7. Film videorecording and image processing systems: structural element welding

    Science.gov (United States)

    Konovalov, Nikolai A.; Veselovsky, Vladimir B.; Kovalenko, Vladimir I.; Lakhno, Nikolay I.; Skorik, Alexander D.; Furmanov, Valeri B.; Polyakov, Gennadiy A.

    1999-06-01

    With the aim of technological process automatization and control for high-frequency welding of different diameters pipes the machine-program complex (APC) was designed. APC gives the opportunity to create the cine- and telerecording of process in production conditions at the mill '159 - 529' of Novomoskovsky Tube Rolling Mill, Ukraine). With the help of APC in real functioning mill conditions the character of flashing zone length changing and the angle of convergence depending on pipe welding speed was investigated, also the zone of jumpers is defined. The comparison of theoretical and experimental data gave an opportunity to define a welding rate which is optimal for the most qualitative values of welded joints in the range of pipe products of mill '159 - 529.'

  8. Degradation Processes of Al-Zn Welded Joints

    Directory of Open Access Journals (Sweden)

    Jiří Votava

    2014-01-01

    Full Text Available Welding of metal materials belongs to non-demountable joints. Current trend especially in an automotive industry is to join materials with a different melting temperature. Most of all, there are dural profiles with ferrite or austenite steel. The reason for this is the effort to lower the weight of the whole construction and at the same time preserve sufficient mechanical characteristics. However, there is a big risk of different electrical potentials of both of these metals in this type of non-demountable joints. The experimental part of this paper brings evaluation of mechanical-corrosion processes of overlapped joints produced by the CMT (cold metal transfer method. The base material for weld bead is dural sheet AlMg3 and dural sheet with a surface treatment aluzinc DX51D+AZ 150. Material AlSi5 in the form of a wire was used as an additional material for a welding bath. Method CMT was used in order to create a weld bead. Initial analysis of weld bead was done visually using a binocular microscope. Further, a metallographic analysis of weld bead and base material was processed. The aim was to identify the heat affected area around the welded joint. Microhardness of intermetallic aluminium phases was measured, after the identification of intermetallic phases a chemical analysis EDS was processed. Prepared samples underwent corrosion degradation in a salt spray environment in compliance with the norm ČSN EN ISO 9227. Visual and metallographic evaluation of the individual samples was processed after every week of exposition to the salt spray environment. The goal of this experiment was to record the initial impulse of galvanic corrosion which consists in corrosion degradation in the area of welded joint.

  9. Residual Stress Evaluation of Weld Inlay Process on Reactor Vessel Nozzles

    Energy Technology Data Exchange (ETDEWEB)

    Cho, Kihyun; Cho, Hong Seok [KEPCO KPS, Naju (Korea, Republic of)

    2015-10-15

    Weld overlay, weld inlay and stress improvement are mitigation technologies for butt joints. Weld overlay is done on pressurizer nozzles which are the highest potential locations occurring PWSCC due to high temperature in Korea. Reactor vessel nozzles are other big safety concerns for butt joints. Weld overlay and stress improvement should be so difficult to apply to those locations because space is too limited. Weld inlay should be one of the solutions. KEPCO KPS has developed laser welding system and process for reactor nozzles. Welding residual stress analysis is necessary for flaw evaluation. United States nuclear regulatory commission has calculated GTAW(Gas Tungsten Arc Welding) residual stress using ABAQUS. To confirm effectiveness of weld inlay process, welding residual stress analysis was performed. and difference between GTAW and LASER welding process was compared. Evaluation of weld inlay process using ANSYS and ABAQUS is performed. All of the both results are similar. The residual stress generated after weld inlay was on range of 450-500 MPa. Welding residual stresses are differently generated by GTAW and LASER welding. But regardless of welding process type, residual tensile stress is generated on inside surface.

  10. The development of a quality prediction system for aluminum laser welding to measure plasma intensity using photodiodes

    Energy Technology Data Exchange (ETDEWEB)

    Yu, Ji Young [Technical Research Center, Hyundai Steel Company, Dangjin (Korea, Republic of); Sohn, Yong Ho [Dept. of Materials Science and Engineering, University of Central Florida, Orlando (United States); Park, Young Whan; Kwak, Jae Seob [Dept. of Mechanical Engineering, Pukyong National University, Busan (Korea, Republic of)

    2016-10-15

    Lightweight metals have been used to manufacture the body panels of cars to reduce the weight of car bodies. Typically, aluminum sheets are welded together, with a focus on weld quality assurance. A weld quality prediction system for the laser welding of aluminum was developed in this research to maximize welding production. The behavior of the plasma was also analyzed, dependent on various welding conditions. The light intensity of the plasma was altered with heat input and wire feed rate conditions, and the strength of the weld and sensor signals correlated closely for this heat input condition. Using these characteristics, a new algorithm and program were developed to evaluate the weld quality. The design involves a combinatory algorithm using a neural network model for the prediction of tensile strength from measured signals and a fuzzy multi-feature pattern recognition algorithm for the weld quality classification to improve predictability of the system.

  11. Evaluation of weld porosity in laser beam seam welds: optimizing continuous wave and square wave modulated processes.

    Energy Technology Data Exchange (ETDEWEB)

    Ellison, Chad M. (Honeywell FM& T, Kansas City, MO); Perricone, Matthew; Faraone, Kevin M. (Honeywell FM& T, Kansas City, MO); Roach, Robert Allen; Norris, Jerome T.

    2007-02-01

    Nd:YAG laser joining is a high energy density (HED) process that can produce high-speed, low-heat input welds with a high depth-to-width aspect ratio. This is optimized by formation of a ''keyhole'' in the weld pool resulting from high vapor pressures associated with laser interaction with the metallic substrate. It is generally accepted that pores form in HED welds due to the instability and frequent collapse of the keyhole. In order to maintain an open keyhole, weld pool forces must be balanced such that vapor pressure and weld pool inertia forces are in equilibrium. Travel speed and laser beam power largely control the way these forces are balanced, as well as welding mode (Continuous Wave or Square Wave) and shielding gas type. A study into the phenomenon of weld pool porosity in 304L stainless steel was conducted to better understand and predict how welding parameters impact the weld pool dynamics that lead to pore formation. This work is intended to aid in development and verification of a finite element computer model of weld pool fluid flow dynamics being developed in parallel efforts and assist in weld development activities for the W76 and future RRW programs.

  12. Research on overall assembling and welding process of steel box girder tuyere blocks of Taizhou Bridge

    Institute of Scientific and Technical Information of China (English)

    Yan Shiguang; Li Hongtao; Wang Chao

    2012-01-01

    This article presents in detail the assembling and welding process technique of the steel box girder tuyere blocks of Taizhou Bridge. The application of this process technique effectively solves the problem of welding stress release in tuyere block assembling and welding without increasing the number of turns of the blocks and overhead welding, thus avoiding possible structural deformation due to excessive accumulation of internal welding stress, greatly reducing the repeated deformation and correction work during assembling and welding, and ensuring the weld seam quality and overall dimensions of tuvere blocks of Taizhou Bridze.

  13. Current-driven ion-acoustic and potential-relaxation instabilities excited in plasma plume during electron beam welding

    Science.gov (United States)

    Trushnikov, D. N.; Mladenov, G. M.; Belenkiy, V. Ya.; Koleva, E. G.; Varushkin, S. V.

    2014-04-01

    Many papers have sought correlations between the parameters of secondary particles generated above the beam/work piece interaction zone, dynamics of processes in the keyhole, and technological processes. Low- and high-frequency oscillations of the current, collected by plasma have been observed above the welding zone during electron beam welding. Low-frequency oscillations of secondary signals are related to capillary instabilities of the keyhole, however; the physical mechanisms responsible for the high-frequency oscillations (>10 kHz) of the collected current are not fully understood. This paper shows that peak frequencies in the spectra of the collected high-frequency signal are dependent on the reciprocal distance between the welding zone and collector electrode. From the relationship between current harmonics frequency and distance of the collector/welding zone, it can be estimated that the draft velocity of electrons or phase velocity of excited waves is about 1600 m/s. The dispersion relation with the properties of ion-acoustic waves is related to electron temperature 10 000 K, ion temperature 2 400 K and plasma density 1016 m-3, which is analogues to the parameters of potential-relaxation instabilities, observed in similar conditions. The estimated critical density of the transported current for creating the anomalous resistance state of plasma is of the order of 3 A.m-2, i.e. 8 mA for a 3-10 cm2 collector electrode. Thus, it is assumed that the observed high-frequency oscillations of the current collected by the positive collector electrode are caused by relaxation processes in the plasma plume above the welding zone, and not a direct demonstration of oscillations in the keyhole.

  14. Analysis of the Covered Electrode Welding Process Stability on the Basis of Linear Regression Equation

    Directory of Open Access Journals (Sweden)

    Słania J.

    2014-10-01

    Full Text Available The article presents the process of production of coated electrodes and their welding properties. The factors concerning the welding properties and the currently applied method of assessing are given. The methodology of the testing based on the measuring and recording of instantaneous values of welding current and welding arc voltage is discussed. Algorithm for creation of reference data base of the expert system is shown, aiding the assessment of covered electrodes welding properties. The stability of voltage–current characteristics was discussed. Statistical factors of instantaneous values of welding current and welding arc voltage waveforms used for determining of welding process stability are presented. The results of coated electrodes welding properties are compared. The article presents the results of linear regression as well as the impact of the independent variables on the welding process performance. Finally the conclusions drawn from the research are given.

  15. Developing Friction Stir Welding Process Model for ICME Application

    Science.gov (United States)

    Yang, Yu-Ping

    2015-01-01

    A framework for developing a product involving manufacturing processes was developed with integrated computational materials engineering approach. The key component in the framework is a process modeling tool which includes a thermal model, a microstructure model, a thermo-mechanical, and a property model. Using friction stir welding (FSW) process as an example, development of the process modeling tool was introduced in detail. The thermal model and the microstructure model of FSW of steels were validated with the experiment data. The model can predict reasonable temperature and hardness distributions as observed in the experiment. The model was applied to predict residual stress and joint strength of a pipe girth weld.

  16. A computer-based control system for keyhole plasma arc welding

    Institute of Scientific and Technical Information of China (English)

    Jia Chuanbao; Wu Chuansong; Zhang Yuming

    2007-01-01

    A new kind of control system for keyhole plasma arc welding (K-PAW) was developed based on the computer and the Graphics Language-LabVIEW. It can set and output the required current waveforms with desired decreasing slopes so that the corresponding "opening and closing" of keyhole can occur periodically. With this control strategy of welding current waveforms, the workpiece is fully penetrated while no burn-through occurs. Keyhole plasma arc welding experiments were conducted to verify the stability and reliability of the developed system.

  17. Modifying welding process parameters can reduce the neurotoxic potential of manganese-containing welding fumes.

    Science.gov (United States)

    Sriram, Krishnan; Lin, Gary X; Jefferson, Amy M; Stone, Samuel; Afshari, Aliakbar; Keane, Michael J; McKinney, Walter; Jackson, Mark; Chen, Bean T; Schwegler-Berry, Diane; Cumpston, Amy; Cumpston, Jared L; Roberts, Jenny R; Frazer, David G; Antonini, James M

    2015-02-03

    Welding fumes (WF) are a complex mixture of toxic metals and gases, inhalation of which can lead to adverse health effects among welders. The presence of manganese (Mn) in welding electrodes is cause for concern about the potential development of Parkinson's disease (PD)-like neurological disorder. Consequently, from an occupational safety perspective, there is a critical need to prevent adverse exposures to WF. As the fume generation rate and physicochemical characteristics of welding aerosols are influenced by welding process parameters like voltage, current or shielding gas, we sought to determine if changing such parameters can alter the fume profile and consequently its neurotoxic potential. Specifically, we evaluated the influence of voltage on fume composition and neurotoxic outcome. Rats were exposed by whole-body inhalation (40 mg/m(3); 3h/day × 5 d/week × 2 weeks) to fumes generated by gas-metal arc welding using stainless steel electrodes (GMA-SS) at standard/regular voltage (25 V; RVSS) or high voltage (30 V; HVSS). Fumes generated under these conditions exhibited similar particulate morphology, appearing as chain-like aggregates; however, HVSS fumes comprised of a larger fraction of ultrafine particulates that are generally considered to be more toxic than their fine counterparts. Paradoxically, exposure to HVSS fumes did not elicit dopaminergic neurotoxicity, as monitored by the expression of dopaminergic and PD-related markers. We show that the lack of neurotoxicity is due to reduced solubility of Mn in HVSS fumes. Our findings show promise for process control procedures in developing prevention strategies for Mn-related neurotoxicity during welding; however, it warrants additional investigations to determine if such modifications can be suitably adapted at the workplace to avert or reduce adverse neurological risks.

  18. Study on the welding process of the CTB outbox prototype of ITER

    Energy Technology Data Exchange (ETDEWEB)

    Liu, Chen, E-mail: liuchen@ipp.ac.cn [Institute of Plasma Physics, Chinese Academy of Sciences (China); Lu, Kun; Song, Yuntao; Zhu, Rui [Institute of Plasma Physics, Chinese Academy of Sciences (China); Bao, Hongwei; Li, Shoukang; Zhang, Chunjie; Tuo, Fuxing [Shanghai Aerospace Equipments Manufacturer (China)

    2015-10-15

    Highlights: • Welding progress simulation of ITER CTB outbox by SYSWELD. • 2 m length box mockup welding for R&D. • Special welding tooling and groove design for welding deformation control and improvement of welding quality. • Double torch automatic MIG welding method application. - Abstract: The current study investigated the main welding process of the box. We first performed a simple simulation of the welding process for the four long weld lines on CTB (Coil Terminal Box) outbox by using the finite element analysis mode of SYSWELD. Then a 2 m length mock up box was welded for R&D to optimize the welding parameters and deformation distribution. Base on the R&D experiences, we designed a special tooling of the prototype box which can be used to control the deformation during the welding process. A 8 m length CTB outbox prototype was successfully welded by using double torch automatic MIG (Metal Inert-Gas) welding. The dimension inspection results confirmed that the welding deformation of the box can be controlled within 3 mm on each side. Based on the ultrasonic inspection, all the welding seams met quality level B by standard EN 5817.

  19. Tomographical process monitoring of laser transmission welding with OCT

    Science.gov (United States)

    Ackermann, Philippe; Schmitt, Robert

    2017-06-01

    Process control of laser processes still encounters many obstacles. Although these processes are stable, a narrow process parameter window during the process or process deviations have led to an increase on the requirements for the process itself and on monitoring devices. Laser transmission welding as a contactless and locally limited joining technique is well-established in a variety of demanding production areas. For example, sensitive parts demand a particle-free joining technique which does not affect the inner components. Inline integrated non-destructive optical measurement systems capable of providing non-invasive tomographical images of the transparent material, the weld seam and its surrounding areas with micron resolution would improve the overall process. Obtained measurement data enable qualitative feedback into the system to adapt parameters for a more robust process. Within this paper we present the inline monitoring device based on Fourier-domain optical coherence tomography developed within the European-funded research project "Manunet Weldable". This device, after adaptation to the laser transmission welding process is optically and mechanically integrated into the existing laser system. The main target lies within the inline process control destined to extract tomographical geometrical measurement data from the weld seam forming process. Usage of this technology makes offline destructive testing of produced parts obsolete. 1,2,3,4

  20. Research on environmental impact assessment of flame oxyacetylene welding processes

    Directory of Open Access Journals (Sweden)

    Gh. Amza

    2013-10-01

    Full Text Available This paper presents the factors that may cause pollution of the work environment when working with the oxyacetylene flame welding process. Experiments were performed using an oven that allows the analysis of all gases resulted in the welding process, but also enables their monitoring using a video camera, and the resulting film was processed in that the frames for each second of experimentation were extracted. The materials used in the experiments were S235JR steel as the base material, and as filler materials, E70S. In order to assess the impact on the work environment of this welding process, the pollution coefficient CP was defined based on the equation of the material balance.

  1. Magnetic fabric and welding processes in high-grade tuffs

    Science.gov (United States)

    Pioli, L.; Ort, M.; Lanza, R.; Rosi, M.

    2003-04-01

    The welding fabric of tuffs is generally quantified through two main parameters: porosity and fiamme aspect ratio. However, these parameters are not useful for high-grade ignimbrites that display features indicating extensive rheomorphic flow, partial to complete obliteration of primary vitroclastic textures, and syn-depositional welding rather than load-related compaction. In this case, a 3D-microstructural characterization of the rock fabric is a fundamental proxy for the assessment of the dynamics and duration of welding processes. We have investigated the relations between magnetic fabric and welding textures in a rhyolitic, high-grade ignimbrite from the Sulcis volcanic District (SW Sardinia, Italy). The ignimbrite is characterized by dense welding throughout its preserved thickness and by regular lateral and vertical variations of welding, devitrification and vesiculation facies. Field and structural data indicate that syn-depositional welding and non-particulate (NP) flow were extensive and continuous during the emplacement of the ignimbrite. Paleomagnetic measurements of AMS, NRM, and AIRM of samples from the tuff indicate that the magnetic fabric is strain-sensitive and it is not significantly affected by post-depositional, static processes such as devitrification and vapor-phase alteration; in particular, magnetic susceptibility of the rock and the welding texture correlate well in terms of shape and orientation of the anisotropy ellipsoid. The direction of the K1 axis is indicative of the flow direction in the site of measurement. The anisotropy degree (P) increases with increasing welding and foliation (F) and lineation (L) are directly related to the strain facies. Onset of welding increased the degree of anisotropy and foliation; a non particulate, laminar flow stage further deformed the fabric stretching it along the flow direction and thus increasing L. The intensity of L is strictly related to the duration and the effect of simple shear (laminar

  2. Virtual Welded-Joint Design Integrating Advanced Materials and Processing Technologies

    Energy Technology Data Exchange (ETDEWEB)

    Yang, Z.; Dong, P.; Liu, S.; Babu, S.; Olson, G.; DebRoy, T.

    2005-04-15

    The primary goal of this project is to increase the fatigue life of a welded-joint by 10 times and to reduce energy use by 25% through product performance and productivity improvements using an integrated modeling approach. The fatigue strength of a welded-joint is currently the bottleneck to design high performance and lightweight welded structures using advanced materials such as high strength steels. In order to achieve high fatigue strength in a welded-joint it is necessary to manage the weld bead shape for lower stress concentration, produce preferable residual stress distribution, and obtain the desired microstructure for improved material toughness and strength. This is a systems challenge that requires the optimization of the welding process, the welding consumable, the base material, as well as the structure design. The concept of virtual welded-joint design has been proposed and established in this project. The goal of virtual welded-joint design is to develop a thorough procedure to predict the relationship of welding process, microstructure, property, residual stress, and the ultimate weld fatigue strength by a systematic modeling approach. The systematic approach combines five sub-models: weld thermal-fluid model, weld microstructure model, weld material property model, weld residual stress model, and weld fatigue model. The systematic approach is thus based on interdisciplinary applied sciences including heat transfer, computational fluid dynamics, materials science, engineering mechanics, and material fracture mechanics. The sub-models are based on existing models with further development. The results from modeling have been validated with critical experiments. The systematic modeling approach has been used to design high fatigue resistant welds considering the combined effects of weld bead geometry, residual stress, microstructure, and material property. In particular, a special welding wire has been developed in this project to introduce

  3. Monitoring and Control of the Hybrid Laser-Gas Metal-Arc Welding Process

    Energy Technology Data Exchange (ETDEWEB)

    Kunerth, D. C.; McJunkin, T. R.; Nichol, C. I.; Clark, D.; Todorov, E.; Couch, R. D.; Yu, F.

    2013-07-01

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

  4. Effects of process parameters and die geometry on longitudinal welds quality in aluminum porthole die extrusion process

    Institute of Scientific and Technical Information of China (English)

    LIU Jian; LIN Gao-yong; FENG Di; ZOU Yan-ming; SUN Li-ping

    2010-01-01

    By using the rigid-visco-plasticity finite element method,the welding process of aluminum porthole die extrusion to form a tube was simulated based on Deform-3D software.The welding chamber height(H),back dimension of die leg(D),process velocity and initial billet temperature were used in FE simulations so as to determine the conditions in which better longitudinal welding quality can be obtained.According to K criterion,the local welding parameters such as welding pressure,effective stress and welding path length on the welding plane are linked to longitudinal welds quality.Simulation turns out that pressure-to-effective stress ratio(p/σ)and welding path length(L)are the key factors affecting the welding quality.Higher welding chamber best and sharper die leg give better welding quality.When H=10 mm and D=0.4 mm,the longitudinal welds have the best quality.Higher process velocity decreases welds quality.The proper velocity is 10 mm/s for this simulation.In a certain range,higher temperature is beneficial to the longitudinal welds.It is found that both 450 and 465℃ can satisfy the requirements of the longitudinal welds.

  5. Atomic diffusion behavior in Cu-Al explosive welding process

    Science.gov (United States)

    Chen, S. Y.; Wu, Z. W.; Liu, K. X.; Li, X. J.; Luo, N.; Lu, G. X.

    2013-01-01

    A hybrid method is proposed to study atomic diffusion behavior in Cu-Al explosive welding process. The method combines molecular dynamics simulation and classical diffusion theory. Cu-Al explosive welding and scanning electron microscope experiments are done to verify the method. Using the method, we find that the atomic diffusion mostly takes place in the unloading stage of the welding process. The diffusion coefficients are collision velocity-dependent, with higher velocities generating larger coefficients. When there is no transverse velocity, the diffusion coefficient is directly proportional to the longitudinal velocity. With the longitudinal velocity fixed, the diffusion coefficient is proportional to the square of the transverse velocity. The thickness of the diffusion layer is calculated from the simulation result, and it is in good agreement with the experiment result.

  6. Optimization of Friction Welding Process Parameters for Joining Carbon Steel and Stainless Steel%Optimization of Friction Welding Process Parameters for Joining Carbon Steel and Stainless Steel

    Institute of Scientific and Technical Information of China (English)

    R Paventhan; P R Lakshminarayanan; V Balasubramanian

    2012-01-01

    Friction weIding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. An attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AISI 1040 grade medium carbon steel and AISI 304 austenitic stainless steel, incorporating the process parameters such as friction pressure, forging pressure, friction time and forging time, which have great influence on strength of the joints. Response surface methodology was applied to optimize the friction welding process parameters to attain maximum tensile strength of the joint. The maximum tensile strength of 543 MPa could be obtained for the joints fabricated under the welding conditions of friction pressure of 90 MPa, forging pressure of 90 MPa, friction time of 6 s and forging time of 6 s.

  7. Effect of process parameters on optimum welding condition of DP590 steel by friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Young Gon; Kim, Ji Sun; Kim, In Ju [Korea Institute of Industrial Technology, Gwangju (Korea, Republic of)

    2014-12-15

    In the automotive industry, vehicle weight reduction techniques have been actively studied to improve the rate of fuel consumption and to cope with the regulation restricting exhaust gas. For this reason, advanced high-strength steel (AHSS) is preferred in the automobile industry as its tensile strength is 590 MPa and over. In this study, to obtain the optimum welding condition, the friction stir welding (FSW) process applied to AHSS was considered. The FSW experiment was performed on a stir plate using a Si{sub 3}N{sub 4} tool and a 1.4-mm thick DP590 steel sheet manufactured by cold rolling. In addition, to investigate the temperature distribution of the advancing and retreating sides in the welding state, the tool rotation speed of 800 rpm, and the welding speed of 180 mm/min, a K-type thermocouple was inserted in the backing plate, and the peak temperature was evaluated at each point. Especially, the correlation between the heat input per unit length and the formation of the FSW zone was minutely analyzed.

  8. Infrared welding process on composite: Effect of interdiffusion at the welding interface

    Science.gov (United States)

    Asseko, André Chateau Akué; Lafranche, Éric; Cosson, Benoît; Schmidt, Fabrice; Le Maoult, Yannick

    2016-10-01

    In this study, the effects of the welding temperature field developed during the infrared assembly process on the joining properties of glass fibre reinforced polycarbonate/ unreinforced polycarbonate with carbon black were investigated. The temperature field and the contact time govern together the quality of the adhesion at the welding interface. The effect of the semi-transparent glass fibre reinforced polycarbonate composite / unreinforced polycarbonate composite with carbon black interface was quantified in term of quadratic distance of diffusion or diffusion depth through the welding interface. The microstructural characterizations were investigated in order to inspect the welding zones quality and to observe their failure modes. The diffusion theory has then been applied to calculate the variation of the quadratic distance of diffusion versus time at different locations. The complete self-diffusion is supposed occurring only at temperature above the polycarbonate glass transition temperature (140°C) and with a quadratic distance of diffusion superior to the mean square end-to-end distance.

  9. Fragmentation processes during explosion welding (review)

    Science.gov (United States)

    Grinberg, B. A.; Ivanov, M. A.; Rybin, V. V.; Elkina, O. A.; Patselov, A. M.; Antonova, O. V.; Inozemtsev, A. V.; Tolmachev, T. P.

    2013-10-01

    The fragmentation during explosion welding is briefly reviewed. Fragmentation of partitioning type (FPT), which consists in partitioning into particles that either fly away or join each other, is detected. FPT is an analog of the fragmentation during an explosion that was studied by Mott. In both cases, the flight of particles (fragments) takes place, and the integrity of the material is retained in FPT. FPT is a powerful channel for the dissipation of supplied energy, since the surface of flying particles has a large total area.

  10. Process control based on double-side image sensing of keyhole puddle for the VPPA welding of aluminum alloys

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    The double-side image sensing of the keyhole puddle in the variable polarity plasma arc welding of aluminum alloys has been investigated in this paper, to extract the characteristically geometrical size of the keyhole and to realize the feedback controlling for weld formation in the welding process. Some geometrical sizes of the visible keyhole in the front and back images such as the width, height, area, etc. can be used to monitor both the keyhole puddle and the weld formation in the welding process. Under the condition of the varied heat sink, varied gap and misalignment, the trend from normal welding to cutting can be reflected from the variations of geometrical sizes of the keyhole puddle respectively. The keyhole area, the keyhole height and the shape parameters of the keyhole puddle are the key parameters which reflect the trend from normal welding to cutting when meeting the condition of the varied heat sink, varied gap and misalignment respectively. The algorithm for the image processing of the keyhole puddle and the periphery extracting of the visible keyhole developed in the paper can be used to determine real-timely the geometrical sizes of the visible keyhole. Artificial neural network is applied to establish the model for predicting the geometrical sizes of the back keyhole puddle. The inputs of the model are the geometrical sizes of the front keyhole puddle and the weld parameters, the outputs of the model are the geometrical sizes of the back keyhole puddle. The model can be used to control the stability of keyhole and the weld formation.

  11. THERMAL FIELD MODELING IN THE MIG / MAG - CMT BRAZE-WELDING PROCESS OF GALVANIZED SHEETS

    Directory of Open Access Journals (Sweden)

    GHEORGHE SIMA

    2013-10-01

    Full Text Available This paper deals with some technical aspects of the optimization process braze-welding of galvanized steel sheet with a thickness of 0.7-1.5 mm. The braze-welding process is presented systemic, highlighting the input and output variables (of the zinc layer and intermetallic layer characteristics. It is presented the test for statistical analysis performed on a four-level factorial experiment aimed at studying the influence of the main simultaneously welding parameters of the welding technology CMT (Cold Metal Transfer: determining an optimal welding current IS, welding speed vS, boos current Ina and arc length correction factor l0.

  12. A Real-Time Spectroscopic Sensor for Monitoring Laser Welding Processes

    Science.gov (United States)

    Sibillano, Teresa; Ancona, Antonio; Berardi, Vincenzo; Lugarà, Pietro Mario

    2009-01-01

    In this paper we report on the development of a sensor for real time monitoring of laser welding processes based on spectroscopic techniques. The system is based on the acquisition of the optical spectra emitted from the laser generated plasma plume and their use to implement an on-line algorithm for both the calculation of the plasma electron temperature and the analysis of the correlations between selected spectral lines. The sensor has been patented and it is currently available on the market. PMID:22412317

  13. Plasma diagnostics approach to welding heat source/molten pool interaction

    Energy Technology Data Exchange (ETDEWEB)

    Key, J.F.; McIlwain, M.E.; Isaacson, L.

    1980-01-01

    Plasma diagnostic techniques show that weld fusion zone profile and loss of metal vapors from the molten pool are strongly dependent on both the intensity and distribution of the heat source. These plasma properties, are functions of cathode vertex angle and thermal conductivity of the shielding gas, especially near the anode.

  14. Colosed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Ppart Qualification Project

    Data.gov (United States)

    National Aeronautics and Space Administration — Thermal Stir Welding (TSW) provides advancement over the more conventional Friction Stir Welding (C-FSW) process because it separates the primary processes variables...

  15. Closed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Part Qualification Project

    Data.gov (United States)

    National Aeronautics and Space Administration — Thermal Stir Welding (TSW) provides advancement over the more conventional Friction Stir Welding (C-FSW) process because it separates the primary processes variables...

  16. VPPA weld model evaluation

    Science.gov (United States)

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

    1992-07-01

    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.

  17. Welding of AA1050 aluminum with AISI 304 stainless steel by rotary friction welding process

    Directory of Open Access Journals (Sweden)

    Chen Ying An

    2010-09-01

    Full Text Available The purpose of this work was to assess the development of solid state joints of dissimilar material AA1050 aluminum and AISI 304 stainless steel, which can be used in pipes of tanks of liquid propellants and other components of the Satellite Launch Vehicle. The joints were obtained by rotary friction welding process (RFW, which combines the heat generated from friction between two surfaces and plastic deformation. Tests were conducted with different welding process parameters. The results were analyzed by means of tensile tests, Vickers microhardness, metallographic tests and SEM-EDX. The strength of the joints varied with increasing friction time and the use of different pressure values. Joints were obtained with superior mechanical properties of the AA1050 aluminum, with fracture occurring in the aluminum away from the bonding interface. The analysis by EDX at the interface of the junction showed that interdiffusion occurs between the main chemical components of the materials involved. The RFW proves to be a great method for obtaining joints between dissimilar materials, which is not possible by fusion welding processes.

  18. Development of automated welding process for field fabrication of thick walled pressure vessels. Fourth quarter, FY 1980

    Energy Technology Data Exchange (ETDEWEB)

    1980-12-19

    Progress is reported in research on the automated welding of heavy steel plate for the fabrication of pressure vessels. Information is included on: torch and shield adaptation; mechanical control of the welding process; welding parameters; joint design; filler wire optimizaton; nondestructive testing of welds; and weld repair. (LCL)

  19. Numerical simulation of linear fiction welding (LFW) processes

    Science.gov (United States)

    Fratini, L.; La Spisa, D.

    2011-05-01

    Solid state welding processes are becoming increasingly important due to a large number of advantages related to joining "unweldable" materials and in particular light weight alloys. Linear friction welding (LFW) has been used successfully to bond non-axisymmetric components of a range of materials including titanium alloys, steels, aluminum alloys, nickel, copper, and also dissimilar material combinations. The technique is useful in the research of quality of the joints and in reducing costs of components and parts of the aeronautic and automotive industries. LFW involves parts to be welded through the relative reciprocating motion of two components under an axial force. In such process the heat source is given by the frictional forces work decaying into heat determining a local softening of the material and proper bonding conditions due to both the temperature increase and the local pressure of the two edges to be welded. This paper is a comparative test between the numerical model in two dimensions, i.e. in plane strain conditions, and in three dimensions of a LFW process of AISI1045 steel specimens. It must be observed that the 3D model assures a faithful simulation of the actual threedimensional material flow, even if the two-dimensional simulation computational times are very short, a few hours instead of several ones as the 3D model. The obtained results were compared with experimental values found out in the scientific literature.

  20. Optimisation of process parameters in friction stir welding based on residual stress analysis: a feasibility study

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    2010-01-01

    The present paper considers the optimisation of process parameters in friction stir welding (FSW). More specifically, the choices of rotational speed and traverse welding speed have been investigated using genetic algorithms. The welding process is simulated in a transient, two-dimensional sequen......The present paper considers the optimisation of process parameters in friction stir welding (FSW). More specifically, the choices of rotational speed and traverse welding speed have been investigated using genetic algorithms. The welding process is simulated in a transient, two......, and this is presented as a Pareto optimal front. Moreover, a higher welding speed for a fixed rotational speed results, in general, in slightly higher stress levels in the tension zone, whereas a higher rotational speed for a fixed welding speed yields somewhat lower peak residual stress, however, a wider tension zone...

  1. Influential Parameters and Numerical Simulation of Heat Generated in the Process of Friction Stir Welding

    National Research Council Canada - National Science Library

    KOVACEVIC, Ilija; DJELOSEVIC, Mirko; TEPIC, Goran; MILISAVLJEVIC, Stevan

    2016-01-01

    The paper analyzes the problem of friction stir welding (FSW) technology. The mechanism of thermo-mechanical process of the FSW method has been identified and a correlation between the weld zone and its microstructure established...

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

    Science.gov (United States)

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

    2015-07-01

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

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

    Science.gov (United States)

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

    2016-06-01

    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.

  4. Optimizing pulsed current micro plasma arc welding parameters to ...

    African Journals Online (AJOL)

    user

    Pulsed current MPAW involves cycling the welding current at selected regular frequency. ..... At high pulse, the vibration amplitude and temperature oscillation induced on .... received his Masters Degree from JNTU Hyderabad, India in 2002.

  5. NIR-camera-based online diagnostics of laser beam welding processes

    Science.gov (United States)

    Dorsch, Friedhelm; Braun, Holger; Keßler, Steffen; Pfitzner, Dieter; Rominger, Volker

    2012-03-01

    We have developed an on-axis camera-based online sensor system for laser beam welding diagnostics that detects the thermal radiation in the near-infrared (NIR) spectral range between 1200 and 1700 nm. In addition to a sensor in the visible (VIS) range, our camera detects the thermal radiation of the weld pool more clearly, and it is also sensible to the radiation of the solidified weld seam. The NIR images are analyzed by real-time image processing. Features are extracted from the images and evaluated to characterize the welding process. Keyhole and weld pool analysis complement VIS diagnostics, whereas the observation of the weld seam and heat affected zone with an NIR camera allows online heat flux thermography. By this means we are able to detect bad joints in overlap weldings ("false friends") online during the welding process.

  6. The effect of welding process and shielding atmosphere on the AlMg4.5Mn weld metal properties

    Energy Technology Data Exchange (ETDEWEB)

    Prokic Cvetkovic, Radica; Popovic, Olivera [Belgrade Univ. (Serbia). Faculty of Mechanical Engineering; Burzic, Meri; Jovicic, Radomir [Belgrade Univ. (Serbia). Innovation Center; Kastelec Macura, Sandra [Technikum Taurunum, Zemun (Serbia); Buyukyildirim, Galip [IWE, Istanbul (Turkey)

    2013-01-15

    In this paper, the AlMg4.5Mn alloy has been welded using tungsten inert gas (TIG) and metal inert gas (MIG) processes with different gas shielding atmospheres. Tensile strength, hardness, impact and fracture toughness, fatigue crack growth parameters ({Delta}K{sub th}, da/dN), as well as microstructure were determined. By comparing results for different gas mixtures, the main conclusion for TIG welding was that increased helium content has an important effect on toughness and fatigue crack growth parameters, whereas its effect on other mechanical properties is not significant. On the other hand, in the case of MIG welding, adding helium does not affect mechanical properties, except the fatigue crack growth rate. It was also established that adding nitrogen (TIG welding) and oxygen (MIG welding) reduces toughness and increases crack growth rate, so their use in shielding mixtures is not recommended. (orig.)

  7. Influence of Processing Parameters on the Flow Path in Friction Stir Welding

    Science.gov (United States)

    Schneider, J. A.; Nunes, A. C., Jr.

    2006-01-01

    Friction stir welding (FSW) is a solid phase welding process that unites thermal and mechanical aspects to produce a high quality joint. The process variables are rpm, translational weld speed, and downward plunge force. The strain-temperature history of a metal element at each point on the cross-section of the weld is determined by the individual flow path taken by the particular filament of metal flowing around the tool as influenced by the process variables. The resulting properties of the weld are determined by the strain-temperature history. Thus to control FSW properties, improved understanding of the processing parameters on the metal flow path is necessary.

  8. Thermal and mechanical response of steel sheets welded by laser process: Preanalysis made by ABAQUS code

    Energy Technology Data Exchange (ETDEWEB)

    Carmignani, B.; Daneri, A.; Giambuzzi, S.; Toselli, G. [ENEA, Bologna (Italy). Centro Ricerche Energia `E. Clementel` - Area Energetica

    1994-11-01

    In this work, the conclusive report on the activity, developed in the frame of the european project EUREKA-FASP (EU353), concerning the numerical simulation of the thermal and mechanical response of steel sheets, welded by a laser welding process, is presented. This type of welding process is of interest in the shipyard field. ABAQUS code, in its implicit version, has been used. Besides the description of the studies concerning more directly the laser welding, simulations of traditional welding processes, executed in order to single out particular aspects and calculation strategies to be utilized for the simulation of the process object of the study made, are presented and discussed.

  9. Diffusion welding process and joint's microstructure behavior of SiCw/6061Al composite

    Institute of Scientific and Technical Information of China (English)

    LIU Liming; DONG Changfu; GAO Zhenkun

    2004-01-01

    The rules such as process parameters affecting joint properties and the evolution principle of weld's microstructure have been researched by adopting diffusion welding process to connect SiCw/6061Al composite. Experimental results show that there exists a critical temperature region between solid and liquid phase line of SiCw/6061Al composite, and the region will shrink with the increasing of welding pressure. When diffusion welding occurred under the critical temperature region, welding joint exhibits bad property of bonding, and the matrix and the reinforcement can't bond effectively. When diffusion welding occurred in the critical temperature region, the strength of welding joint changes widely with the variation of welding temperature. When welding temperature varies in 10℃, the strength of welding joint will change obviously.Only when welding temperature is higher than the critical temperature region, stable joint properties can be obtained. Simultaneously the matrix and the reinforcement has better interfacial bonded in diffusion welding interface, and no obvious interface reaction occurred, and thus diffusion welding of SiCw/6061Al composite can be successfully realized.

  10. Double-sided gas tungsten arc welding process on TC4 titanium alloy

    Institute of Scientific and Technical Information of China (English)

    GAO Hong-ming; BAI Yan; YANG Tian-dong

    2005-01-01

    TC4 titanium alloy was welded by double-sided gas tungsten arc welding(GTAW) process in comparison with conventional GTAW process, the microstructure and mechanical performance of weld were also studied. The results indicate that double-sided GTAW is superior over regular single-sided GTAW on the aspects of increasing penetration, reducing welding deformation and improving welding efficiency. Good weld joint was obtained, which can reach 96.14% tensile strength and 70.85 % elongation percentage of the base metal. The grains in heat-affected zone(HAZ) are thin and equiaxed and the degree of grain coarsening increases as one moves to the weld center line,and the interior of grains are α and α' structures. The coarse columned and equiaxed grains, which interlace martensitic structures α' and acicular α structures, are observed in weld zone. The fracture mode is ductile fracture.

  11. Design and Implementation of Software for Resistance Welding Process Simulations

    DEFF Research Database (Denmark)

    Zhang, Wenqi

    2003-01-01

    by engineers and technicians in industry, all of the important parameters in resistance welding are considered and automatically implemented into the software. With the specially designed graphic user interface for Windows, engineers (even without prior knowledge of FEM) can quickly learn and easily operate...... and utilize the software. All industrial users, including welding engineers from DaimlerChrysler, Volkswangen, PSA Peugeot Citroen, VOLVO, Siemens, ABB and so on, have started using the software just after taking a one-day training course. With the user-friendly facilities for flexible geometric design...... of work pieces and electrodes as well as process parameter settings similar to real machine settings, the software has been readily applied in industry for supporting product development and process optimization. After simulation, the dynamic process parameters are graphically displayed. The distributions...

  12. Process optimization of friction stir welding based on thermal models

    DEFF Research Database (Denmark)

    Larsen, Anders Astrup

    2010-01-01

    This thesis investigates how to apply optimization methods to numerical models of a friction stir welding process. The work is intended as a proof-of-concept using different methods that are applicable to models of high complexity, possibly with high computational cost, and without the possibility...... information of the high-fidelity model. The optimization schemes are applied to stationary thermal models of differing complexity of the friction stir welding process. The optimization problems considered are based on optimizing the temperature field in the workpiece by finding optimal translational speed....... Also an optimization problem based on a microstructure model is solved, allowing the hardness distribution in the plate to be optimized. The use of purely thermal models represents a simplification of the real process; nonetheless, it shows the applicability of the optimization methods considered...

  13. Design and Implementation of Software for Resistance Welding Process Simulations

    DEFF Research Database (Denmark)

    Zhang, Wenqi

    2003-01-01

    by engineers and technicians in industry, all of the important parameters in resistance welding are considered and automatically implemented into the software. With the specially designed graphic user interface for Windows, engineers (even without prior knowledge of FEM) can quickly learn and easily operate...... and utilize the software. All industrial users, including welding engineers from DaimlerChrysler, Volkswangen, PSA Peugeot Citroen, VOLVO, Siemens, ABB and so on, have started using the software just after taking a one-day training course. With the user-friendly facilities for flexible geometric design...... of work pieces and electrodes as well as process parameter settings similar to real machine settings, the software has been readily applied in industry for supporting product development and process optimization. After simulation, the dynamic process parameters are graphically displayed. The distributions...

  14. The Studies of the Welding Processes and Procedures on the West-East Pipeline Project

    Institute of Scientific and Technical Information of China (English)

    SuiYongli; HuangFuxiang; ZhaoHaihong; YinChanghua

    2004-01-01

    The West-East pipeline project attracted the attention from all over the world for its long distance, huge diameter, complex geographic conditions, and diversified welding techniques being applied. In this paper the detail welding process and procedures used in the project are discussed and the distinguished achievements on welding techniques of China pipeline construction are described.

  15. Seam gap bridging of laser based processes for the welding of aluminium sheets for industrial applications

    NARCIS (Netherlands)

    Aalderink, B.J.; Aalderink, Benno; Pathiraj, B.; Aarts, Ronald G.K.M.

    2010-01-01

    Laser welding has a large potential for the production of tailor welded blanks in the automotive industry, due to the low heat input and deep penetration. However, due to the small laser spot and melt pool, laser-based welding processes in general have a low tolerance for seam gaps. In this paper,

  16. Seam gap bridging of laser based processes for the welding of aluminium sheets for industrial applications

    NARCIS (Netherlands)

    Aalderink, Bernard Johan; Pathiraj, B.; Aarts, R.G.K.M.

    2010-01-01

    Laser welding has a large potential for the production of tailor welded blanks in the automotive industry, due to the low heat input and deep penetration. However, due to the small laser spot and melt pool, laser-based welding processes in general have a low tolerance for seam gaps. In this paper, f

  17. Modeling of material flow in friction stir welding process

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    This paper presents a 3D numerical model to study the material flow in the friction stir welding process. Results indicate that the material in front of the pin moves upwards due to the extrusion of the pin, and then the upward material rotates with the pin. Behind the rotating tool, the material starts to move downwards and to deposit in the wake. This process is the real cause to make friction stir welding process continuing successfully. The tangent movement of the material takes the main contribution to the flow of the material in friction stir welding process. There exists a swirl on the advancing side and with the increase of the translational velocity the inverse flow of the material on the advancing side becomes faster. The shoulder can increase the velocity of material flow in both radial direction and tangent direction near the top surface. The variations of process parameters do have an effect on the velocity field near the pin, especially in the region in which the material flow is faster.

  18. Corrosion Resistance of Synergistic Welding Process of Aluminium Alloy 6061 T6 in Sea Water

    Directory of Open Access Journals (Sweden)

    Kharia Salman Hassan

    2014-12-01

    Full Text Available This work involves studying corrosion resistance of AA 6061T6 butt welded joints using Two different welding processes, tungsten inert gas (TIG and a solid state welding process known as friction stir welding, TIG welding process carried out by using Rolled sheet of thickness6mm to obtain a weld joint with dimension of (100, 50, 5 mm using ER4043 DE (Al Si5 as filler metal and argon as shielding gas, while Friction stir welding process carried out using CNC milling machine with a tool of rotational speed 1000 rpm and welding speed of 50mm/min to obtain the same butt joint dimensions. Also one of weld joint in the same dimensions subjected to synergistic weld process TIG and FSW weld process at the same previous weld conditions. All welded joints were tested by X-ray radiography and Faulty pieces were excluded. The joints without defects used to prepare many specimens for Corrosion test by the dimensions of (15*15*3 mm according to ASTM G71-31. Specimens subjected to micro hardness and microstructure test. Corrosion test was achieved by potential at scan rate( +1000 ,-1000mv/sec to estimate corrosion parameters by extrapolator Tafle method after polarized ±100 mv around open circuit potential,in seawater (3.5%NaCl at a temperature of 25°C. From result which obtained by Tafel equation. It was found that corrosion rate for TIG weld joint was higher than the others but synergistic weld process contributed in improving TIG corrosion resistance by a percentage of 14.3%. and FSW give the lest corrosion rate comparing with base metal.

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

    Science.gov (United States)

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

    2012-06-01

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

  20. Optimization of process parameters during vibratory welding technique using Taguchi's analysis

    Directory of Open Access Journals (Sweden)

    Pravin Kumar Singh

    2016-09-01

    Full Text Available With an aim to improve the mechanical properties of a weld joint, a new concept of vibratory setup has been designed which is capable to stir the molten weld pool before it solidifies during shielded metal arc welding (SMAW operation. Mechanical vibration having resonance frequency of 300 Hz and amplitude of 0.5 mm was transferred to the molten weld pool of 6 mm thick mild steel butt-welded joints during the welding operation. The experimental work was conducted at various ranges of frequencies, welding current and welding speed. Taguchi's analysis technique has been applied to optimize the process parameters; the response values for analysis are yield strength and micro-hardness. The test results showed that with the application of the vibratory treatment the values of hardness and tensile properties increased. The auxiliary vibrations induced into the weld pool resulted in increased micro-hardness of the weld metal which indicates the orientation of the crystal and refinement of grains took place. This study shows that vibration applied into the weld pool can be successfully improved the mechanical properties of welded joints. Thus this research attempt provided an alternative welding technique for grain refinement of weldments.

  1. An investigation on SA 213-Tube to SA 387-Tube plate using friction welding process

    Energy Technology Data Exchange (ETDEWEB)

    Rajan, S. Pandia; Kumaraswamidhas, L. A. [Indian Institute of Technology, Jharkhand (India); Kumaran, S. Senthil [RVS School of Engineering and Technology, Tamil Nadu (India); Muthukumaran, S. [National Institute of Technology, Tamil Nadu (India)

    2016-01-15

    Friction welding of tube to tube plate using an external tool (FWTPET) is a relatively newer solid state welding process used for joining tube to tube plate of either similar or dissimilar materials with enhanced mechanical and metallurgical properties. In the present study, FWTPET has been used to weld SA 213 (Grade T12) tube with SA 387 (Grade 22) tube plate. The welded samples are found to have satisfactory joint strength and the Energy dispersive X-ray analysis (EDX), X-ray diffraction (XRD) study showed that inter metallic compound is absent in the weld zone. The different weld joints have been identified and the phase composition is found using EDX and XRD. Microstructures have been analyzed using optical and Scanning electron microscopy (SEM). The mechanical properties such as hardness, compressive shear strength and peel test for different weld conditions are studied and the hardness survey revealed that there is increase in hardness at the weld interface due to grain refinement. The corrosion behavior for different weld conditions have been analyzed and the weld zone is found to have better corrosion resistance due to the influence of the grain refinement after FWTPET welding process. Hence, the present investigation is carried out to study the behavior of friction welded dissimilar joints of SA 213 tube and SA 387 tube plate joints and the results are presented. The present study confirms that a high quality tube to tube plate joint can be achieved using FWTPET process at 1120 rpm.

  2. INVESTIGATION OF LASER BEAM WELDING PROCESS OF AZ61 MAGNESIUM-BASED ALLOY

    Institute of Scientific and Technical Information of China (English)

    H.Y. Wang; Z.J. Li

    2006-01-01

    Laser welding process of AZ61 magnesium alloys is investigated using a special CO2 laser experimental system. The effect of processing parameters including laser power, welding speed,and protection gas flow at the top and bottom is researched The results show that an ideal weld bead can be formed by choosing the processing parameters properly. An optimized parameter range is obtained by a large number of experiments. Among them, laser power and welding speed are the two main parameters that determine the weld width and dimensions. The protect gas flow rate has a slight effect on the weld width, but it directly effects the surface color of the weld. The test results for typical welds indicate that the microhardness and tensile strength of the weld zone are better than that of the base metal. A fine-grained weld region has been observed and no obvious heat-affected zone is found. The weld zone mainly consists of small α-Mg phase, (α +Al12Mg17), and other eutectic phases. The small grains and the eutectic phases in the joint are believed to play an important role in the increase of the strength of welds for AZ61 magnesium alloys.

  3. Welding.

    Science.gov (United States)

    Cowan, Earl; And Others

    The curriculum guide for welding instruction contains 16 units presented in six sections. Each unit is divided into the following areas, each of which is color coded: terminal objectives, specific objectives, suggested activities, and instructional materials; information sheet; transparency masters; assignment sheet; test; and test answers. The…

  4. An experimental study of high-hydrogen welding processes

    Energy Technology Data Exchange (ETDEWEB)

    Fydrych, D.; Labonowski, J.

    2015-07-01

    This paper presents investigation results of determination of the diffusible hydrogen content in deposited metal obtained by means of two most often used methods-the glycerin method and the mercury method. Relation has been defined between results of those methods in the area characteristic of low-hydrogen as well as high-hydrogen welding processes. Relations available in the literature do not include the diffusible hydrogen content in deposited metal greater than 35 ml/100 g. Extending the scope of analysis of the diffusible hydrogen quantity to an 80 ml/100 g level considerably simplifies carrying out the steel weldability assessment with the use of high-hydrogen processes and with welding in water environment. (Author)

  5. Welding process simulation. Fundamentals and applications; Schweissprozesssimulation. Grundlagen und Anwendungen

    Energy Technology Data Exchange (ETDEWEB)

    Radaj, D.

    1999-07-01

    Welding process simulation is an increasingly important element in technical design. It supports or replaces conventional experimental techniques. The book reviews the state of knowledge, methods and data for numerical welding process simulation on the basis of English-language, Russian and Japanese publications supplemented by results of the author's own projects. The necessary physical fundamentals are explained. [German] Die Schweissprozesssimulation gewinnt als Teilbereich der Konstruktions- und Fertigungsentwicklung zunehmend an Bedeutung. Sie unterstuetzt oder ersetzt die bisherige versuchstechnische Vorgehensweise. Die industrielle Technologieentwicklung wird dadurch in den Bereichen der Verfahrens- und Anlagenentwicklung, der Konstruktions- Werkstoffentwicklung sowie der Forschung und Ausbildung vorangebracht. Das vorliegende Buch fasst den derzeitigen Stand der Kenntnisse, Verfahren und Daten zur numerischen Schweissprozesssimulation zusammen, wobei auf das vornehmlich englische, russische und japanische Spezialschrifttum zurueckgegriffen wird und Erfahrungen und Kontakte aus der eigenen Projektarbeit genutzt werden. Die fuer das Verstaendnis erforderlichen physikalischen Grundlagen werden dabei erlaeutert. (orig.)

  6. Improved Gas Metal Arc Welding Multi-Physics Process Model and Its Application to MIL A46100 Armor-Grade Steel Butt-welds

    Science.gov (United States)

    2014-01-01

    within the weld. Design/methodology/approach The improved GMAW process model is next applied to the case of butt-welding of MIL A46100 (a...improved GMAW process model pertaining to the spatial distribution of the material microstructure and properties within the MIL A46100 butt-weld are

  7. Effects of heat treatment and welding process on superelastic behaviour and microstructure of micro electron beam welded NiTi

    Directory of Open Access Journals (Sweden)

    Balz Isabel

    2016-09-01

    Full Text Available Medical devices with small dimensions made of superelastic NiTi become more popular, but joining these parts remains challenging. Since laser welding was found to be an option, electron beam welding seems to be an interesting alternative as it provides additional advantages due to the precise beam positioning and the high vacuum. Superelasticity is influenced by microstructure and surface layer composition that are mainly affected by welding process and by heat treatment and therefore will be investigated in the present paper.

  8. Friction Stir.Welding is an advance metal joining process: A Review

    Directory of Open Access Journals (Sweden)

    Umasankar Das,

    2015-09-01

    Full Text Available The friction stir welding is recently developed solid state welding process which overcome the problem associated with fusion welding technology. The properties achieved by friction stir welding is better than that achieve by fusion welding technique It has been invented as a solid-state joining technique and initially applied to aluminum alloys. FSW is used to replace rivets joints in the aeronautical industry. Recently the aircraft and military industries widely have been using aluminum alloys particularly because of their fine strength to weight ratio. However in compare with steels they represent welding difficulties and also lower ductility. In last years it has been observed that Friction Stir Welding (FSW method represents better microstructure and mechanical properties than conventional methods in welding aluminum alloys. It has been widely investigated for mostly low melting materials, such as Al, Mg and Cu alloys. Aluminum is the most usable material in engineering application and a lot of improvement is needed in the area of its welding. The latest works on friction stir welding of aluminum have been directed towards improving the quality of weld, reducing defects and applying the process of FSW to aluminum for specific applications. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a last decade. The FSW of Aluminums and its alloys has been commercialized; and recent interest is focused on joining dissimilar materials. However, in order to commercialize the process, research studies are required to characterize and establish proper process parameters for FSW. This paper summarizes the trends and advances of this welding processes in the field of welding. Future aspects of

  9. IT Systems in Aid of Welding Processes Quality Management in the Automotive Industry

    Directory of Open Access Journals (Sweden)

    Restecka M.

    2016-12-01

    Full Text Available The most important issue for the producers nowadays is to meet the requirements of customers, satisfying their perceived but also the unperceived needs. In order to control the quality of welding processes correctly one must have knowledge of welding drawings, symbols, designs of welded joints, welding procedures, requirements set in codes and standards, also have knowledge of the techniques of inspection and testing connected with the automotive industry. The article shows ways to increase quality in the industry through the use of robotization and computerization. Presented examples and application of IT systems in aid of welding processes quality management in the automotive industry.

  10. Optimization of pulsed TIG welding process parameters on mechanical properties of AA 5456 Aluminum alloy weldments

    Energy Technology Data Exchange (ETDEWEB)

    Kumar, A. [Department of Mechanical Engineering, National Institute of Technology, Warangal 506 004 (India)], E-mail: adepu_kumar7@yahoo.co.in; Sundarrajan, S. [Scientist ' G' , Defence Research and Development Laboratory, Hyderabad 500 028 (India)

    2009-04-15

    The present work pertains to the improvement of mechanical properties of AA 5456 Aluminum alloy welds through pulsed tungsten inert gas (TIG) welding process. Taguchi method was employed to optimize the pulsed TIG welding process parameters of AA 5456 Aluminum alloy welds for increasing the mechanical properties. Regression models were developed. Analysis of variance was employed to check the adequacy of the developed models. The effect of planishing on mechanical properties was also studied and observed that there was improvement in mechanical properties. Microstructures of all the welds were studied and correlated with the mechanical properties.

  11. Numerical Simulation of Projection Welding Processes for Door Hinge of Automobile Based on Coupled Fields Analysis

    Institute of Scientific and Technical Information of China (English)

    QIAN Chang-ming; LUO Ai-hui; CHEN Guan-long

    2007-01-01

    Projection welding is a variation of electric resistance welding with the dynamic changes of the flow paths for heat and electrical properties with changing temperature caused by the large plastic deformation collapse of projection. As the joint type between the auto door hinge and the inner plate, projection welding may bring welding distortions and would affect the assembly quality of auto body. A comprehensive electric-thermal-mechanical numerical simulation was performed to quantitatively simulate the processes of projection welding by using a coupled finite element method. The mechanism of projection collapse and the formation process of nugget were discussed and good conclusions have been achieved comparing with the test results.

  12. STUDY ON THE PRESSURE IN PLASMA ARC

    Institute of Scientific and Technical Information of China (English)

    2003-01-01

    The axial pressure in plasma arc is measured under different conditions. The effects of the parameters, such as welding current, plasma gas flow rate, electrode setback and arc length, on the pressure in plasma arc are investigated and quantitative analyzed to explain the relationship between the quality of weld and the matching of parameters in plasma arc welding process.

  13. THE IMPACT OF SELECTED PROCESSES AND TECHNOLOGICAL PARAMETERS ON THE GEOMETRY OF THE WELD POOL WHEN WELDING IN SHIELS GAS ATMOSPHERE

    Directory of Open Access Journals (Sweden)

    Josef Bradáč

    2017-05-01

    Full Text Available This paper is focused on welding with a consumable electrode in a gas shield atmosphere and its main aim is to show the influence of selected processes and technological parameters on the geometry of the weld pool in terms of theoretical and experimental views. For this purpose, the parametric areas defined by the change of the welding current and welding rate were determined. Apart from the influence of these parametric areas, the influence of other technological input variables, including the wire diameter and preheating temperature, was also studied. The experimentally obtained geometric data of the weld pool can be used for technological welding procedures WPS and especially for simulation calculations to obtain a more accurate numerical model of the heat source. This makes it possible to get accurate simulation results and to better understand the impact of other variables that influence the welding process. This all helps to the optimization of the welding process for several applications.

  14. Primary research on image of plasma in CO II laser welding with high-speed photography

    Science.gov (United States)

    Liu, Jinhe; Ma, Licai; Xie, Yaozheng; Zhang, Yong

    2006-02-01

    In this paper the image by high-speed photography of plasma in CO II laser welding is studied including the area of these images, the change rate of these images, the isogray line of the image and the maximal variation of the image gray. The used laser is RS850 made in German and the high-speed photography is NAC-10 made in Japan. The weld material is low carbon steel. The welding parameters include laser power 4KW, welding speed 1.2m/min, shielding gas Helium, Helium flow rate 11L/min. The parameters for high-speed photography are as exposure time 1/5000 of second, shoot frequency 1000 frame/s. According to the analyses the main conclusion as follows: In the experiment, the values of gray of these images cover from 40 to 255. The area of the plasma is oscillation and the average frequency of the oscillation is about 300Hz. The laser welding plasma can be divided to three parts: periphery, smoothness and core from the external to inner. The isogray line of the periphery is very irregular because of shocking of the shielding gas and the metal spatter. In the core region, the thermal motion of the electrons is violent, so there is lots of little division with complex shape. The gap of isogrey line in the periphery region and core region are larger than it in the smoothing region. The isogrey lines of the image in the melting pool link with the isogray line of the image of the laser welding plasma, so it can be used to checking the temperature field each other. There exits an isothermal kernel in the core region.

  15. Efficiency of the Inertia Friction Welding Process and Its Dependence on Process Parameters

    Science.gov (United States)

    Senkov, O. N.; Mahaffey, D. W.; Tung, D. J.; Zhang, W.; Semiatin, S. L.

    2017-07-01

    It has been widely assumed, but never proven, that the efficiency of the inertia friction welding (IFW) process is independent of process parameters and is relatively high, i.e., 70 to 95 pct. In the present work, the effect of IFW parameters on process efficiency was established. For this purpose, a series of IFW trials was conducted for the solid-state joining of two dissimilar nickel-base superalloys (LSHR and Mar-M247) using various combinations of initial kinetic energy ( i.e., the total weld energy, E o), initial flywheel angular velocity ( ω o), flywheel moment of inertia ( I), and axial compression force ( P). The kinetics of the conversion of the welding energy to heating of the faying sample surfaces ( i.e., the sample energy) vs parasitic losses to the welding machine itself were determined by measuring the friction torque on the sample surfaces ( M S) and in the machine bearings ( M M). It was found that the rotating parts of the welding machine can consume a significant fraction of the total energy. Specifically, the parasitic losses ranged from 28 to 80 pct of the total weld energy. The losses increased (and the corresponding IFW process efficiency decreased) as P increased (at constant I and E o), I decreased (at constant P and E o), and E o (or ω o) increased (at constant P and I). The results of this work thus provide guidelines for selecting process parameters which minimize energy losses and increase process efficiency during IFW.

  16. Finite element synthesized analysis of the forming process of spiral welded pipe

    Institute of Scientific and Technical Information of China (English)

    Yu Jianrong; Wu Bo; Zhao Zenghui; Ling Xingzhong; Xiao Yunfeng; Chen Haiyang

    2006-01-01

    Numerical simulation concerning the forming and welding process of spiral welded pipe was conducted, which included three steps: the first step was the stress analysis when the spiral was formed, and then the stress was regarded as initial condition of melding during the temperature field analysis in the process of welding, the last step was the thermal stress analysis of the weld seam after the welding was over. Moreover, when the steel strip was pushed, the stress was also calculated by non-linearity contact technology using Abaqus Software. By finite element modeling and calculating of the forming and welding process of the spiral welded pipe, the key points of the multi-fields synthetic simulating were studied and discussed.

  17. Thermo-mechanical process for treatment of welds

    Energy Technology Data Exchange (ETDEWEB)

    Malik, R K

    1980-03-01

    Benefits from thermo-mechanical processing (TMP) of austenitic stainless steel weldments, analogous to hot isostatic pressing (HIP) of castings, most likely result from compressive plastic deformation, enhanced diffusion, and/or increased dislocation density. TMP improves ultrasonic inspectability of austenitic stainless steel welds owing to: conversion of cast dendrites into equiaxed austenitic grains, reduction in size and number of stringers and inclusions, and reduction of delta ferrite content. TMP induces structural homogenization and healing of void-type defects and thus contributes to an increase in elongation, impact strength, and fracture toughness as well as a significant reduction in data scatter for these properties. An optimum temperature for TMP or HIP of welds is one which causes negligible grain growth and an acceptable reduction in yield strength, and permits healing of porosity.

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

    Energy Technology Data Exchange (ETDEWEB)

    Coniglio, N.; Mathieu, A., E-mail: alexandre.mathieu@u-bourgogne.fr [Laboratoire Interdisciplinaire Carnot de Bourgogne (ICB), UMR 6303 CNRS/Université de Bourgogne, 12 rue de la Fonderie, 71200 Le Creusot (France); Aubreton, O.; Stolz, C. [Université de Bourgogne Laboratoire Le2i UMR CNRS 6306, allée Alain Savary, 21000 Dijon (France)

    2014-03-31

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

  19. Fatigue cracking of hybrid plasma gas metal arc welded 2205 duplex stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Yurtisik, Koray; Tirkes, Suha [Middle East Technical Univ., Ankara (Turkey). Welding Technology and Nondestructive Testing Research/Application Center

    2014-10-01

    Contrary to other keyhole welding applications on duplex stainless steels, a proper cooling time and a dilution were achieved during hybrid plasma gas metal arc welding that provided sufficient reconstructive transformation of austenite without sacrificing its high efficiency and productivity. Simultaneous utilization of keyhole and metal deposition in the hybrid welding procedure enabled us to get an as-welded 11 mm-thick standard duplex stainless steel plate in a single pass. Metallographic examination on hybrid plasma-gas metal arc weldments revealed only primary austenite in ferrite matrix, whereas in addition to reconstructive transformation of primary austenite during solidification, secondary austenite was also transformed in a displacive manner due to successive thermal cycles during multi-pass gas metal arc welding. On the one hand, secondary austenite provided barriers and retarded the crack propagation during the tests in laboratory air. On the other hand, chromium and molybdenum depletion in the neighborhood of secondary austenite precipitates yielded relatively high crack propagation rates in multi-pass weldments under chloride attack.

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

    Science.gov (United States)

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

    2016-04-01

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

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

    Science.gov (United States)

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

    2017-08-01

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

  2. NUMERICAL MODELING OF HEAT TRANSFER AND FLUID FLOW IN KEYHOLE PLASMA ARC WELDING OF DISSIMILAR STEEL JOINTS

    Directory of Open Access Journals (Sweden)

    M. A. Daha

    2012-02-01

    Full Text Available The evolution of temperature profiles and weld pool geometry during dissimilar welding between 2205 duplex stainless steel and A36 low carbon steel using keyhole plasma arc welding has been simulated using a three dimensional numerical heat transfer and fluid flow model. An adaptive heat source is proposed as a heat source model for performing a non-linear transient thermal analysis, based on the configuration feature of keyhole plasma arc welds. Temperature profiles and solidified weld pool geometry are presented for three different welding heat input. The reversed bugle shape parameters (width of fusion zone at both top and bottom surfaces of the weld pool geometry features for a dissimilar 2205–A36 weld joint are summarized to successfully explain the observations. The model was also applied to keyhole plasma welding of 6.8 mm thick similar 2205 duplex stainless steel joint for validation. The simulation results were compared with independently obtained experimental data and good agreements have been obtained.

  3. Plasma-MIG hybrid arc welding with PID increment constant current or voltage control algorithm%增量型PID恒流恒压控制的Plasma-MIG复合电弧焊接

    Institute of Scientific and Technical Information of China (English)

    杨涛; 张生虎; 高洪明; 吴林; 许可望; 刘永贞

    2013-01-01

    Plasma-MIG复合电弧焊接对电源的外特性输出及焊接过程控制有着很高的要求,以VC++软件开发工具为平台,推导了适合于Plasma-MIG复合电弧焊接的增量型PID控制算法,实现了对复合电弧焊接过程控制及电源外特性的要求.结果表明,增量型PID恒流恒压控制能够满足Plasma-MIG对电源外特性的输出要求.Plasma电弧和MIG电弧并不是相互独立的,两者以共享的电磁空间、导电气氛和焊丝为媒介建立起耦合关系.Plasma-MIG复合电弧焊接过程中,增量型PID控制下的Plasma电弧能够自发的调节自身电参数,来稳定电弧空间的电流密度,使得焊接过程中无飞溅.采用控制后,Plasma-MIG复合电弧焊焊接过程焊缝铺展好,焊接过程稳定,焊缝成形好.%Output characteristics of the power supply and welding process control are important factors for plasma-MIG hybrid arc welding. PID increment control algorithm suitable for Plasma-MIG hybrid arc welding was developed based on VC + + language in this paper, which optimized the output characteristics of the power supply and welding process control. The results show that the plasma arc and MIG arc were coupled with each other by sharing the electro-magnetic space, gas and filler metal. Plasma are controlled by PID increment control algorithm was capable of stabilizing the current density through the arc due to its self-adjusting function, without sputtering in the welding process. High stability, molten metal with excellent liquidity and weld with smooth surface were realized by plasma-MIG hybrid arc welding with PID increment control algorithm.

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

    Science.gov (United States)

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

    2017-01-01

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

  5. Optimizing Friction Stir Welding via Statistical Design of Tool Geometry and Process Parameters

    Science.gov (United States)

    Blignault, C.; Hattingh, D. G.; James, M. N.

    2012-06-01

    This article considers optimization procedures for friction stir welding (FSW) in 5083-H321 aluminum alloy, via control of weld process parameters and tool design modifications. It demonstrates the potential utility of the "force footprint" (FF) diagram in providing a real-time graphical user interface (GUI) for process optimization of FSW. Multiple force, torque, and temperature responses were recorded during FS welding using 24 different tool pin geometries, and these data were statistically analyzed to determine the relative influence of a number of combinations of important process and tool geometry parameters on tensile strength. Desirability profile charts are presented, which show the influence of seven key combinations of weld process variables on tensile strength. The model developed in this study allows the weld tensile strength to be predicted for other combinations of tool geometry and process parameters to fall within an average error of 13%. General guidelines for tool profile selection and the likelihood of influencing weld tensile strength are also provided.

  6. Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

    Science.gov (United States)

    Perez Regalado, Waldo Josue

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

  7. Processing-Microstructure Relationships in Friction Stir Welding of MA956 Oxide Dispersion Strengthened Steel

    Science.gov (United States)

    Baker, Bradford W.; Menon, E. Sarath K.; McNelley, Terry R.; Brewer, Luke N.; El-Dasher, Bassem; Farmer, Joseph C.; Torres, Sharon G.; Mahoney, Murray W.; Sanderson, Samuel

    2014-12-01

    A comprehensive set of processing-microstructure relationships is presented for friction stir welded oxide dispersion strengthened MA956 steel. Eight rotational speed/traverse speed combinations were used to produce friction stir welds on MA956 plates using a polycrystalline cubic boron nitride tool. Weld conditions with high thermal input produced defect-free, full-penetration welds. Electron backscatter diffraction results showed a significant increase in grain size, a persistent body centered cubic torsional texture in the stir zone, and a sharp transition in grain size across the thermo-mechanically affected zone sensitive to weld parameters. Micro-indentation showed an asymmetric reduction in hardness across a transverse section of the weld. This gradient in hardness was greatly increased with higher heat inputs. The decrease in hardness after welding correlates directly with the increase in grain size and may be explained with a Hall-Petch type relationship.

  8. Hastelloy C-276Weld Overlay bySMAW Process

    Directory of Open Access Journals (Sweden)

    Er. Rahul Sharma

    2017-05-01

    Full Text Available In the modern world of industrialization the wear is eating metal assets worth millions of dollars per year. The wear is in the form of corrosion, erosion, abrasion etc. which occur in the process industries like oil & gas, refineries, cement plants, steel plants, shipping and offshore working structures. The equipments like pressure vessels, heat exchangers, hydro processing reactors which very often work at elevated temperatures face corrosion in the internal diameter.Hastelloy C-276weld overlay on ferrous material is developed for outstanding resistance to wide variety of chemical process environments such as ferric and cupric chlorides, hot contaminated mineral acids, solvents, chlorine and chlorine contained media, both inorganic and organic, dry chlorine, formic and acetic acids, acetic anhydride, sea water and brine solutions.Selection of SMAW is for development of hastalloy C-276 material with SMAW process to use as a weld overlay process at non accessible area & where position is constraint which is not feasible by other processes like ESSC, FCAW, and SAW etc.

  9. Wear resistance of laser cladding and plasma spray welding layer on stainless steel surface

    Institute of Scientific and Technical Information of China (English)

    Xinlin Wang(王新林); Shihong Shi(石世宏); Qiguang Zheng(郑启光)

    2004-01-01

    The effect of coatings, which are formed with laser cladding and plasma spray welding on 1Cr18Ni9Ti base metal, on wear resistance is studied, A 5-kW transverse flowing CO2 laser is used for cladding Co base alloy powder pre-placed on the substrate. Comparing with the plasma spray coatings, the spoiled rate of products with laser clad layers was lower and the rate of finished products was higher. Their microstructure is extremely fine. They have close texture and small size grain. Their dilution resulting from the compositions of the base metal and thermal effect on base metal are less. The hardness, toughness,and strength of the laser cladding layers are higher. Wear tests show that the laser layers have higher properties of anti-friction, anti-scour and high-temperature sliding strike. The wear resistance of laser clad layers are about one time higher than that of plasma spray welding layer.

  10. Dissimilar friction stir welds in AA5083-AA6082. Part I: Process parameter effects on thermal history and weld properties

    Science.gov (United States)

    Peel, M. J.; Steuwer, A.; Withers, P. J.; Dickerson, T.; Shi, Q.; Shercliff, H.

    2006-07-01

    The aim of this study was to explore the so-called processing window, within which good-quality welds can be produced, for the friction stir welding of AA5083 to AA6082. To that end a systematic set of nine instrumented welds were made using rotation speeds of 280, 560, and 840 rpm and traverse speeds of 100, 200, and 300 mm/min with AA5083 on the advancing side and another nine with the materials reversed. For comparison a smaller series of AA5083-AA5083 and AA6082-AA6082 welds were also made. Thermocouple measurements, tool torque, extent of material mixing, and macrostructural observations all indicate that the temperature under the tool is more strongly dependent on the rotation than the traverse speed. It was found that in the current case, the power (energy/s) and heat input (energy/mm) do not correlate simply with the weld temperature. As a result, such metrics may not be suitable for characterizing the conditions under which welds are produced.

  11. Closed Loop Control of Penetration Depth during CO2 Laser Lap Welding Processes

    Directory of Open Access Journals (Sweden)

    Antonio Ancona

    2012-08-01

    Full Text Available In this paper we describe a novel spectroscopic closed loop control system capable of stabilizing the penetration depth during laser welding processes by controlling the laser power. Our novel approach is to analyze the optical emission from the laser generated plasma plume above the keyhole, to calculate its electron temperature as a process-monitoring signal. Laser power has been controlled by using a quantitative relationship between the penetration depth and the plasma electron temperature. The sensor is able to correlate in real time the difference between the measured electron temperature and its reference value for the requested penetration depth. Accordingly the closed loop system adjusts the power, thus maintaining the penetration depth.

  12. Closed Loop Control of Penetration Depth during CO2 Laser Lap Welding Processes

    Science.gov (United States)

    Sibillano, Teresa; Rizzi, Domenico; Mezzapesa, Francesco P.; Lugarà, Pietro Mario; Konuk, Ali Riza; Aarts, Ronald; Veld, Bert Huis in 't; Ancona, Antonio

    2012-01-01

    In this paper we describe a novel spectroscopic closed loop control system capable of stabilizing the penetration depth during laser welding processes by controlling the laser power. Our novel approach is to analyze the optical emission from the laser generated plasma plume above the keyhole, to calculate its electron temperature as a process-monitoring signal. Laser power has been controlled by using a quantitative relationship between the penetration depth and the plasma electron temperature. The sensor is able to correlate in real time the difference between the measured electron temperature and its reference value for the requested penetration depth. Accordingly the closed loop system adjusts the power, thus maintaining the penetration depth. PMID:23112646

  13. Weld pool temperatures of steel S235 while applying a controlled short-circuit gas metal arc welding process and various shielding gases

    Science.gov (United States)

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

    2013-11-01

    The temperature determination of liquid metals is difficult and depends strongly on the emissivity. However, the surface temperature distribution of the weld pool is an important characteristic of an arc weld process. As an example, short-arc welding of steel with a cold metal transfer (CMT) process is considered. With optical emission spectroscopy in the spectral region between 660 and 840 nm and absolute calibrated high-speed camera images the relation between temperature and emissivity of the weld pool is determined. This method is used to obtain two-dimensional temperature profiles in the pictures. Results are presented for welding materials (wire G3Si1 on base material S235) using different welding CMT processes with CO2 (100%), Corgon 18 (18% CO2 + 82% Ar), VarigonH6 (93.5% Ar + 6.5% H2) and He (100%) as shielding gases. The different gases are used to study their influence on the weld pool temperature.

  14. Knowledge expression and reasoning process in an expert system for welding procedure qualification

    Institute of Scientific and Technical Information of China (English)

    Zhang Jianxun; Wang Hongyu; Song Xu

    2007-01-01

    After analyzing the welding procedure knowledge in Chinese national standards for welding procedure qualification of steel pressure vessel from the point of establishing expert system, it can be divided into five types of knowledge, i.e. practice, definition, regularity, process and description knowledge. The knowledge expression methods are established according to the different type of welding procedure knowledge. The reasoning process based on rule is adopted. And the reasoning engine is embedded among objects integrated with the knowledge base.

  15. Metal cutting analogy for establishing Friction Stir Welding process parameters

    Science.gov (United States)

    Stafford, Sylvester Allen

    A friction stir weld (FSW) is a solid state joining operation whose processing parameters are currently determined by lengthy trial and error methods. To implement FSWing rapidly in various applications will require an approach for predicting process parameters based on the physics of the process. Based on hot working conditions for metals, a kinematic model has been proposed for calculating the shear strain and shear strain rates during the FSW process, validation of the proposed model with direct measuring is difficult however. Since the shear strain and shear strain rates predicted for the FSW process, are similar to those predicted in metal cutting, validation of the FSW algorithms with microstructural studies of metal chips may be possible leading to the ability to predict FSW processing parameters.

  16. Research on the controller of an arc welding process based on a PID neural network

    Institute of Scientific and Technical Information of China (English)

    Kuanfang HE; Shisheng HUANG

    2008-01-01

    A controller based on a PID neural network(PIDNN)is proposed for an arc welding power source whose output characteristic in responding to a given value is quickly and intelligently controlled in the welding process.The new method syncretizes the PID control strategy and neural network to control the welding process intelligently,so it has the merit of PID control rules and the trait of better information disposal ability of the neural network.The results of simulation show that the controller has the properties of quick response,low overshoot quick convergence and good stable accuracy,which meet the requirements for control of the welding process.

  17. Evaluation model for process stability of short-circuiting arc welding

    Institute of Scientific and Technical Information of China (English)

    Cai Yan; Yang Hailan; Hua Xueming; Wu Yixiong

    2008-01-01

    stability of welding process is the prerequisite and assurance for ideal joint. The structure of stability model and its optimization are the key to on-line evaluation technology of arc welding. Characteristic parameters are extracted from the single transfer period while variation coefficients of the characteristic parameters are concerned for whole welding process of continuous drop transfer. Based on the characteristic parameters and their variation coefficients, stability model of short-circuit arc welding process is established by partial-least-square regression (PLSR) that can overcome multicollinearity of input parameters. The experiment results show that this model can meet the requirement of accuracy.

  18. Simulation of droplet transfer process and current waveform control of CO2 arc welding

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    A simulation system used in the arc welding short-circuit transfer process and current waveform control process was developed in this paper. The simulation results are basically consistent with welding technical experiments. The simulation system can be used to simulate and test the current waveform control parameters with welding variables. By this simulation system, the influence regularities of the current waveform control parameters in the CO2 arc welding droplet short-circuit transfer process can be got. Moreover, the basic mode of real-time current waveform control can be also established by the simulation testing.

  19. Evaluation of sheet mechanical response to laser welding processes

    Energy Technology Data Exchange (ETDEWEB)

    Carmignani, B.; Daneri, A.; Toselli, G. [ENEA, Bologna (Italy). Centro Ricerche Energia `E. Clementel` - Area Energia e Innovazione; Vitali, R.; Zanotelli, G.L. [Hibbit, Karlsson and Sorensen, Milan (Italy); Bellei, M. [Industrialconsult, Milan (Italy)

    1995-11-01

    The simulation of the mechanical response of steel sheets, due to the heating during welding processes by a laser source beam, obtained by Abaqus standard code, is discussed. Different hypotheses for the material behaviour at temperatures greater than the fusion one have been tested and compared; in particular, some tests have been made taking the annealing effect into account by means of an user routine UMAT developed ad hoc. This work was presented at the 8th international Abaqus Users` conference at Paris, 31 May - 2 June 1995.

  20. Resistance Welding of Thermoplastic Composites: Process and Performance

    OpenAIRE

    Shi, H.

    2014-01-01

    Compared to thermoset composites, thermoplastic composites are drawing more and more attention by aircraft industries not only due to their excellent material properties but also due to their potentials to reduce cycle time and structure cost by using low-cost manufacturing technologies such as welding. Resistance welding has been regarded as one of the most promising welding techniques owing to the low energy consumption, simplicity of welding operation and capability for scaling up. Previou...

  1. In-process monitoring and feedback control for stable production of full-penetration weld in continuous wave fibre laser welding

    Science.gov (United States)

    Kawahito, Yousuke; Ohnishi, Terumasa; Katayama, Seiji

    2009-04-01

    Laser micro-welding has been applied for device sealing in electronics and automobile industries. Welding of corners in goods and products is a problem owing to easier formation of a weld with burn-through, shallow penetration or a non-bonded part when a drastic change in the welding speed or laser power occurs. This research was therefore undertaken with the objective of obtaining a fundamental knowledge of in-process monitoring and feedback control for the stable production of a full-penetration weld with a constant bead width on the bottom surface irrespective of the changes in the laser power and the welding speed. Variation in weld penetration geometry was investigated by rapid deceleration and acceleration in the welding speed during lap welding of pure titanium thin sheets with a continuous wave (CW) single-mode fibre laser beam. The rapid deceleration in the welding speed led to a considerable change in the full-penetration weld geometry or a partially penetrated weld (if the power was accordingly reduced), resulting in the difficulty in the stable production of a full-penetration weld bead. The heat radiation intensity measured from the laser-irradiated area was useful as an in-process monitoring signal for detecting the molten pool size on the laser-irradiated surface. However, the utilization of monitoring of heat radiation was difficult for predicting the weld bead width on the bottom surface due to the formation of partial penetration or the change in the penetration shape. The laser power was controlled at a 4 ms interval according to the heat radiation signal in order to adjust the weld bead width on the laser-irradiated surface to the target weld penetration geometry affected by thermal storage. Consequently, the feedback-controlled laser power produced a stable full-penetration weld with the designed bead width on the bottom surface irrespective of the rapid deceleration of the welding speed and the corresponding decrease in laser power

  2. In-process monitoring and feedback control for stable production of full-penetration weld in continuous wave fibre laser welding

    Energy Technology Data Exchange (ETDEWEB)

    Kawahito, Yousuke; Ohnishi, Terumasa; Katayama, Seiji, E-mail: kawahito@jwri.osaka-u.ac.j [Joining and Welding Research Institute (JWRI), Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047 (Japan)

    2009-04-21

    Laser micro-welding has been applied for device sealing in electronics and automobile industries. Welding of corners in goods and products is a problem owing to easier formation of a weld with burn-through, shallow penetration or a non-bonded part when a drastic change in the welding speed or laser power occurs. This research was therefore undertaken with the objective of obtaining a fundamental knowledge of in-process monitoring and feedback control for the stable production of a full-penetration weld with a constant bead width on the bottom surface irrespective of the changes in the laser power and the welding speed. Variation in weld penetration geometry was investigated by rapid deceleration and acceleration in the welding speed during lap welding of pure titanium thin sheets with a continuous wave (CW) single-mode fibre laser beam. The rapid deceleration in the welding speed led to a considerable change in the full-penetration weld geometry or a partially penetrated weld (if the power was accordingly reduced), resulting in the difficulty in the stable production of a full-penetration weld bead. The heat radiation intensity measured from the laser-irradiated area was useful as an in-process monitoring signal for detecting the molten pool size on the laser-irradiated surface. However, the utilization of monitoring of heat radiation was difficult for predicting the weld bead width on the bottom surface due to the formation of partial penetration or the change in the penetration shape. The laser power was controlled at a 4 ms interval according to the heat radiation signal in order to adjust the weld bead width on the laser-irradiated surface to the target weld penetration geometry affected by thermal storage. Consequently, the feedback-controlled laser power produced a stable full-penetration weld with the designed bead width on the bottom surface irrespective of the rapid deceleration of the welding speed and the corresponding decrease in laser power

  3. Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes.

    Science.gov (United States)

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

    2016-09-15

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

  4. Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes

    Directory of Open Access Journals (Sweden)

    Jesús Emilio Pinto-Lopera

    2016-09-01

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

  5. Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes

    Science.gov (United States)

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

    2016-01-01

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

  6. TIG打底焊工艺研究%Research on TIG Bottoming Welding Process

    Institute of Scientific and Technical Information of China (English)

    邱葭菲; 邹金桥; 王瑞权

    2012-01-01

    分析了TIG打底焊工艺特点,介绍了TIG与焊条电弧焊打底焊工艺试验,提出了TIG打底焊工艺与操作技巧,这些工艺与措施对锅炉制造与安装中TIG打底焊工艺的实施具有一定的借鉴和指导作用.%The characteristic of TIG bottoming welding process was analyzed. The bottoming welding process test about TIG welding and shielded metal arc welding was introduced. The TIG bottoming welding technology and operation skill were pointed out. The technology and measures of TIG bottoming welding for boiler manufacture and installation will play a certain reference and guidance role.

  7. Solid state welding processes for an oxide dispersion strengthened nickel-chromium-aluminum alloy

    Science.gov (United States)

    Moore, T. J.

    1975-01-01

    Solid-state welding processes were evaluated for joining TD-NiCrAl (Ni-16Cr-4Al-2ThO2) alloy sheet. Both hot-press and resistance spot welding techniques were successfully applied in terms of achieving grain growth across the bond line. Less success was achieved with a resistance seam welding process. In stress-rupture shear and tensile shear tests of lap joints at 1100 C, most failures occurred in the parent material, which indicates that the weld quality was good and that the welds were not a plane of weakness. The overall weld quality was not as good as previously attained with TD-NiCr, probably because the presence of alumina at the faying surfaces and the developmental TD-NiCrAl sheet, which was not of the quality of the TD-NiCr sheet in terms of surface flatness and dimensional control.

  8. Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process

    Directory of Open Access Journals (Sweden)

    Kirk A. Fraser

    2014-04-01

    Full Text Available Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges, being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS. A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.

  9. Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process.

    Science.gov (United States)

    Fraser, Kirk A; St-Georges, Lyne; Kiss, Laszlo I

    2014-04-30

    Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.

  10. Assisting Gas Optimization in CO2 Laser Welding

    DEFF Research Database (Denmark)

    Gong, Hui; Olsen, Flemming Ove

    1996-01-01

    High quality laser welding is achieved under the condition of optimizing all process parameters. Assisting gas plays an important role for sound welds. In the conventional welding process assisting gas is used as a shielding gas to prevent that the weld seam oxidates. In the laser welding process...... assisting gas is also needed to control the laser induced plasma.Assisting gas is one of the most important parameters in the laser welding process. It is responsible for obtaining a quality weld which is characterized by deep penetration, no interior imperfections, i.e. porosity, no crack, homogeneous seam...... are applied with three different flow rates for each of the gases. A number of systematic laboratory experiments is carried out by employing various experimental designs, 33 and 32 Factorial Design. In the experiments a CO2 laser is used to weld thin sheets of mild steel. The welding specimens are evaluated...

  11. Cold plasma welding of polyaniline nanofibers with enhanced electrical and mechanical properties

    Science.gov (United States)

    Ye, Dong; Yu, Yao; Liu, Lin; Lu, Xinpei; Wu, Yue

    2015-12-01

    Joining conducting polymer (CP) nanofibers into an interconnected porous network can result in good mechanical and electrical contacts between nanofibers that can be beneficial for the high performance of CP-based devices. Here, we demonstrate the cold welding of polyaniline (PAni) nanofiber loose ends with cold plasma. The room-temperature and atmospheric-pressure helium micro-plasma jet launches highly charged ion bullets at a PAni nanofiber target with high precision and the highly charged ion bullet selectively induces field emission at the sharp nanofiber loose ends. This technique joins nanofiber tips without altering the morphology of the film and protonation thus leading to significantly enhanced electrical and mechanical properties. In addition, this technique has high spatial resolution and is able to selectively weld and dope regions of nanofiber film with promising novel device applications.

  12. Role of heat equation in lap joint for welding process

    Science.gov (United States)

    Kumar, P.; Rohit, Sooraj

    2017-07-01

    Welding is predominantly used in industrial purposes and growth in their industry, which gives exact welding and more efficient. The major advantage of using this welding technique at initial stage it takes very low heat to weld the portion and gives a good result of low distortion in modules. In this context, two dissimilar metals copper and nickel are chosen for analysis in tungsten inert gas welding (TIG) in which length is 300 mm and breadth is 100 mm thickness 15 mm welded at room temperature a welded portion zone is formed simulation analysis has done on CATIA® and ANSYS®and MATLAB® code is generated for calculating temperatures at each node to calculate temperature at each node a new technique is used tri-diagonal matrix algorithm is used (TDMA) Steady state one dimension heat is calculated results compared between simulation analysis and analytical analysis temperature at each node is calculated both the temperatures are equal with error.

  13. Process Parameter Optimization for Wobbling Laser Spot Welding of Ti6Al4V Alloy

    Science.gov (United States)

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

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

  14. Spectroscopic closed loop control of penetration depth in laser beam welding process

    NARCIS (Netherlands)

    Sibillano, T.; Ancona, A.; Rizzi, D.; Mezzapesa, F.; Konuk, A.R.; Aarts, R.G.K.M.; Huis in 't Veld, A.J.; Lugara, P.M.

    2012-01-01

    In-process monitoring and feedback control are fundamental actions for stable and good quality laser welding process. In particular, penetration depth is one of the most critical features to be monitored. In this research, overlap welding of stainless steel is investigated to stably reproduce a fixe

  15. Comparison of the pulsed MIG welding process for different median current

    Institute of Scientific and Technical Information of China (English)

    Wen Yuanmei; Xue Jiaxiang; Yao Ping; Huang Shisheng

    2009-01-01

    Based on the high speed video system with electrical signals collecting and wavelet analyzing, the welding processes under three different median currents with the same median time were detected. The experimental results show that, when the median current is higher, the input peak energy is lower. And the droplet transfer is almost in spray mode. The welding process is the stablest.

  16. Optimization of process parameters for friction stir lap welding of carbon fibre reinforced thermoplastic composites by Taguchi method

    Energy Technology Data Exchange (ETDEWEB)

    Ahmadi, H.; Arab, N. B. Mostafa; Ghasemi, F. Ashenai [Shahid Rajaee Teacher Training University, Tehran (Iran, Islamic Republic of)

    2014-01-15

    Friction stir welding process parameters such as welding speed, rotational speed and tilt angle affect the strength of the weld joint. For maximizing the weld strength, these process parameters must therefore be properly selected and optimized. This study presents an application of Taguchi method to optimize process parameters like welding speed, rotational speed and tilt angle to maximize lap weld tensile-shear strength in 4 mm thick polypropylene composite sheets with 20 wt% carbon fiber. To this end, a L9 orthogonal array of Taguchi method using three factors at three levels was used. Analysis of variance and confirmation tests were conducted. The results indicated that welding speed, rotational speed and tilt angle are respectively the significant parameters affecting the lap weld strength. Optimization results also showed that tensile-shear strength of 6.06 MPa was obtained when welding speed, rotational speed and tilt angle were 25 mm/min, 1250 rpm and 1 degree, respectively.

  17. Numerical simulation of friction stir spot welding process for aluminum alloys

    Science.gov (United States)

    Kim, Dongun; Badarinarayan, Harsha; Ryu, Ill; Kim, Ji Hoon; Kim, Chongmin; Okamoto, Kazutaka; Wagoner, R. H.; Chung, Kwansoo

    2010-04-01

    Thermo-mechanical simulations of the Friction Stir Spot Welding (FSSW) processes were performed for AA5083-H18 and AA6022-T4, utilizing commercial Finite Element Method (FEM) and Finite Volume Method (FVM) codes, which are based on Lagrangian and Eulerian formulations, respectively. The Lagrangian explicit dynamic FEM code, PAM-CRASH, and the Eulerian Computational Fluid Dynamics (CFD) FVM code, STAR-CD, were utilized to understand the effect of pin geometry on weld strength and material flow under the unsteady state condition. Using FVM code, material flow patterns near the tool boundary were analyzed to explain weld strength difference between welds by a cylindrical pin and welds by a triangular pin, whereas the frictional energy concept using the FEM code had a limited capacity to explain the weld strength difference.

  18. Prediction of welding distortion during assembly process of thin plate structures

    Institute of Scientific and Technical Information of China (English)

    Luo Yu; Deng De'an; Jiang Xiaoling

    2005-01-01

    Ships and automobiles are fabricated from thin plates. To assemble parts, welding is commonly employed.However, welding distortion in large thin-plate panel structure is usually cased by buckling due to the residual stress. In this study, an elastic finite element method for predicting the welding distortion of three-dimensional thin-plate structures with considering welding sequence was proposed. In this method, the inherent strain was employed to model the local shrinkage due to welding itself, and the interface element was introduced to simulate the assembly process. The proposed method was applied to study the influence of welding sequence on the buckling distortion of the large thin-plate panel structure during assembly.

  19. Prediction of Welded Joint Strength in Plasma Arc Welding: A Comparative Study Using Back-Propagation and Radial Basis Neural Networks

    Science.gov (United States)

    Srinivas, Kadivendi; Vundavilli, Pandu R.; Manzoor Hussain, M.; Saiteja, M.

    2016-09-01

    Welding input parameters such as current, gas flow rate and torch angle play a significant role in determination of qualitative mechanical properties of weld joint. Traditionally, it is necessary to determine the weld input parameters for every new welded product to obtain a quality weld joint which is time consuming. In the present work, the effect of plasma arc welding parameters on mild steel was studied using a neural network approach. To obtain a response equation that governs the input-output relationships, conventional regression analysis was also performed. The experimental data was constructed based on Taguchi design and the training data required for neural networks were randomly generated, by varying the input variables within their respective ranges. The responses were calculated for each combination of input variables by using the response equations obtained through the conventional regression analysis. The performances in Levenberg-Marquardt back propagation neural network and radial basis neural network (RBNN) were compared on various randomly generated test cases, which are different from the training cases. From the results, it is interesting to note that for the above said test cases RBNN analysis gave improved training results compared to that of feed forward back propagation neural network analysis. Also, RBNN analysis proved a pattern of increasing performance as the data points moved away from the initial input values.

  20. Syllabus in Trade Welding.

    Science.gov (United States)

    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…

  1. Corrosion behavior of Al6061 alloy weldment produced by friction stir welding process

    OpenAIRE

    Farhad Gharavi; Khamirul Amin Matori; Robiah Yunus; Norinsan Kamil Othman; Firouz Fadaeifard

    2015-01-01

    In this work, the corrosion behavior of welded lap joints of AA6061-T6 aluminum alloy produced by friction stir welding process has been investigated. Corrosion properties of welded lap joints were studied by cyclic polarization and electrochemical impedance spectroscopy tests. All tests were performed in an aerated 0.6 mol L−1 NaCl aqueous solution with pH = 6.5 at a temperature of 30 °C to characterize corrosion morphology and realize corrosion features of weld regions as opposed to the par...

  2. Effect of Welding Parameters and Aging Process on the Mechanical Properties of Friction Stir-Welded 6063-T4 Al Alloy

    Science.gov (United States)

    Toktaş, Alaaddin; Toktaş, Gülcan

    2012-06-01

    6063-T4 Al alloy was friction stir welded at various tool rotations (800, 1120, and 1600 rpm) and welding speeds (200 and 315 mm/min) using a specially manufactured tool with a height-adjustable and right-hand-threaded pin. The postweld aging process (at 185 °C for 7 h) was applied to a group of the welded plates. In this study, the effects of the welding parameters and the postweld aging treatment on the microstructural and mechanical properties of 6063-T4 Al alloy were studied. The maximum weld temperatures during the welding process were recorded, and the fracture surfaces of tensile specimens were examined using a scanning electron microscope. The homogeneous hardness profiles were obtained for all the weldings with no trace of softening regions. It was observed that the ultimate tensile strengths (UTS) increased slightly (on average by approx. 8%) and the percent elongations decreased (on average by approx. 33%) by the postweld aging treatment. The maximum bending forces ( F max) of all the welds were less than that of the base metal. It was observed that the F max values increased after the postweld aging process at the welding speed of 315 mm/min and decreased at the welding speed of 200 mm/min.

  3. Retractable Pin Tools for the Friction Stir Welding Process

    Science.gov (United States)

    1998-01-01

    Two companies have successfully commercialized a specialized welding tool developed at the Marshall Space Flight Center (MSFC). Friction stir welding uses the high rotational speed of a tool and the resulting frictional heat created from contact to crush, 'stir' together, and forge a bond between two metal alloys. It has had a major drawback, reliance on a single-piece pin tool. The pin is slowly plunged into the joint between two materials to be welded and rotated as high speed. At the end of the weld, the single-piece pin tool is retracted and leaves a 'keyhole,' something which is unacceptable when welding cylindrical objects such as drums, pipes and storage tanks. Another drawback is the requirement for different-length pin tools when welding materials of varying thickness. An engineer at the MSFC helped design an automatic retractable pin tool that uses a computer-controlled motor to automatically retract the pin into the shoulder of the tool at the end of the weld, preventing keyholes. This design allows the pin angle and length to be adjusted for changes in material thickness and results in a smooth hole closure at the end of the weld. Benefits of friction stir welding, using the MSFC retractable pin tool technology, include the following: The ability to weld a wide range of alloys, including previously unweldable and composite materials; provision of twice the fatigue resistance of fusion welds and no keyholes; minimization of material distortion; no creation of hazards such as welding fumes, radiation, high voltage, liquid metals, or arcing; automatic retraction of the pin at the end of the weld; and maintaining full penetration of the pin.

  4. Influential Parameters and Numerical Simulation of Heat Generated in the Process of Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Ilija KOVACEVIC

    2016-09-01

    Full Text Available The paper analyzes the problem of friction stir welding (FSW technology. The mechanism of thermo-mechanical process of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Presented are the basic analytical formulations for the definition of temperature fields. Analysis of influential parameters of welding FSW technology at the zone of the weld material and mechanical properties of the realized joint was performed. Influential welding parameters were defined based on tool geometry, technological parameters of processing and the axial load of tool. Specific problems with the FSW process are related to gaps (holes left behind by a tool at the end of the process and inflexibility of welding regarding the degree of variation of material thickness. Numerical simulation of process welding FSW proceeding was carried out on the example of Aluminum Alloy (AA 2219 using the ANSYS Mechanical ADPL (Transient Thermal software package. The defined was the temperature field in the welding process at specified time intervals.DOI: http://dx.doi.org/10.5755/j01.ms.22.3.10022

  5. Corrosion behavior of Al6061 alloy weldment produced by friction stir welding process

    Directory of Open Access Journals (Sweden)

    Farhad Gharavi

    2015-07-01

    Full Text Available In this work, the corrosion behavior of welded lap joints of AA6061-T6 aluminum alloy produced by friction stir welding process has been investigated. Corrosion properties of welded lap joints were studied by cyclic polarization and electrochemical impedance spectroscopy tests. All tests were performed in an aerated 0.6 mol L−1 NaCl aqueous solution with pH = 6.5 at a temperature of 30 °C to characterize corrosion morphology and realize corrosion features of weld regions as opposed to the parent alloy. The microstructure of weld nugget (WN, heated affected zone (HAZ, and parent alloy were analyzed using scanning electron microscopy and energy dispersive spectroscopy. The experimental results indicated that the welding process has a major effect on the corrosion resistance, which possibly associated to the break-down and dissolution of intermetallic particles. It is supposed that an increasing in intermetallic distributed throughout the matrix of weld regions increases the galvanic corrosion couples. Furthermore, by decreasing the grain size in the weld regions, the susceptibility to corrosion is enhanced. The pitting corrosion and intergranular attack are the dominant corrosion types in the weld regions and the parent alloy.

  6. Friction stir welding of AZ31 magnesium alloys processed by equal channel angular pressing

    Institute of Scientific and Technical Information of China (English)

    ZHANG Bing; YUAN Shouqian; WANG Xunhong

    2008-01-01

    Equal channel angular pressing (ECAP) is an effective thermo-mechanical process to make ultrafine grains.An investigation was carried out on the friction stir welding (FSW) of ECAPed AZ31 magnesium alloys with a thickness of 15 mm.For different process parameters,the optimum FSW conditions of ECAPed AZ31 magnesium alloys were examined.The basic characterization of weld formation and the mechanical properties of the joints were discussed.The results show that the effect of welding parameters on welding quality was evident and welding quality was sensitive to welding speed.Sound joints could be obtained when the welding speed was 37.5 mm/min and the rotation speed of the stir tool was 750 r/min.The maximum tensile strength (270 MPa) of FSW was 91% that of the base materials.The value of microhardness varied between advancing side and retreating side because of the speed field near the pin of the stir tool,which weakened the deformed stress field.The value of microhardness of the welding zone was lower than that of the base materials.The maximum value was located near the heat-affected zone (HAZ).Remarkable ductile character was observed from the fracture morphologies of welded joints.

  7. Structural Changes of Surface Layers of Steel Plates in the Process of Explosive Welding

    Science.gov (United States)

    Bataev, I. A.; Bataev, A. A.; Mali, V. I.; Bataev, V. A.; Balaganskii, I. A.

    2014-01-01

    Structural changes developing in surface layers of plates from steel 20 in the process of explosive welding are studied with the help of light metallography and scanning and transmission electron microscopy. Mathematical simulation is used to compute the depth of the action of severe plastic deformation due to explosive welding of steel plates on the structure of their surface layers.

  8. Plasma Processing of Materials

    Science.gov (United States)

    1985-02-22

    used in France. In this case, three ’ movable electrodes arranged about the central axis with a coaxial sheath gas are employed. Initially the...Demiocratic Republic plasma furnace. chrome -magnesite; the bottom section is lined with rammed chrome -magnesite refractory. Due to the high heat loads... sheath injector design, cathode tip shape, and degree of water cooling are important parameters in providing a stable, uncontaminating, long-lifetime

  9. Modeling of Fume Formation from Shielded Metal Arc Welding Process

    Science.gov (United States)

    Sivapirakasam, S. P.; Mohan, Sreejith; Santhosh Kumar, M. C.; Surianarayanan, M.

    2017-04-01

    In this study, a semi-empirical model of fume formation rate (FFR) from a shielded metal arc welding (SMAW) process has been developed. The model was developed for a DC electrode positive (DCEP) operation and involves the calculations of droplet temperature, surface area of the droplet, and partial vapor pressures of the constituents of the droplet to predict the FFR. The model was further extended for predicting FFR from nano-coated electrodes. The model estimates the FFR for Fe and Mn assuming constant proportion of other elements in the electrode. Fe FFR was overestimated, while Mn FFR was underestimated. The contribution of spatters and other mechanism in the arc responsible for fume formation were neglected. A good positive correlation was obtained between the predicted and experimental FFR values which highlighted the usefulness of the model.

  10. Modeling of Fume Formation from Shielded Metal Arc Welding Process

    Science.gov (United States)

    Sivapirakasam, S. P.; Mohan, Sreejith; Santhosh Kumar, M. C.; Surianarayanan, M.

    2017-01-01

    In this study, a semi-empirical model of fume formation rate (FFR) from a shielded metal arc welding (SMAW) process has been developed. The model was developed for a DC electrode positive (DCEP) operation and involves the calculations of droplet temperature, surface area of the droplet, and partial vapor pressures of the constituents of the droplet to predict the FFR. The model was further extended for predicting FFR from nano-coated electrodes. The model estimates the FFR for Fe and Mn assuming constant proportion of other elements in the electrode. Fe FFR was overestimated, while Mn FFR was underestimated. The contribution of spatters and other mechanism in the arc responsible for fume formation were neglected. A good positive correlation was obtained between the predicted and experimental FFR values which highlighted the usefulness of the model.

  11. A Study on Process Characteristics and Performance of Hot Wire Gas Tungsten Arc Welding Process for High Temperature Materials

    OpenAIRE

    Padmanaban MR,Anantha; Neelakandan, Baskar; Kandasamy,Devakumaran

    2016-01-01

    Hot wire gas tungsten arc welding (HW-GTAW) process is the one where the filler wire is pre-heated close to its melting point before it is fed in to the arc. The effect of HW-GTAW parameters such as welding current, hot wire current and the wire feed rate during welding of super ASS 304H stainless steel tubes were evaluated in terms of heat input, voltage-current (V-I) characteristics and weld bead characteristics such as bead weight and geometry. The results obtained indicate that for a cons...

  12. Thermocapillary and arc phenomena in stainless steel welds

    Energy Technology Data Exchange (ETDEWEB)

    Pierce, S.W.

    1993-10-01

    Goal was to study effect of power level and distribution on thermocapiilary-induced weld shape and of arc factors on weld shape. Thermocapillarity was apparent in both conduction mode EB welds and GTA welds, particularly in the former. A non-Gaussian arc distribution is suggested for accounting for the differences between the twoss processes. At higher current levels (200--300 A), plasma shear force also contributes to weld shape development. Evidence suggests that thermocapillary flow reversal is not a factor in normal GTA welds; EDB flow reversal occurs only at high power density levels where the keyhole mode is present.

  13. Effect of welding processes on mechanical and microstructural characteristics of high strength low alloy naval grade steel joints

    Directory of Open Access Journals (Sweden)

    S. Ragu Nathan

    2015-09-01

    Full Text Available Naval grade high strength low alloy (HSLA steels can be easily welded by all types of fusion welding processes. However, fusion welding of these steels leads to the problems such as cold cracking, residual stress, distortion and fatigue damage. These problems can be eliminated by solid state welding process such as friction stir welding (FSW. In this investigation, a comparative evaluation of mechanical (tensile, impact, hardness properties and microstructural features of shielded metal arc (SMA, gas metal arc (GMA and friction stir welded (FSW naval grade HSLA steel joints was carried out. It was found that the use of FSW process eliminated the problems related to fusion welding processes and also resulted in the superior mechanical properties compared to GMA and SMA welded joints.

  14. An experimental study of high-hydrogen welding processes

    Directory of Open Access Journals (Sweden)

    Fydrych, Dariusz

    2015-12-01

    Full Text Available This paper presents investigation results of determination of the diffusible hydrogen content in deposited metal obtained by means of two most often used methods-the glycerin method and the mercury method. Relation has been defined between results of those methods in the area characteristic of low-hydrogen as well as high-hydrogen welding processes. Relations available in the literature do not include the diffusible hydrogen content in deposited metal greater than 35 ml/100 g. Extending the scope of analysis of the diffusible hydrogen quantity to an 80 ml/100 g level considerably simplifies carrying out the steel weldability assessment with the use of high-hydrogen processes and with welding in water environment.Este trabajo presenta los resultados de una investigación sobre la determinación del contenido de hidrógeno difusible en el material aportado mediante dos métodos: el de la glicerina (el más utilizado y el del mercurio. El contenido de dicho hidrógeno se ha definido a partir de los resultados de esos métodos en una zona con bajo contenido en hidrógeno, así como procesos de soldadura con alto contenido en hidrógeno. No hay datos disponibles en la literatura para contenidos de hidrógeno difusible en metal depositado mayores de 35 ml/100 g. Ampliando el análisis de la cantidad de dicho hidrógeno hasta los 80 ml/100 g, se simplifica considerablemente la realización de ensayos de soldabilidad del acero en procesos de alto contenido en hidrógeno así como en la soldadura en medio acuoso.

  15. Human biomonitoring of aluminium after a single, controlled manual metal arc inert gas welding process of an aluminium-containing worksheet in nonwelders.

    Science.gov (United States)

    Bertram, Jens; Brand, Peter; Hartmann, Laura; Schettgen, Thomas; Kossack, Veronika; Lenz, Klaus; Purrio, Ellwyn; Reisgen, Uwe; Kraus, Thomas

    2015-10-01

    Several existing field studies evaluate aluminium welding works but no thoroughly controlled exposure scenario for welding fume has been described yet. This study provides information about the uptake and elimination of aluminium from welding fumes under controlled conditions. In the Aachen Workplace Simulation Laboratory, we are able to generate welding fumes of a defined particle mass concentration. We exposed 12, until then occupationally unexposed participants with aluminium-containing welding fumes of a metal inert gas (MIG) welding process of a total dust mass concentration of 2.5 mg/m(3) for 6 h. Room air filter samples were collected, and the aluminium concentration in air derived. Urine and plasma samples were collected directly before and after the 6-h lasting exposure, as well as after 1 and 7 days. Human biomonitoring methods were used to determine the aluminium content of the samples with high-resolution continuum source atomic absorption spectrometry. Urinary aluminium concentrations showed significant changes after exposure compared to preexposure levels (mean t(1) (0 h) 13.5 µg/L; mean t(2) (6 h) 23.5 µg/L). Plasma results showed the same pattern but pre-post comparison did not reach significance. We were able to detect a significant increase of the internal aluminium burden of a single MIG aluminium welding process in urine, while plasma failed significance. Biphasic elimination kinetic can be observed. The German BAT of 60 µg/g creatinine was not exceeded, and urinary aluminium returned nearly to baseline concentrations after 7 days.

  16. Thermodynamics analysis of diffusion in spark plasma sintering welding Cr3C2 and Ni

    Science.gov (United States)

    Zhang, Fan; Zhang, Jinyong; Leng, Xiaoxuan; Lei, Liwen; Fu, Zhengyi

    2017-03-01

    Spark plasma sintering (SPS) welding of chromium carbide (Cr3C2) and nickel (Ni) was used to investigate the atomic diffusion caused by bypassing current. It was found that the diffusion coefficient with bypassing current was enhanced by almost 3.57 times over that without bypassing current. Different from the previous researches, the thermodynamics analysis conducted herein showed that the enhancement included a current direction-independent part besides the known current direction-dependent part. A local temperature gradient (LTG) model was proposed to explain the current direction-independent effect. Assuming that the LTG was mainly due to the interfacial electric resistance causing heterogeneous Joule heating, the theoretical results were in good agreement with the experimental results both in the present and previous studies. This new LTG model provides a reasonable physical meaning for the low-temperature advantage of SPS welding and should be useful in a wide range of applications.

  17. Space-dependent characterization of laser-induced plasma plume during fiber laser welding

    Science.gov (United States)

    Xiao, Xianfeng; Song, Lijun; Xiao, Wenjia; Liu, Xingbo

    2016-12-01

    The role of a plasma plume in high power fiber laser welding is of considerable interest due to its influence on the energy transfer mechanism. In this study, the space-dependent plasma characteristics including spectrum intensity, plasma temperature and electron density were investigated using optical emission spectroscopy technique. The plasma temperature was calculated using the Boltzmann plot of atomic iron lines, whereas the electron density was determined from the Stark broadening of the Fe I line at 381.584 nm. Quantitative analysis of plasma characteristics with respect to the laser radiation was performed. The results show that the plasma radiation increases as the laser power increases during the partial penetration mode, and then decreases sharply after the initiation of full penetration. Both the plasma temperature and electron density increase with the increase of laser power until they reach steady state values after full penetration. Moreover, the hottest core of the plasma shifts toward the surface of the workpiece as the penetration depth increases, whereas the electron density is more evenly distributed above the surface of the workpiece. The results also indicate that the absorption and scattering of nanoparticles in the plasma plume is the main mechanism for laser power attenuation.

  18. The softening effect of heat-treated strengthened Al-Zn-Mg alloy in welding process

    Science.gov (United States)

    Zhang, Xiaohong; Chen, Jingqing; Zhang, Kang; Chen, Hui

    2017-07-01

    Weld joint softening occurs during the welding process of heat-treatable aluminum alloys and strongly influences the mechanical properties. In this work, the softening of heat-treated Al-Zn-Mg alloy was studied in the multipass welding process. By Gleeble-3500 thermal-mechanical simulator, the heat treatment and tensile test with welding thermal cycles were carried out to simulate the microstructure evolution and mechanical softening during multipass welding. After that, the softening mechanism of the HAZ was analyzed by microstructure analysis. The results indicate that the heat-treated Al-Zn-Mg alloy exhibited obvious softening after several thermal cycles with peak temperature higher than 200∘C, and this phenomenon is worse with increasing peak temperature. Based on the microstructure analysis, it was found that the reinforcement phase changes according to the applied thermal cycles, which strongly affects the strength of Al-Zn-Mg alloys.

  19. JOINTING PROCESS OF THE SAE 1020 WITH MAG WELD'S REGION HAVE BEEN INVESTIGATED AND FACTOR OF MISMATCH DETERMINED

    Directory of Open Access Journals (Sweden)

    Cevdet MERİÇ

    1997-03-01

    Full Text Available In this study, the jointing process of the SAE 1020 low carbon steel, generally used in the industry, has been done by the MAG weld method. The aim of this study is to examine the mismatch between base and weld metal. After the jointing process, mechanical and metalographical properties of the weld region, HAZ, and the weld metal of the samples considered here were searched, and CTOD (Crack Tip Opening Displacement was identified.

  20. Optimization of process parameters of the activated tungsten inert gas welding for aspect ratio of UNS S32205 duplex stainless steel welds

    OpenAIRE

    G. Magudeeswaran; Sreehari R. Nair; Sundar, L.; N. Harikannan

    2014-01-01

    The activated TIG (ATIG) welding process mainly focuses on increasing the depth of penetration and the reduction in the width of weld bead has not been paid much attention. The shape of a weld in terms of its width-to-depth ratio known as aspect ratio has a marked influence on its solidification cracking tendency. The major influencing ATIG welding parameters, such as electrode gap, travel speed, current and voltage, that aid in controlling the aspect ratio of DSS joints, must be optimized to...

  1. Optimization of the Process Parameters for Controlling Residual Stress and Distortion in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Schmidt, Henrik Nikolaj Blicher; Hattel, Jesper Henri

    2008-01-01

    , is investigated. The welding process is simulated in 2-dimensions with a sequentially coupled transient thermo-mechanical model using ANSYS. The numerical optimization problem is implemented in modeFRONTIER and solved using the Multi-Objective Genetic Algorithm (MOGA-II). An engineering-wise evaluation or ranking......In the present paper, numerical optimization of the process parameters, i.e. tool rotation speed and traverse speed, aiming minimization of the two conflicting objectives, i.e. the residual stresses and welding time, subjected to process-specific thermal constraints in friction stir welding...

  2. Integrated risk estimation of metal inert gas (MIG and metal active gas (MAG welding processes

    Directory of Open Access Journals (Sweden)

    T. Karkoszka

    2012-04-01

    Full Text Available Taking into account the technical characteristics of the welding processes, associated with the fulfilling clients’ requirements, the assurance of safe and healthy working places as well as the environment protection the fundamental meaning belongs to the application of the appropriate methods of risk assessment of these processes. The paper presents the results of risk analysis, using an integrated risk indicator implemented into operation of the MIG and MAG welding processes in the practice. In the welding risk management one can decide about reduce the risk by avoiding the risky ventures, or as a result of the proper preventive actions’ application.

  3. Friction Stir Spot Welding: A Review on Joint Macro- and Microstructure, Property, and Process Modelling

    Directory of Open Access Journals (Sweden)

    X. W. Yang

    2014-01-01

    Full Text Available Friction stir spot welding (FSSW is a very useful variant of the conventional friction stir welding (FSW, which shows great potential to be a replacement of single-point joining processes like resistance spot welding and riveting. There have been many reports and some industrial applications about FSSW. Based on the open literatures, the process features and variants, macro- and microstructural characteristics, and mechanical properties of the resultant joints and numerical simulations of the FSSW process were summarized. In addition, some applications of FSSW in aerospace, aviation, and automobile industries were also reviewed. Finally, the current problems and issues that existed in FSSW were indicated.

  4. Experimental studies of parameters affecting the heat generation in friction stir welding process

    Directory of Open Access Journals (Sweden)

    Mijajlović Miroslav M.

    2012-01-01

    Full Text Available Heat generation is a complex process of transformation of a specific type of energy into heat. During friction stir welding, one part of mechanical energy delivered to the welding tool is consumed in the welding process, another is used for deformational processes etc., and the rest of the energy is transformed into heat. The analytical procedure for the estimation of heat generated during friction stir welding is very complex because it includes a significant number of variables and parameters, and many of them cannot be fully mathematically explained. Because of that, the analytical model for the estimation of heat generated during friction stir welding defines variables and parameters that dominantly affect heat generation. These parameters are numerous and some of them, e. g. loads, friction coefficient, torque, temperature, are estimated experimentally. Due to the complex geometry of the friction stir welding process and requirements of the measuring equipment, adequate measuring configurations and specific constructional solutions that provide adequate measuring positions are necessary. This paper gives an overview of the process of heat generation during friction stir welding, the most influencing parameters on heat generation, constructional solutions for the measuring equipment needed for these experimental researches and examples of measured values.

  5. Mechanical properties of 9Cr–1W reduced activation ferritic martensitic steel weldment prepared by electron beam welding process

    Energy Technology Data Exchange (ETDEWEB)

    Das, C.R., E-mail: chitta@igcar.gov.in [Indira Gandhi Center for Atomic Research, Kalpakkam 603102 (India); Albert, S.K. [Indira Gandhi Center for Atomic Research, Kalpakkam 603102 (India); Sam, Shiju [Institute for Plasma Research, Gandhinagar (India); Mastanaiah, P. [Defense Research and Development Laboratory, Hyderabad (India); Chaitanya, G.M.S.K.; Bhaduri, A.K.; Jayakumar, T. [Indira Gandhi Center for Atomic Research, Kalpakkam 603102 (India); Murthy, C.V.S. [Defense Research and Development Laboratory, Hyderabad (India); Kumar, E. Rajendra [Institute for Plasma Research, Gandhinagar (India)

    2014-11-15

    Highlights: • Width of HAZ is smaller in the 9Cr–1W RAFM weldment prepared by EB process compared to that reported for TIG weldments in literature. • Weld joint is stronger than that of the base metal. • Toughness of weld metal prepared by EB welding process is comparable to that (in PWHT condition) prepared by TIG process. • DBTT of as-welded 9Cr–1W RAFM weldment prepared by EB process is comparable to that reported for TIG weld metal in PWHT condition. - Abstract: Microstructure and mechanical properties of the weldments prepared from 9Cr–1W reduced activation ferritic martensitic (RAFM) steel using electron beam welding (EBW) process were studied. Microstructure consists of tempered lath martensite where precipitates decorating the boundaries in post weld heat treated (PWHT) condition. Lath and precipitate sizes were found to be finer in the weld metal than in base metal. Accordingly, hardness of the weld metal was found to be higher than the base metal. Tensile strength of the cross weldment specimen was 684 MPa, which was comparable with the base metal tensile strength of 670 MPa. On the other hand, DBTT of 9Cr–1W weld metal in as-welded condition is similar to that reported for TIG weld metal in PWHT condition.

  6. Study on robot motion control for intelligent welding processes based on the laser tracking sensor

    Science.gov (United States)

    Zhang, Bin; Wang, Qian; Tang, Chen; Wang, Ju

    2017-06-01

    A robot motion control method is presented for intelligent welding processes of complex spatial free-form curve seams based on the laser tracking sensor. First, calculate the tip position of the welding torch according to the velocity of the torch and the seam trajectory detected by the sensor. Then, search the optimal pose of the torch under constraints using genetic algorithms. As a result, the intersection point of the weld seam and the laser plane of the sensor is within the detectable range of the sensor. Meanwhile, the angle between the axis of the welding torch and the tangent of the weld seam meets the requirements. The feasibility of the control method is proved by simulation.

  7. Process of friction-stir welding high-strength aluminum alloy and mechanical properties of joint

    Institute of Scientific and Technical Information of China (English)

    王大勇; 冯吉才; 郭德伦; 孙成彬; 栾国红; 郭和平

    2004-01-01

    The process of friction-stir welding 2A12CZ alloy has been studied. And strength and elongation tests have been performed, which demonstrated that the opportunity existed to manipulate friction-stir welding parameters in order to improve a range of material properties. The results showed that the joint strength and elongation arrived at their parameters changing, joint tensile strength and elongation had similar development. Hardness measurement indicated that the weld was softened. However, there was considerable difference in softening degree for different joint zone. The weld top had lower hardness and wider softening zone than other zone of the weld. And softening zone at advancing side was wider than that at retreating side.

  8. An analysis of the dynamic resistance and the instantaneous energy of the CO2 arc welding process

    Institute of Scientific and Technical Information of China (English)

    Wang Zhenmin; Xue Jiaxiang; Dong Fei; Yang Guohua; Lu Xiaoming

    2007-01-01

    A self-developed welding dynamic arc wavelet analyzer was adopted to analyze and assess the welding process of two CO2 arc welding machines. The experimental results indicate that the instantaneous energy can reflect the influence of the welding current and voltage on dynamic arc characteristic synthetically. Through calculating and analyzing the instantaneous energy, the energy during arc ignition and short circuit in CO2 welding process can be confirmed rationally, thus the foundation for the accurate design and control of the welding current and voltage can be provided. By reducing the ripple disturbance of the dynamic resistance, avoiding peak current and voltage waveform,and enhancing the transition frequency of short circuit suitably, the stability of the welding arc and the weld appearance can be improved.

  9. A new measurement method for the dynamic resistance signal during the resistance spot welding process

    Science.gov (United States)

    Wang, Lijing; Hou, Yanyan; Zhang, Hongjie; Zhao, Jian; Xi, Tao; Qi, Xiangyang; Li, Yafeng

    2016-09-01

    To measure the dynamic resistance signal during the resistance spot welding process, some original work was carried out and a new measurement method was developed. Compared with the traditional method, using the instantaneous electrode voltage and welding current at peak current point in each half cycle, the resistance curve from the newly proposed method can provide more details of the dynamic resistance changes over time. To test the specific performance of the proposed method, a series of welding experiments were carried out and the tensile shear strengths of the weld samples were measured. Then, the measurement error of the proposed method was evaluated. Several features were extracted from the dynamic resistance curves. The correlations between the extracted features and weld strength were analyzed and the results show that these features are closely related to the weld strength and they can be used for welding quality monitoring. Moreover, the dynamic resistance curve from the newly proposed method can also be used to monitor some abnormal welding conditions.

  10. Process Parameter Optimization of the Pulsed Current Argon Tungsten Arc Welding of Titanium Alloy

    Institute of Scientific and Technical Information of China (English)

    M.Balasubramanian; V.Jayabalan; V.Balasubramanian

    2008-01-01

    The selection of process parameters for obtaining optimal tensile properties in the pulsed current gas tungsten arc welding is presented. The tensile properties include ultimate tensile strength, yield strength and notch tensile strength. All these characteristics are considered together in the selection of process parameters by modified taguchi method to analyse the effect of each welding process parameter on tensile properties. Experimental results are furnished to illustrate the approach.

  11. 厚板铝合金变极性等离子弧焊工艺%Research on VPPA helium arc welding process of thick Al-Mg alloy plate

    Institute of Scientific and Technical Information of China (English)

    薛根奇; 马丽

    2012-01-01

    分析铝镁合金的焊接特性和变极性等离子弧焊的焊接特点及氩-氦电弧的特性,依据8~12 mm板厚5083的焊接经验,选用变极性等离子孤焊,分别采用氩气、氩气+氦气作为保护气体,对16 mm厚的5083铝合金进行焊接试验,通过优化焊接工艺参数,获得良好的焊缝成形;按JB/T 4730《承压设备无损检测》的要求对获得的焊接接头进行射线检测和渗透检测,通过机械性能试验验证焊接接头的机械性能,各项检测及试验结果均符合NB/T 47014《承压设备焊接工艺评定》的要求,获得的焊接工艺规范参数在高压封闭电器外壳筒体的焊接中稳定应用.%Based on the welding properties of aluminum-magnesium alloy,the welding characteristics of variable polarity plasma arc welding (VPPAW)and Argon-helium mixed arc,relay on the practical experience of 8-12mm 5083 alloy in variable polarity plasma arc welding,The variable polarity plasma helium arc welding was used to weld 16mm thick plate 5083 alloy with Argon and Argon-helium gas;Optimized welding parameters by study on die welding process,Gain the welded joints with Excellent weld shape,perfect internal quality and excellent mechanical properties. Use the non-destructive testing of pressure equipment of RT and FT to verify the weld surface and internal quality, verified the mechanical properties of welded joints by mechanical properties tests;The test results in line with the NB/T 47014"welding procedure qualification for pressure equipment",The welding process specification parameters are stable application in the welding of high pressure closed electrical enclosure tube.

  12. Arc sensing system for automatic weld seam tracking (II) ——Signal processing

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Due to violent disturbance of the welding arc, signal processingis the key problem of application of the sensor. By means of the new technique the arc sensor can recognize not only V-groove but also lap joint and butt joint. The sensor has good recognition ability even for welding process with very large current disturbance, e.g. pulsed arc and short circuit welding process, etc. The proposed technique is developed on the basis of modern digital filtering theory and mathematic transformation of the signals from time domain into frequency domain.

  13. Optimization of Gas Metal Arc Welding (GMAW) Process for Maximum Ballistic Limit in MIL A46100 Steel Welded All-Metal Armor

    Science.gov (United States)

    Grujicic, M.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.

    2015-01-01

    Our recently developed multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been upgraded with respect to its predictive capabilities regarding the process optimization for the attainment of maximum ballistic limit within the weld. The original model consists of six modules, each dedicated to handling a specific aspect of the GMAW process, i.e., (a) electro-dynamics of the welding gun; (b) radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler metal consumable electrode to the weld; (c) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (d) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; (e) spatial distribution of the as-welded material mechanical properties; and (f) spatial distribution of the material ballistic limit. In the present work, the model is upgraded through the introduction of the seventh module in recognition of the fact that identification of the optimum GMAW process parameters relative to the attainment of the maximum ballistic limit within the weld region entails the use of advanced optimization and statistical sensitivity analysis methods and tools. The upgraded GMAW process model is next applied to the case of butt welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler metal electrodes made of the same material. The predictions of the upgraded GMAW process model pertaining to the spatial distribution of the material microstructure and ballistic limit-controlling mechanical properties within the MIL A46100 butt weld are found to be consistent with general expectations and prior observations.

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

    Science.gov (United States)

    Grujicic, M.; Arakere, A.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.; Montgomery, J. S.

    2013-06-01

    A conventional gas metal arc welding (GMAW) butt-joining process has been modeled using a two-way fully coupled, transient, thermal-mechanical finite-element procedure. To achieve two-way thermal-mechanical coupling, the work of plastic deformation resulting from potentially high thermal stresses is allowed to be dissipated in the form of heat, and the mechanical material model of the workpiece and the weld is made temperature dependent. Heat losses from the deposited filler-metal are accounted for by considering conduction to the adjoining workpieces as well as natural convection and radiation to the surroundings. The newly constructed GMAW process model is then applied, in conjunction with the basic material physical-metallurgy, to a prototypical high-hardness armor martensitic steel (MIL A46100). The main outcome of this procedure is the prediction of the spatial distribution of various crystalline phases within the weld and the heat-affected zone regions, as a function of the GMAW process parameters. The newly developed GMAW process model is validated by comparing its predictions with available open-literature experimental and computational data.

  15. Optimization Of Pulsed Current Parameters To Minimize Pitting Corrosion İn Pulsed Current Micro Plasma Arc Welded Aısı 304l Sheets Using Genetic Algorithm

    Directory of Open Access Journals (Sweden)

    Kondapalli Siva Prasad

    2013-06-01

    Full Text Available Austenitic stainless steel sheets have gathered wide acceptance in the fabrication of components, which require high temperature resistance and corrosion resistance, such as metal bellows used in expansion joints in aircraft, aerospace and petroleum industry. In case of single pass welding of thinner sections of this alloy, Pulsed Current Micro Plasma Arc Welding (PCMPAW was found beneficial due to its advantages over the conventional continuous current process. This paper highlights the development of empirical mathematical equations using multiple regression analysis, correlating various process parameters to pitting corrosion rates in PCMPAW of AISI 304L sheets in 1 Normal HCl. The experiments were conducted based on a five factor, five level central composite rotatable design matrix. A Genetic Algorithm (GA was developed to optimize the process parameters for minimizing the pitting corrosion rates.

  16. Optimization of weld bead geometry in laser welding with filler wire process using Taguchi’s approach

    Science.gov (United States)

    dongxia, Yang; xiaoyan, Li; dingyong, He; zuoren, Nie; hui, Huang

    2012-10-01

    In the present work, laser welding with filler wire was successfully applied to joining a new-type Al-Mg alloy. Welding parameters of laser power, welding speed and wire feed rate were carefully selected with the objective of producing a weld joint with the minimum weld bead width and the fusion zone area. Taguchi approach was used as a statistical design of experimental technique for optimizing the selected welding parameters. From the experimental results, it is found that the effect of welding parameters on the welding quality decreased in the order of welding speed, wire feed rate, and laser power. The optimal combination of welding parameters is the laser power of 2.4 kW, welding speed of 3 m/min and the wire feed rate of 2 m/min. Verification experiments have also been conducted to validate the optimized parameters.

  17. Effects on mechanical properties in electron beam welding of TC4 alloy by laser shock processing

    Institute of Scientific and Technical Information of China (English)

    LU Jinzhong; ZHANG Yongkang; KONG Dejun; REN Xudong; GE Tao; ZOU Shikun

    2007-01-01

    The surface of TC4 titanium alloy welding line by electron beam welding (EBW) was processed by high power Q-switched and repetition-rate Nd: glass laser. Effects of laser power and spot diameter on residual stress and microhardness of the TC4 alloy welding line by laser shock processing (LSP) have been analyzed. Results show that residual stresses almost do not change as laser poweris 45.9 J,spot diameter is φ9 mm; While laser power is 45.9 J, spot diameter less than φ3 mm, the distribution of residual stress in welding line occurs obvious variation, which residual stress increase obviously with spot diameter decrease. When power density is bigger than 1.8×1010W/cm2, residual stresses of electron beam welding line occur change by LSP,which improve obviously residual stress distribution; while laser power is bigger than 1.2×1010W/cm2, the surface micro-hardness of electron beam welding line occurs change by LSP, which improve obviously micro-hardness distribution. Mechanical properties of TC4 titanium alloy welding line will be improved by LSP, which provides experimental foundation for further controlling the distributions of residual stress and micro-hardness during laser shock processing.

  18. Keyhole formation and its characteristics in laser welding mode transition

    Institute of Scientific and Technical Information of China (English)

    Qin Guoliang; Gao Jinqiang; Lin Shangyang

    2010-01-01

    Keyhole is the most important characteristic for laser deep penetration welding, and its formation indicates the beginning of laser deep penetration welding mode. The keyhole developing process was analyzed and the keyhole formation time was calculated according to welding speed and the length of weld bead formed in the keyhole formation process. The results showed that the keyhole forms in 40-70 ms at different rate of change of laser power. In laser deep penetration welding process, the variation of light intensity radiated by laser induced plasma can identify the keyhole formation, but it can not be used to estimate the keyhole formation time because of delay effect.

  19. Effect of the Metal Transport on the Mechanical Properties of Al-2Si Alloys Processed through Friction Stir Welding Processes

    Science.gov (United States)

    Shailesh Rao, A.; Naik, Yuvaraja

    2017-03-01

    In this study, Al-2Si alloys were joined using friction stir welding with various process parameters. The process parameters considered here were rotational speeds from 600 to 1200 rpm, feed rate from 50 to 150 mm/min with three equal increments. In this study, the mushy state metal movements during the processes are discussed. The experimental observation and results indicate that the flaw formations, surface roughness of the weld, and hardness value depend on the metal movement and are explained in this study. The microstructure of the weld zone was studied finally.

  20. Development of automated welding process for field fabrication of thick walled pressure vessels. Fourth quarter technical progress report for period ending September 28, 1980

    Energy Technology Data Exchange (ETDEWEB)

    1980-01-01

    Progress is reported in research aimed at optimizing an automated welding process for the field fabrication of thick-walled pressure vessels and for evaluating the welded joints. Information is included on the welding equipment, mechanical control of the process, joint design, filler wire optimization, in-process nondestructive testing of welds, and repair techniques. (LCL)

  1. A secondary fuel removal process: plasma processing

    Energy Technology Data Exchange (ETDEWEB)

    Min, J. Y.; Kim, Y. S. [Hanyang Univ., Seoul (Korea, Republic of); Bae, K. K.; Yang, M. S. [Korea Atomic Energy Research Institute, Taejon (Korea, Republic of)

    1997-07-01

    Plasma etching process of UO{sub 2} by using fluorine containing gas plasma is studied as a secondary fuel removal process for DUPIC (Direct Use of PWR spent fuel Into Candu) process which is taken into consideration for potential future fuel cycle in Korea. CF{sub 4}/O{sub 2} gas mixture is chosen for reactant gas and the etching rates of UO{sub 2} by the gas plasma are investigated as functions of CF{sub 4}/O{sub 2} ratio, plasma power, substrate temperature, and plasma gas pressure. It is found that the optimum CF{sub 4}/O{sub 2} ratio is around 4:1 at all temperatures up to 400 deg C and the etching rate increases with increasing r.f. power and substrate temperature. Under 150W r.f. power the etching rate reaches 1100 monolayers/min at 400 deg C, which is equivalent to about 0.5mm/min. (author).

  2. Linear friction weld process monitoring of fixture cassette deformations using empirical mode decomposition

    Science.gov (United States)

    Bakker, O. J.; Gibson, C.; Wilson, P.; Lohse, N.; Popov, A. A.

    2015-10-01

    Due to its inherent advantages, linear friction welding is a solid-state joining process of increasing importance to the aerospace, automotive, medical and power generation equipment industries. Tangential oscillations and forge stroke during the burn-off phase of the joining process introduce essential dynamic forces, which can also be detrimental to the welding process. Since burn-off is a critical phase in the manufacturing stage, process monitoring is fundamental for quality and stability control purposes. This study aims to improve workholding stability through the analysis of fixture cassette deformations. Methods and procedures for process monitoring are developed and implemented in a fail-or-pass assessment system for fixture cassette deformations during the burn-off phase. Additionally, the de-noised signals are compared to results from previous production runs. The observed deformations as a consequence of the forces acting on the fixture cassette are measured directly during the welding process. Data on the linear friction-welding machine are acquired and de-noised using empirical mode decomposition, before the burn-off phase is extracted. This approach enables a direct, objective comparison of the signal features with trends from previous successful welds. The capacity of the whole process monitoring system is validated and demonstrated through the analysis of a large number of signals obtained from welding experiments.

  3. Online NIR diagnostic of laser welding processes and its potential for quality assuring sensor systems

    Science.gov (United States)

    Dorsch, Friedhelm; Braun, Holger; Keβler, Steffen; Pfitzner, Dieter; Rominger, Volker

    2014-02-01

    We have integrated an imaging thermographic sensor into commercial welding optics for observation of the weld zone. Key element of the sensor is an InGaAs-camera that detects the thermal radiation of the welding process in the wavelength range of 1,200 to 1,700 nm. This is well suited to record images of the keyhole, the melt pool and the thermal trace. The sensor was integrated to the welding heads for on-axis observation to minimize the interfering contour to ensure easy adaption to industrial processes. The welding heads used were established industrial-grade TRUMPF optics: a BEO fixed optics with 280 mm focal length, or a TRUMPF PFO-3D scanner optics with 450 mm focal length. We used a TRUMPF TruDisk 16002 16kW-thin disk laser that transmits its power through a 200 μm core diameter light cable. The images were recorded and features of the various process zones were evaluated by image processing. It turns out that almost all weld faults can be clearly detected in the NIR images. Quantitative features like the dimension of the melt pool and the thermal trace can be derived from the captured images. They are correlated to process input parameters as well as to process results. In contrast to observation in the visible spectrum the NIR camera records the melt pool without auxiliary illumination. As an unrivaled attribute of the NIR sensor it supports an online heat flow thermography of the seam and allows identifying missing fusion ("false friends") of lap joints virtually during the welding process. Automated weld fault detection and documentation is possible by online image processing which sets the basis for comprehensive data documentation for quality assurance and traceability.

  4. 3D visualization of the material flow in friction stir welding process

    Institute of Scientific and Technical Information of China (English)

    Zhao Yanhua; Lin Sanbao; Shen Jiajie; Wu Lin

    2005-01-01

    The material flow in friction stir welded 2014 Al alloy has been investigated using a marker insert technique (MIT). Results of the flow visualization show that the material flow is asymmetrical during the friction stir welding(FSW)process and there are also significant differences in the flow patterns observed on advancing side and retreating side. On advancing side, some material transport forward and some move backward, but on retreating side, material only transport backward. At the top surface of the weld, significant material traasport forward due to the action of the rotating tool shoulder.Combining the data from all the markers, a three-dimensional flow visualization, similar to the 3D image reconstruction technique, was obtained. The three-dimensional plot gives the tendency chart of material flow in friction stir welding process and from the plot it can be seen that there is a vertical, circular motion around the longitudinal axis of the weld. On the advancing side of the weld, the material is pushed downward but on the retreating side, the material is pushed toward the crown of the weld. The net result of the two relative motions in both side of the advancing and the retreating is that a circular motion comes into being. Comparatively, the material flow around the longitudinal axis is a secondary motion.

  5. Reduction in Repair rate of Welding Processes by Determination & Controlling of Critical KPIVs

    Directory of Open Access Journals (Sweden)

    Faheem Yousaf

    2014-01-01

    Full Text Available Six Sigma is being Implemented all over the World as a successful Quality Improvement Methodology. Many Companies are now days are using Six Sigma as an Approach towards zero defects. This article provides a practical case study regarding the implementation of Six Sigma Project in a Welding Facility and discusses the Statistical Analysis performed for bringing the welding processes in the desired sigma Limits.DMAIC was chosen as potential Six Sigma methodology with the help of findings of this Methodology, Six Sigma Team First Identified the critical Factors affecting the Process Yield and then certain Improvement Measures were taken to improve the Capability of Individual welding Processes and also of Overall Welding Facility.   Cost of Quality was also measured to Validate the Improvement results achieved after Conducting the Six Sigma Project.

  6. Plasma detachment with molecular processes in divertor plasmas

    Energy Technology Data Exchange (ETDEWEB)

    Ohno, N.; Ezumi, N.; Nishijima, D.; Takamura, S. [Dept. of Energy Engineering and Science, Graduate School of Engineering, Nagoya Univ., Nagoya, Aichi (Japan); Krasheninnikov, S.I.; Pigarov, A.Yu. [MIT Plasma Science and Fusion Center, Cambridge, MA (United States)

    2000-01-01

    Molecular processes in detached recombining plasmas are briefly reviewed. Several reactions with vibrationally excited hydrogen molecule related to recombination processes are described. Experimental evidence of molecular activated recombination observed in a linear divertor plasma simulator is also shown. (author)

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

    Science.gov (United States)

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

    2010-07-27

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

  8. Temperature distribution study during the friction stir welding process of Al2024-T3 aluminum alloy

    Science.gov (United States)

    Yau, Y. H.; Hussain, A.; Lalwani, R. K.; Chan, H. K.; Hakimi, N.

    2013-08-01

    Heat flux characteristics are critical to good quality welding obtained in the important engineering alloy Al2024-T3 by the friction stir welding (FSW) process. In the present study, thermocouples in three different configurations were affixed on the welding samples to measure the temperatures: in the first configuration, four thermocouples were placed at equivalent positions along one side of the welding direction; the second configuration involved two equivalent thermocouple locations on either side of the welding path; while the third configuration had all the thermocouples on one side of the layout but with unequal gaps from the welding line. A three-dimensional, non-linear ANSYS computational model, based on an approach applied to Al2024-T3 for the first time, was used to simulate the welding temperature profiles obtained experimentally. The experimental thermal profiles on the whole were found to be in agreement with those calculated by the ANSYS model. The broad agreement between the two kinds of profiles validates the basis for derivation of the simulation model and provides an approach for the FSW simulation in Al2024-T3 and is potentially more useful than models derived previously.

  9. Resistance welding

    DEFF Research Database (Denmark)

    Bay, Niels; Zhang, Wenqi; Rasmussen, Mogens H.

    2003-01-01

    Resistance welding comprises not only the well known spot welding process but also more complex projection welding operations, where excessive plastic deformation of the weld point may occur. This enables the production of complex geometries and material combinations, which are often not possible...... to weld by traditional spot welding operations. Such joining processes are, however, not simple to develop due to the large number of parameters involved. Development has traditionally been carried out by large experimental investigations, but the development of a numerical programme system has changed...... this enabling prediction of the welding performance in details. The paper describes the programme in short and gives examples on industrial applications. Finally investigations of causes for failure in a complex industrial joint of two dissimilar metals are carried out combining numerical modelling...

  10. Resistance welding

    DEFF Research Database (Denmark)

    Bay, Niels; Zhang, Wenqi; Rasmussen, Mogens H.

    2003-01-01

    this enabling prediction of the welding performance in details. The paper describes the programme in short and gives examples on industrial applications. Finally investigations of causes for failure in a complex industrial joint of two dissimilar metals are carried out combining numerical modelling......Resistance welding comprises not only the well known spot welding process but also more complex projection welding operations, where excessive plastic deformation of the weld point may occur. This enables the production of complex geometries and material combinations, which are often not possible...... to weld by traditional spot welding operations. Such joining processes are, however, not simple to develop due to the large number of parameters involved. Development has traditionally been carried out by large experimental investigations, but the development of a numerical programme system has changed...

  11. Hot-crack test for aluminium alloys welds using TIG process

    Directory of Open Access Journals (Sweden)

    Deschaux-beaume F.

    2010-06-01

    Full Text Available Hot cracking is a critical defect frequently observed during welding of aluminium alloys. In order to better understand the interaction between cracking phenomenon, process parameters, mechanical factors and microstructures resulting from solidification after welding, an original hot-cracking test during welding is developed. According to in-situ observations and post mortem analyses, hot cracking mechanisms are investigated, taking into account the interaction between microstructural parameters, depending on the thermal cycles, and mechanical parameters, depending on geometry and clamping conditions of the samples and on the thermal field on the sample. Finally, a process map indicating the limit between cracking and non-cracking zones according to welding parameters is presented.

  12. Process parameters optimization for friction stir welding of RDE-40 aluminium alloy using Taguchi technique

    Institute of Scientific and Technical Information of China (English)

    A.K.LAKSHMINARAYANAN; V.BALASUBRAMANIAN

    2008-01-01

    Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of friction stir welded RDE-40 aluminium alloy. In order to evaluate the effect of process parameters such as tool rotational speed, traverse speed and axial force on tensile strength of friction stir welded RDE-40 aluminium alloy, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined. The results indicate that the rotational speed, welding speed and axial force are the significant parameters in deciding the tensile strength of the joint. The predicted optimal value of tensile strength of friction stir welded RDE-40 aluminium alloy is 303 MPa. The results were confirmed by further experiments.

  13. Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology

    OpenAIRE

    Ramanjaneyulu Kadaganchi; Madhusudhan Reddy Gankidi; Hina Gokhale

    2015-01-01

    The heat treatable aluminum–copper alloy AA2014 finds wide application in the aerospace and defence industry due to its high strength-to-weight ratio and good ductility. Friction stir welding (FSW) process, an emerging solid state joining process, is suitable for joining this alloy compared to fusion welding processes. This work presents the formulation of a mathematical model with process parameters and tool geometry to predict the responses of friction stir welds of AA 2014-T6 aluminum allo...

  14. Progress Report for Diffusion Welding of the NGNP Process Application Heat Exchangers

    Energy Technology Data Exchange (ETDEWEB)

    R.E. Mizia; D.E. Clark; M.V. Glazoff; T.E. Lister; T.L. Trowbridge

    2011-04-01

    The NGNP Project is currently investigating the use of metallic, diffusion welded, compact heat exchangers to transfer heat from the primary (reactor side) heat transport system to the secondary heat transport system. The intermediate heat exchanger will transfer this heat to downstream applications such as hydrogen production, process heat, and electricity generation. The channeled plates that make up the heat transfer surfaces of the intermediate heat exchanger will have to be assembled into an array by diffusion welding.

  15. A study of process induced voids in resistance welding of thermoplastic composites

    OpenAIRE

    Shi, H.; Fernandez Villegas, I.; Bersee, H.E.N.

    2015-01-01

    Void formation in resistance welding of woven fabric reinforced thermoplastic composites was investigated. Void contents were measured using optical microscopy and digital image process. Un-even void distributions were observed in the joints, and more voids were found in the middle of the joints than the edges. A higher welding pressure was shown to help reduce the void generation. The mechanisms of void formation, in particular fibre de-compaction induced voids and residual moisture induced ...

  16. Effect of Process Variables on the Inertia Friction Welding of Superalloys LSHR and Mar-M247

    Science.gov (United States)

    Mahaffey, D. W.; Senkov, O. N.; Shivpuri, R.; Semiatin, S. L.

    2016-08-01

    The effect of inertia friction welding process parameters on microstructure evolution, weld plane quality, and the tensile behavior of welds between dissimilar nickel-base superalloys was established. For this purpose, the fine-grain, powder metallurgy alloy LSHR was joined to coarse-grain cast Mar-M247 using a fixed level of initial kinetic energy, but different combinations of the flywheel moment of inertia and initial rotation speed. It was found that welds made with the largest moment of inertia resulted in a sound bond with the best microstructure and room-temperature tensile strength equal to or greater than that of the parent materials. A relationship between the moment of inertia and weld process efficiency was established. The post-weld tensile behavior was interpreted in the context of observed microstructure gradients and weld-line defects.

  17. Thermal analysis of friction stir welding process and investigation into affective parameters using simulation

    Energy Technology Data Exchange (ETDEWEB)

    Abbasi, Mahmoud [University of Kashan, Kashan (Iran, Islamic Republic of); Bagheri, Behrouz [Amirkabir University of Technology, Tehran (Iran, Islamic Republic of); Keivani, Rasoul [Islamic Azad University, Tehran (Iran, Islamic Republic of)

    2015-02-15

    Friction stir welding (FSW) as an efficient solid state joining process has numerous applications in industries. Temperature distribution analysis through simulation not only brings the possibility to characterize the microstructure of different zones, but also enables one to save cost and energy as optimum welding variables are obtained with less concern. In the present study, the temperature distribution during the friction stir welding (FSW) process of AA6061-T6 was evaluated using finite element method (FEM). Since experimental measurements cannot be readily made in the weld region, it is difficult to understand physics in the stir zone of the welds without simulation. Abaqus software was applied to model the parts and simulate the process of welding, while Johnson-Cook law utilized to evaluate the effect of strain rate and generated heat. FE-results were verified by experimental results. The comparisons revealed a good compatibility between the results. The effect of probe shape on temperature distribution was also studied. It was found that spherical pins result in the highest temperatures at workpieces with respect to cylindrical and tapered pins. Additionally, it was concluded that more heat is generated in workpieces as pin angle increases.

  18. Numerical analysis of the heat transfer and fluid flow in the butt-fusion welding process

    Science.gov (United States)

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

    2017-02-01

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

  19. A study of the friction stir welding process by experimental investigation and numerical simulation

    Science.gov (United States)

    Long, Tianzhong

    2005-12-01

    In this study, 2-D and 3-D models based on a commercial computational fluid dynamics (CFD) code (FLUENT) and suitable user defined viscosity law are used to capture many of the trends observed in FSW. The fully thermo-mechanically coupled 2 D CFD model can run in a few hours on a PC based system. The low computational cost for 2-D model enables rapid assessment of the effects of various material properties and the criticality of inclusion or exclusion of some property details. The effects of varying material properties and process parameters, on the trends in x-axis forces and potential weld defect formation (via material flow pattern) are studied and compared with the experimental observations. It was found that the minimum x-force that occurs in the median RPM range is strongly influenced by the cutoff temperature in the viscosity law. The bifurcation of material flow in the weld path also occurs when the maximum temperature ahead of the pin surpasses the cutoff temperature. Aluminum alloys AA2219, AA5083, AA6061, and AA7050 were welded using constant welding speed and linearly increased RPM. The grain sizes in the welds were measured and the applied torque and x-force during friction stir welding process were recorded. The correlations of the grain size, the applied torque and x-force were studied using simulation and the experimental methods. The 2D and 3D CFD model simulation results compare well with experimental measurements. Based on the 2D model results, the material's simulated thermo-mechanical history was also studied. The model predicts that the material in the weld region experiences a high temperature after the deformation is complete. This thermo-mechanical history indicates that metallurgical transformations may continue after the end of deformation and that the grain size in the weld cannot be adequately described using a Zener-Holloman parameter approach or by invoking the continuous dynamic recrystallization process.

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

    Science.gov (United States)

    Pan, Yi; Lados, Diana A.

    2017-01-01

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

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

    Science.gov (United States)

    Pan, Yi; Lados, Diana A.

    2017-04-01

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

  2. Gas Tungsten Arc Welding and Plasma Arc Cutting. Teacher Edition [and] Student Edition [and] Student Workbook. Second Edition.

    Science.gov (United States)

    Harper, Eddie; Knapp, John

    This packet of instructional materials for a gas tungsten arc welding (GTAW) and plasma arc cutting course is comprised of a teacher edition, student edition, and student workbook. The teacher edition consists of introductory pages and teacher pages. Introductory pages include training and competency profile, state duty/task crosswalk,…

  3. Effect of welding processes and consumables on fatigue crack growth behaviour of armour grade quenched and tempered steel joints

    Directory of Open Access Journals (Sweden)

    G. Magudeeswaran

    2014-03-01

    Full Text Available Quenched and Tempered (Q&T steels are widely used in the construction of military vehicles due to its high strength to weight ratio and high hardness. These steels are prone to hydrogen induced cracking (HIC in the heat affected zone (HAZ after welding. The use of austenitic stainless steel (ASS consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. The use of stainless steel consumables for a non-stainless steel base metal is not economical. Hence, alternate consumables for welding Q&T steels and their vulnerability to HIC need to be explored. Recent studies proved that low hydrogen ferritic steel (LHF consumables can be used to weld Q&T steels, which can give very low hydrogen levels in the weld deposits. The use of ASS and LHF consumables will lead to distinct microstructures in their respective welds. This microstructural heterogeneity will have a drastic influence in the fatigue crack growth resistance of armour grade Q&T steel welds. Hence, in this investigation an attempt has been made to study the influence of welding consumables and welding processes on fatigue crack growth behaviour of armour grade Q&T Steel joints. Shielded metal arc welding (SMAW and Flux cored arc welding (FCAW were used for fabrication of joints using ASS and LHF consumables. The joints fabricated by SMAW process using LHF consumable exhibited superior fatigue crack growth resistance than all other joints.

  4. Effect of welding processes and consumables on fatigue crack growth behaviour of armour grade quenched and tempered steel joints

    Institute of Scientific and Technical Information of China (English)

    G. MAGUDEESWARAN; V. BALASUBRAMANIAN; G. MADHUSUDHAN REDDY

    2014-01-01

    Quenched and Tempered (Q&T) steels are widely used in the construction of military vehicles due to its high strength to weight ratio and high hardness. These steels are prone to hydrogen induced cracking (HIC) in the heat affected zone (HAZ) after welding. The use of austenitic stainless steel (ASS) consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. The use of stainless steel consumables for a non-stainless steel base metal is not economical. Hence, alternate consumables for welding Q&T steels and their vulnerability to HIC need to be explored. Recent studies proved that low hydrogen ferritic steel (LHF) consumables can be used to weld Q&T steels, which can give very low hydrogen levels in the weld deposits. The use of ASS and LHF consumables will lead to distinct microstructures in their respective welds. This microstructural heterogeneity will have a drastic influence in the fatigue crack growth resistance of armour grade Q&T steel welds. Hence, in this investigation an attempt has been made to study the influence of welding con-sumables and welding processes on fatigue crack growth behaviour of armour grade Q&T Steel joints. Shielded metal arc welding (SMAW) and Flux cored arc welding (FCAW) were used for fabrication of joints using ASS and LHF consumables. The joints fabricated by SMAW process using LHF consumable exhibited superior fatigue crack growth resistance than all other joints.

  5. Plasma diagnostics in plasma processing for nanotechnology and nanolevel chemistry

    Directory of Open Access Journals (Sweden)

    Hiroshi Akatsuka

    2004-01-01

    Full Text Available The author reviews the role of various plasma diagnostics in plasma processing for nanotechnology, and points out some essential methods of spectroscopic methods to diagnose plasmas for nanoprocessing. Two experimental examples are discussed between the characteristics of nanomaterials and plasma parameters. One is measurement of rotation temperature in processing of carbon nanotube. The other is that of vibrational temperature in surface nitriding of titanium by nitrogen plasma processing. We summarize what to measure and how to measure them from the technical viewpoint of plasma diagnostics.

  6. Structure and Hardness of 01570 Aluminum Alloy Friction Stir Welds Processed Under Different Conditions

    Science.gov (United States)

    Il'yasov, R. R.; Avtokratova, E. V.; Markushev, M. V.; Predko, P. Yu.; Konkevich, V. Yu.

    2015-10-01

    Structure and hardness of the 01570 aluminum alloy joints processed by friction stir welding at various speeds are investigated. It is shown that increasing the traverse tool speed lowers the probability of macrodefect formation in the nugget zone; however, this can lead to anomalous grain growth in the zone of contact with the tool shoulder. Typical "onion-like" structure of the weld consisting of rings that differ by optical contrast is formed for all examined welding regimes. It is demonstrated that this contrast is caused by the difference in the grain sizes in the rings rather than by their chemical or phase composition. Mechanisms of transformation of the alloy structure during friction stir welding are discussed.

  7. [Study on the arc spectral information for welding quality diagnosis].

    Science.gov (United States)

    Li, Zhi-Yong; Gu, Xiao-Yan; Li, Huan; Yang, Li-Jun

    2009-03-01

    Through collecting the spectral signals of TIG and MIG welding arc with spectrometer, the arc light radiations were analyzed based on the basic theory of plasma physics. The radiation of welding arc distributes over a broad range of frequency, from infrared to ultraviolet. The arc spectrum is composed of line spectra and continuous spectra. Due to the variation of metal density in the welding arc, there is great difference between the welding arc spectra of TIG and MIG in both their intensity and distribution. The MIG welding arc provides more line spectra of metal and the intensity of radiation is greater than TIG. The arc spectrum of TIG welding is stable during the welding process, disturbance factors that cause the spectral variations can be reflected by the spectral line related to the corresponding element entering the welding arc. The arc spectrum of MIG welding will fluctuate severely due to droplet transfer, which produces "noise" in the line spectrum aggregation zone. So for MIG welding, the spectral zone lacking spectral line is suitable for welding quality diagnosis. According to the characteristic of TIG and MIG, special spectral zones were selected for welding quality diagnosis. For TIG welding, the selected zone is in ultraviolet zone (230-300 nm). For MIG welding, the selected zone is in visible zone (570-590 nm). With the basic theory provided for welding quality diagnosis, the integral intensity of spectral signal in the selected zone of welding process with disturbing factor was studied to prove the theory. The results show that the welding quality and disturbance factors can be diagnosed with good signal to noise ratio in the selected spectral zone compared with signal in other spectral zone. The spectral signal can be used for real-time diagnosis of the welding quality.

  8. Effect Of Process Parameters On Mechanical Properties Of Friction Stir.Welded Joint Of Two Similar &Dissimilar Al-Alloys

    Directory of Open Access Journals (Sweden)

    Umasankar Das,

    2015-09-01

    Full Text Available Friction Stir Welding (FSW is an advance joining process for different similar and dissimilar materials. It is commonly used for joining of Aluminum alloys. However it is necessary to overcome some challenges for its wide-spread uses. Tool design and the selection of process parameters are critical issues in the usage of this process. This study focuses on the process parameters that is required for producing effective friction stir welding of two similar aluminum alloys (AA6101T6 to AA6101T6 and dissimilar Aluminum alloys (AA6101T6 alloy to AA6351T6 . Three different tool diameters such as 20 mm, 25 mm and 30 mm with three different tool rotational speeds such as 600 rpm, 800 rpm and 1200 rpm have been used to weld the joints. The welded samples were tested for mechanical properties as well as microstructure. It was observed that 30 mm tool gives better weld quality for friction stir welding of similar aluminum alloy but 25 mm tool with 1200 rpm rotational speed gave satisfactory weld quality for friction stir welding of dissimilar aluminum alloys. It is one of the important welding process that can adopted for welding of aluminum alloys with excellent mechanical properties. The results were confirmed by further experiments.

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

    Science.gov (United States)

    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.

  10. Advanced Welding Applications

    Science.gov (United States)

    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.

  11. Profiling mild steel welding processes to reduce fume emissions and costs in the workplace.

    Science.gov (United States)

    Keane, Michael J; Siert, Arlen; Chen, Bean T; Stone, Samuel G

    2014-05-01

    To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g(-1) electrode) and lowest for GMAW processes such as pulsed spray (~1.5mg g(-1)) and CMT (~1mg g(-1)). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g(-1) (SMAW) to 0.08 mg g(-1) (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g(-1) (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g(-1) (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides

  12. Hybrid Control and Verification of a Pulsed Welding Process

    DEFF Research Database (Denmark)

    Wisniewski, Rafal; Larsen, Jesper Abildgaard; Izadi-Zamanabadi, Roozbeh

    Currently systems, which are desired to control, are becoming more and more complex and classical control theory objectives, such as stability or sensitivity, are often not sufficient to cover the control objectives of the systems. In this paper it is shown how the dynamics of a pulsed welding...

  13. Resistance Welding of Thermoplastic Composites: Process and Performance

    NARCIS (Netherlands)

    Shi, H.

    2014-01-01

    Compared to thermoset composites, thermoplastic composites are drawing more and more attention by aircraft industries not only due to their excellent material properties but also due to their potentials to reduce cycle time and structure cost by using low-cost manufacturing technologies such as weld

  14. Advanced plasma diagnostics for plasma processing

    Science.gov (United States)

    Malyshev, Mikhail Victorovich

    1999-10-01

    A new, non-intrusive, non-perturbing diagnostic method was developed that can be broadly applied to low pressure, weakly ionized plasmas and glow discharges-trace rare gases optical emission spectroscopy (TRG-OES). The method is based on a comparison of intensities of atomic emission from trace amounts of inert gases (He, Ne, Ar, Kr, and Xe) that are added to the discharge to intensities calculated from the theoretical model. The model assumes a Maxwellian electron energy distribution function (EEDF), computes the population of emitting levels both from the ground state and the metastable states of rare gases, and from the best fit between theory and experiment determines electron temperature (Te). Subject to conditions, TRG-OES can also yield electron density or its upper or lower limit. From the comparison of the emission from levels excited predominantly by high energy electrons to that excited by low energy electrons, information about the EEDF can be obtained. The use of TRG-OES also allows a traditionally qualitative actinometry technique (determination of concentration of radical species in plasma through optical emission) to become a precise quantitative method by including Te and rare gases metastables effects. A combination of TRG-OES, advanced actinometry, and Langmuir probe measurements was applied to several different plasma reactors and regimes of operation. Te measurements and experiments to correct excitation cross section were conducted in a laboratory helical resonator. Two chamber configuration of a commercial (Lam Research) metal etcher were studied to determine the effects of plasma parameters on plasma-induced damage. Two different methods (RF inductive coupling and ultra-high frequency coupling) for generating a plasma in a prototype reactor were also studied. Pulsed plasmas, a potential candidate to eliminate the plasma-induced damage to microelectronics devices that occurs in manufacturing due to differential charging of the wafer, have

  15. X60螺旋焊钢管焊接工艺分析%Welding process analysis of X60 spiral welded pipe

    Institute of Scientific and Technical Information of China (English)

    赵艺

    2014-01-01

    The X60 (L415M) steel grade for 323.9mm×7.1mm spiral submerged arc welded steel pipe, welding, argon arc welding and semi-finished product process parameters are designed and discussed.%对X60(L415M)钢级芰323.9 mm×7.1 mm螺旋缝埋弧焊接钢管内、外焊焊接、半成品氩弧焊,补焊工艺进行设计和探讨。

  16. Modelling the Heating Process in Simultaneous Laser Transmission Welding of Semicrystalline Polymers

    Directory of Open Access Journals (Sweden)

    Christian Hopmann

    2016-01-01

    Full Text Available Laser transmission welding is an established joining process for thermoplastics. A close-to-reality simulation of the heating process would improve the understanding of the process, facilitate and shorten the process installation, and provide a significant contribution to the computer aided component design. For these reasons a thermal simulation model for simultaneous welding was developed which supports determining the size of the heat affected zone (HAZ. The determination of the intensity profile of the laser beam after the penetration of the laser transparent semicrystalline thermoplastic is decisive for the simulation. For the determination of the intensity profile two measurement systems are presented and compared. The calculated size of the HAZ shows a high concordance to the dimensions of the HAZ found using light microscopy. However, the calculated temperatures exceed the indicated decomposition temperatures of the particular thermoplastics. For the recording of the real temperatures during the welding process a measuring system is presented and discussed.

  17. Relationship between geometric welding parameters and optical-acoustic emissions from electric arc in GMAW-S process

    Directory of Open Access Journals (Sweden)

    E. Huanca Cayo

    2011-05-01

    Full Text Available Purpose: Show the relationship between geometric characteristics of the weld bead and the optical-acoustic emissions from electric arc during welding in the GMAW-S process.Design/methodology/approach: Bead on plate welding experiments was carried out setting different process parameters. Every welding parameter group was set aiming to reach a high stability level what guarantee a geometrical uniformity in the weld beads. In each experiment was simultaneously acquired arc voltage, welding current, infrared and acoustic emissions; from them were computed parameters as arc power, acoustic peaks rate and infrared radiation rate. It was used a tri-dimensional LASER scanner for to acquire geometrical information from the weld beads surface as width and height of the bead. Depth penetration was measured from sectional cross cutting of weld beads.Findings: Previous analysis showed that the arc emission parameters reach a stationary state with different characteristic for each experiment group which means that there is some correlation level between them. Posterior analysis showed that from infrared parameter is possible to monitoring external weld bead geometry and principally its penetration depth. From acoustic parameter is possible to monitoring principally the external weld bead geometry. Therefore is concluded that there is a close relation between the arc emissions and the weld bead geometry and that them could be used to measuring the welding geometrical parameters.Research limitations/implications: After analysis it was noticed that the infrared sensing has a better performance than acoustic sensing in the depth penetration monitoring. Infrared sensing also sources some information about external geometric parameters that in conjunction with the acoustic sensing is possible to have reliable information about weld bead geometry. This method of sensing geometric parameters could be applied in other welding processes, but is necessary to have

  18. Development And Optical Absorption Properties Of A Laser Induced Plasma During CO2-Laser Processing

    Science.gov (United States)

    Beyer, E.; Bakowsky, L.; Loosen, P.; Poprawe, R.; Herziger, G.

    1984-03-01

    Laser material processing is accompanied by a laser induced plasma in front of the target surface as soon as the laser radiation exceeds a certain critical intensity. For cw CO2-laser machining of metal targets the threshold for plasma onset is about 106 W/cm2. Critical condition for plasma generation at this intensity level is to reach evaporation temperature at the target's surface. At intensity levels exceeding 106 W/cm2 the laser light is interacting with the laser induced plasma and then the plasma in turn interacts with the target. The absorptivity is no longer constant, but increases with increasing intensity of the incident radiation, so that the total amount of power coupled to the target is increasing. This holds up to intensity levels of 2'10 Wicm2. Then the plasma begins to withdraw from the target surface, thus interrupting plasma-target interaction so that the laser power is no longer coupled into the target completely. The results of laser welding (welding depth) in the intensity level of 106 W/cm2 are governed by the product of incident intensity times focus radius, so that welding results are a measure to determine focus radius and laser intensity.

  19. Processing and Optimization of Dissimilar Friction Stir Welding of AA 2219 and AA 7039 Alloys

    Science.gov (United States)

    Venkateswarlu, D.; Nageswara rao, P.; Mahapatra, M. M.; Harsha, S. P.; Mandal, N. R.

    2015-12-01

    The present paper discusses the optimization of dissimilar friction stir welding of AA 2219 and AA 7039 alloys with respect to tool design issues including microstructural study of weld. The optimized ultimate tensile strength was ~280 MPa, and % elongation was ~11.5. It was observed that the extent of tool shoulder flat surface and tool rotational speed influenced the weld quality significantly. A mathematical model was also developed using response surface regression analysis to predict the effects of tool geometry and process variables on dissimilar AA 2219 and AA 7039 alloys welds. The microstructure evolution and mechanical properties were investigated by employing electron backscatter diffraction technique, Vickers microhardness, and tensile testing, respectively. The microstructural observations indicated that the grain size obtained at advancing side (AA 2219 alloy side) was much finer compared to the retreating side (AA 7039 alloy side). Hardness distribution in the stir zone was inhomogeneous, which might be due to inadequate mixing of weld zone material. The hardness values observed at the weld zone were lower than that in the base materials.

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

    Science.gov (United States)

    Zhang, Kuanshuang; Zhou, Zhenggan; Zhou, Jianghua

    2015-09-01

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

  1. Synthetically quantitative evaluation function of characteristic parameters on CO2 arc welding process

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    The statistical probability and their variation regularity of the measurable characteristic parameters in the CO2 arc welding droplet short-circuiting transfer process have been studied. The statistical analysis shows that the sensitivity of each characteristic parameter with regard to the variation of the short-circuiting transfer process is different. The sensitivity of 4 kinds among these characteristic parameters is more intense than that of the short-circuiting transfer frequency. In order to take account of the synthetic influence of these characteristic parameters, by means of the characteristic parameters synthetic value, a quantitative evaluation function is built up to describe and evaluate the short-circuiting transfer process of CO2 arc welding in real time. The testing shows that the evaluation function can give a suitable synthetic valuation for the short-circuiting transfer process with a variety of welding variables.

  2. Theoretical and experimental contributions regarding the impact on work environment of welding processes in MIG / MAG protective gas medium

    Directory of Open Access Journals (Sweden)

    Gh. Amza

    2013-07-01

    Full Text Available This paper presents the main factors that cause environmental pollution in the case of the welding procedure in a protective gas environment. In the research the MIG and MAG welding processes were taken into account. The materials used in the experiments were 8TiCr170 stainless steel as the base material and as filler materials 4 types of welding wires were used, characterized by different chemical compositions. To assess the impact on the work environment of such welding processes the pollution coefficient Cp was defined based on the material balance equation as the ratio of the mass of all materials used in the welding process Mt and the effective mass of the welded performed Mu.

  3. Repulsive Interaction of Sulfide Layers on Compressor Impeller Blades Remanufactured Through Plasma Spray Welding

    Science.gov (United States)

    Chang, Y.; Zhou, D.; Wang, Y. L.; Huang, H. H.

    2016-12-01

    This study investigated the repulsive interaction of sulfide layers on compressor impeller blades remanufactured through plasma spray welding (PSW). Sulfide layers on the blades made of FV(520)B steel were prepared through multifarious corrosion experiments, and PSW was utilized to remanufacture blade specimens. The specimens were evaluated through optical microscopy, scanning electron microscopy, energy-dispersive spectroscopy, 3D surface topography, x-ray diffraction, ImageJ software analysis, Vicker's micro-hardness test and tensile tests. Results showed a large number of sulfide inclusions in the fusion zone generated by sulfide layers embodied into the molten pool during PSW. These sulfide inclusions seriously degraded the mechanical performance of the blades remanufactured through PSW.

  4. Progress Report for Diffusion Welding of the NGNP Process Application Heat Exchangers

    Energy Technology Data Exchange (ETDEWEB)

    R.E. Mizia; D.E. Clark; M.V. Glazoff; T.E. Lister; T.L. Trowbridge

    2011-12-01

    The U.S. Department of Energy selected the high temperature gas-cooled reactor as the basis for the Next Generation Nuclear Plant (NGNP). The NGNP will demonstrate the use of nuclear power for electricity, hydrogen production, and process heat applications. The NGNP Project is currently investigating the use of metallic, diffusion welded, compact heat exchangers to transfer heat from the primary (reactor side) heat transport system to the secondary heat transport system. An intermediate heat exchanger will transfer this heat to downstream applications such as hydrogen production, process heat, and electricity generation. The channeled plates that make up the heat transfer surfaces of the intermediate heat exchanger will have to be assembled into an array by diffusion welding. This report describes the preliminary results of a scoping study that evaluated the diffusion welding process parameters and the resultant mechanical properties of diffusion welded joints using Alloy 800H. The long-term goal of the program is to progress towards demonstration of small heat exchanger unit cells fabricated with diffusion welds. Demonstration through mechanical testing of the unit cells will support American Society of Mechanical Engineers rules and standards development, reduce technical risk, and provide proof of concept for heat exchanger fabrication methods needed to deploy heat exchangers in several potential NGNP configurations.1 Researchers also evaluated the usefulness of modern thermodynamic and diffusion computational tools (Thermo-Calc and Dictra) in optimizing the parameters for diffusion welding of Alloy 800H. The modeling efforts suggested a temperature of 1150 C for 1 hour with an applied pressure of 5 MPa using 15 {micro}m nickel foil as joint filler to reduce chromium oxidation on the welded surfaces. Good agreement between modeled and experimentally determined concentration gradients was achieved

  5. Friction Stir Welding

    Science.gov (United States)

    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.

  6. Narrow gap HST welding process and its application to candidate pipe material for 700 C USC boiler component

    Energy Technology Data Exchange (ETDEWEB)

    Bao, Gang; Sato, Takashi; Fukuda, Yuji [Babcock-Hitachi K.K., Hiroshima (Japan). Kure Research Lab.; Mitsuhata, Koichi [Babcock-Hitachi K.K., Hiroshima (Japan). Kure Div.

    2008-07-01

    Increasing steam temperature and pressure conditions of 700 C USC (Ultra Super Critical) power plants under consideration require the adoption of Ni-based alloys. One of the most crucial issues for the application of 700 C USC power plants is the establishment of welding technology for the thick-walled components. This paper reports the research results on the practicability of candidate material for the thickwalled components. The weld test was conducted on Ni-based Alloy617 (52Ni-22Cr- 13Co-9Mo-Ti-Al) by using the narrow gap HST (Hot wire Switching TIG) welding process developed by Babcock-Hitachi K.K with the matching filler wire of Alloy617. The weldability and strength properties of weld joint were examined. The sound weld joint was achieved. The advantages of narrow gap HST welding process for the thick-walled components of Ni-based alloy were discussed from the viewpoints of weld metal chemical composition and creep rupture strength. Due to the good shielding effect, the melting loss of alloy elements in the weld consumable during the narrow gap HST welding procedure was suppressed successfully. The narrow gap HST weld joint showed comparable strength with the parent metal. (orig.)

  7. Background Simulation and Correction Algorithm in Spot Weld Image Processing

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    One of the chief works for inspecting spot weld quality by X-ray to obtain an ideal and uniform digital image. This paper introduces three methods of image background simulation algorithm, and the effect of background correction was compared. It may be safely said that Kalman filter method is simple and fast for general image; the FFT method has a good adaptability for background simulation.

  8. Behavior of vapor/plasma within the keyhole and above the workpiece during CO2 laser penetration welding

    Institute of Scientific and Technical Information of China (English)

    2008-01-01

    In this paper, a high-speed camera and an optical emission monitor were used to study the behavior of vapor/plasma during CO2 laser welding of SUS304 stainless steel. Results of optical emission from vapor/plasma show that two characteristic frequency bands exist, 100-500 Hz and 1 500-3 500 Hz. At the same time, the changing images of vapor/plasma and bottom pool also confirm that there are two different fluctuation frequency bands. One of the frequency bands represents the characteristic of vapor/plasma within the keyhole, and it is within 167-500 Hz. Another frequency band is within 1 500-3 500 Hz, and it obviously derives from the shielding gas. Some factors may cause these frequency differences between the keyhole plasma and the shielding gas plasma. One of them is that the vapor/plasma pressure within the keyhole will increase slowly.

  9. Infrared thermography for monitoring heat generation in a linear friction welding process of Ti6Al4V alloy

    Science.gov (United States)

    Maio, L.; Liberini, M.; Campanella, D.; Astarita, A.; Esposito, S.; Boccardi, S.; Meola, C.

    2017-03-01

    The increasing use of titanium alloys in a wider range of applications requires the development of new techniques and processes capable to decrease production costs and manufacturing times. In this regard welding and other joining techniques play an important role. Today, solid state friction joining processes, such as friction stir welding, friction spot welding, inertia friction welding, continuous-drive friction welding and linear friction welding (LFW), represent promising methods for part manufacturing. They allow for joining at temperature essentially below the melting point of the base materials being joined, without the addition of filler metal. However, the knowledge of temperature is essential to understand and model the phenomena involved in metal welding. A global measured value represents only a clue of the heat generation during the process; while, a deep understanding of welding thermal aspects requires temperature field measurement. This paper is focused on the use of infrared thermography applied to the linear friction welding process of Ti6Al4V alloy. The attention is concentrated on thermal field that develops on the outer wall of the two parts to be joined (i.e. heat generated in the friction zone), and on the maximum temperature that characterizes the process before and after the flash formation.

  10. Process Optimization of Dual-Laser Beam Welding of Advanced Al-Li Alloys Through Hot Cracking Susceptibility Modeling

    Science.gov (United States)

    Tian, Yingtao; Robson, Joseph D.; Riekehr, Stefan; Kashaev, Nikolai; Wang, Li; Lowe, Tristan; Karanika, Alexandra

    2016-07-01

    Laser welding of advanced Al-Li alloys has been developed to meet the increasing demand for light-weight and high-strength aerospace structures. However, welding of high-strength Al-Li alloys can be problematic due to the tendency for hot cracking. Finding suitable welding parameters and filler material for this combination currently requires extensive and costly trial and error experimentation. The present work describes a novel coupled model to predict hot crack susceptibility (HCS) in Al-Li welds. Such a model can be used to shortcut the weld development process. The coupled model combines finite element process simulation with a two-level HCS model. The finite element process model predicts thermal field data for the subsequent HCS hot cracking prediction. The model can be used to predict the influences of filler wire composition and welding parameters on HCS. The modeling results have been validated by comparing predictions with results from fully instrumented laser welds performed under a range of process parameters and analyzed using high-resolution X-ray tomography to identify weld defects. It is shown that the model is capable of accurately predicting the thermal field around the weld and the trend of HCS as a function of process parameters.

  11. Development of a welding system for 3D steel rapid prototyping process

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Metal device rapid prototyping with welding is one of the research interests at present. A controlled inertial droplet transfer MAG welding (CIDTMAGW) process was developed for the 3D steel device rapid prototyping with metal deposition. In this process, by using a special designed wire feeder, a controlled inertia is imposed on the droplet formed on the wire tip and combines with the arc force to make it detached. Thus, according to the requirements of rapid prototyping, the arc heat and the droplet detaching force can be separately controlled to attain a stable and satisfactory metal deposition process. A CIDTMAGW system and a testing manipulator for the 3D steel device rapid prototyping are presented. The required software is completed as well. The experiments proved that the geometric formation of the rapid prototyping device with welding deposition is well agreed the data of the device CAD modeling. The surface of the deposited device is comparatively smooth.

  12. Effect of acoustic softening on the thermal-mechanical process of ultrasonic welding.

    Science.gov (United States)

    Chen, Kunkun; Zhang, Yansong; Wang, Hongze

    2017-03-01

    Application of ultrasonic energy can reduce the static stress necessary for plastic deformation of metallic materials to reduce forming load and energy, namely acoustic softening effect (ASE). Ultrasonic welding (USW) is a rapid joining process utilizing ultrasonic energy to form a solid state joint between two or more pieces of metals. Quantitative characterization of ASE and its influence on specimen deformation and heat generation is essential to clarify the thermal-mechanical process of ultrasonic welding. In the present work, experiments were set up to found out mechanical behavior of copper and aluminum under combined effect of compression force and ultrasonic energy. Constitutive model was proposed and numerical implemented in finite element model of ultrasonic welding. Thermal-mechanical analysis was put forward to explore the effect of ultrasonic energy on the welding process quantitatively. Conclusions can be drawn that ASE increases structural deformation significantly, which is beneficial for joint formation. Meanwhile, heat generation from both frictional work and plastic deformation is slightly influenced by ASE. Based on the proposed model, relationship between ultrasonic energy and thermal-mechanical behavior of structure during ultrasonic welding was constructed.

  13. Measurement of the stressed state of welded joints in the NPP process components and circulation pipelines based on acoustoelasticity theory

    Directory of Open Access Journals (Sweden)

    A.I. Trofimov

    2016-09-01

    Full Text Available The paper presents the results of a theoretical justification and an experimental research for a method to measure the stressed state of welded joints in the nuclear power plant (NPP process components and circulation pipelines based on acoustoelasticity theory, as well as for ways to implement them technically. Devices for measuring the stressed state of welded joints in the NPP process components and circulation pipelines based on acoustoelasticity theory allow online measurement of residual stresses along the weld height and detection of crack formation points. The use of such devices will enable early crack detection in welded joints for an increased safety of the NPP operation.

  14. TRANSIENT FINITE ELEMENT SIMULATION AND MICROSTRUCTURE EVOLUTION OF AA2219 WELD JOINT USING GAS TUNGSTEN ARC WELDING PROCESS

    Directory of Open Access Journals (Sweden)

    Sivaraman Arunkumar

    2016-09-01

    Full Text Available In this study we focus on finite element simulation of gas tungsten arc welding (GTAW of AA2219 aluminum alloy and the behavioral of the microstructure before and after weld. The simulations were performed using commercial COMSOL Multiphysics software. The thermal history of the weld region was studied by initially developed mathematical model. A sweep type meshing was used and transient analysis was performed for one welding cycle. The highest temperature noted was 3568 °C during welding. The welding operation was performed on 200×100×25 mm plates. Through metallurgical characterization, it was observed that a fair copper rich cellular (CRC network existed in the weld region. A small amount of intermetallic compounds like Al2Cu is observed through the XRD pattern.

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

    Science.gov (United States)

    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.

  16. Model of a laser heated plasma interacting with walls arising in laser keyhole welding

    Science.gov (United States)

    Tix, C.; Simon, G.

    1994-07-01

    In laser welding with laser intensities of approximately 1011 W/m2, a hole, called a keyhole, is formed in the material. In this keyhole a plasma is detected, which is characterized by high pressure as well as being influenced by the boundary of the keyhole. Experimental data on plasma parameters are rare and difficult to obtain [W. Sokolowski, G. Herziger, and E. Beyer, in High Power Lasers and Laser Machining Technology, edited by A. Quenzer, SPIE Proc. Vol. 1132 (SPIE, Bellingham, WA, 1989), pp. 288-295]. In a previous paper [C. Tix and G. Simon, J. Phys. D 26, 2066 (1993)] we considered just a simple plasma model without excited states and with constant ion-neutral-atom temperature. Therefore we neglected radiative transport of excitations and underestimated the ion-neutral-atom temperature and the ionization rate. Here we extend our previous model for a continuous CO2 laser and iron and take into account radiative transfer of excitations and a variable ion-neutral-atom temperature. We consider singly charged ions, electrons, and three excitation states of neutral atoms. The plasma is divided in plasma bulk, presheath, and sheath. The transport equations are solved with boundary conditions mainly determined through the appearance of walls. Some effort is made to clarify the energy transport mechanism from the laser beam into the material. Dependent on the incident laser power, the mean electron temperature and density are obtained to be 1.0-1.3 eV and 2.5×1023-3×1023 m-3. Radiative transport of excitations does not contribute significantly to the energy transport.

  17. ADVANCED INTEGRATION OF MULTI-SCALE MECHANICS AND WELDING PROCESS SIMULATION IN WELD INTEGRITY ASSESSMENT

    Energy Technology Data Exchange (ETDEWEB)

    Wilkowski, Gery M.; Rudland, David L.; Shim, Do-Jun; Brust, Frederick W.; Babu, Sundarsanam

    2008-06-30

    The potential to save trillions of BTU’s in energy usage and billions of dollars in cost on an annual basis based on use of higher strength steel in major oil and gas transmission pipeline construction is a compelling opportunity recognized by both the US Department of Energy (DOE). The use of high-strength steels (X100) is expected to result in energy savings across the spectrum, from manufacturing the pipe to transportation and fabrication, including welding of line pipe. Elementary examples of energy savings include more the 25 trillion BTUs saved annually based on lower energy costs to produce the thinner-walled high-strength steel pipe, with the potential for the US part of the Alaskan pipeline alone saving more than 7 trillion BTU in production and much more in transportation and assembling. Annual production, maintenance and installation of just US domestic transmission pipeline is likely to save 5 to 10 times this amount based on current planned and anticipated expansions of oil and gas lines in North America. Among the most important conclusions from these studies were: • While computational weld models to predict residual stress and distortions are well-established and accurate, related microstructure models need improvement. • Fracture Initiation Transition Temperature (FITT) Master Curve properly predicts surface-cracked pipe brittle-to-ductile initiation temperature. It has value in developing Codes and Standards to better correlate full-scale behavior from either CTOD or Charpy test results with the proper temperature shifts from the FITT master curve method. • For stress-based flaw evaluation criteria, the new circumferentially cracked pipe limit-load solution in the 2007 API 1104 Appendix A approach is overly conservative by a factor of 4/π, which has additional implications. . • For strain-based design of girth weld defects, the hoop stress effect is the most significant parameter impacting CTOD-driving force and can increase the crack

  18. Process Development and Microstructural Characterization on Friction Plug Welded 2195 and 2219 Alloys

    Science.gov (United States)

    Li, Z. X.; Cantrell, M. A.; Brown, R. J.; McCool, A. (Technical Monitor)

    2000-01-01

    This document is a viewgraph presentation about Friction Plug Welding (FPW). It reviews the process of FPW, showing pictures which review the process. It also reviews the microstructural characterization using Transmission Electron Microscopy. There are several charts which are included for further information.

  19. Hybrid Search for Faster Production and Safer Process Conditions in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Deb, Kalyanmoy; Hattel, Jesper Henri

    2011-01-01

    The objective of this paper is to investigate optimum process parameters and tool geometries in Friction Stir Welding (FSW) to minimize temperature difference between the leading edge of the tool probe and the work piece material in front of the tool shoulder, and simultaneously maximize traverse...... choices have been offered based on several process specific performance and cost related criteria....

  20. Multi-objective Optimization of Process Parameters in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    The objective of this paper is to investigate optimum process parameters in Friction Stir Welding (FSW) to minimize residual stresses in the work piece and maximize production efficiency meanwhile satisfying process specific constraints as well. More specifically, the choices of tool rotational...

  1. The effect of welding line heat-affected-zone on the formability of tube hydroforming process

    Science.gov (United States)

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

    2016-08-01

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

  2. Numerical Modeling of Friction Stir Welding Process by Using Rate-dependent Constitutive Model

    Institute of Scientific and Technical Information of China (English)

    Hongwu ZHANG; Zhao ZHANG

    2007-01-01

    Rate-dependent constitutive model was used to simulate the friction stir welding process. The effect of the viscosity coefficient and the process parameters on the material behaviors and the stress distributions around the pin were studied. Results indicate that the stress in front of the pin is larger than that behind the pin. The difference between the radial/circumferential stress in front of the pin and that behind it becomes smaller when the material gets closer to the top surface. This difference increases with increasing the viscosity coefficient and becomes smaller when the welding speed decreases. The variation of the angular velocity does not significantly affect the difference.

  3. Optimization of process parameters of the activated tungsten inert gas welding for aspect ratio of UNS S32205 duplex stainless steel welds

    Directory of Open Access Journals (Sweden)

    G. Magudeeswaran

    2014-09-01

    Full Text Available The activated TIG (ATIG welding process mainly focuses on increasing the depth of penetration and the reduction in the width of weld bead has not been paid much attention. The shape of a weld in terms of its width-to-depth ratio known as aspect ratio has a marked influence on its solidification cracking tendency. The major influencing ATIG welding parameters, such as electrode gap, travel speed, current and voltage, that aid in controlling the aspect ratio of DSS joints, must be optimized to obtain desirable aspect ratio for DSS joints. Hence in this study, the above parameters of ATIG welding for aspect ratio of ASTM/UNS S32205 DSS welds are optimized by using Taguchi orthogonal array (OA experimental design and other statistical tools such as Analysis of Variance (ANOVA and Pooled ANOVA techniques. The optimum process parameters are found to be 1 mm electrode gap, 130 mm/min travel speed, 140 A current and 12 V voltage. The aspect ratio and the ferrite content for the DSS joints fabricated using the optimized ATIG parameters are found to be well within the acceptable range and there is no macroscopically evident solidification cracking.

  4. Optimization of process parameters of the activated tungsten inert gas welding for aspect ratio of UNS S32205 duplex stainless steel welds

    Institute of Scientific and Technical Information of China (English)

    G. MAGUDEESWARAN; Sreehari R. NAIR; L. SUNDAR; N. HARIKANNAN

    2014-01-01

    The activated TIG (ATIG) welding process mainly focuses on increasing the depth of penetration and the reduction in the width of weld bead has not been paid much attention. The shape of a weld in terms of its width-to-depth ratio known as aspect ratio has a marked influence on its solidification cracking tendency. The major influencing ATIG welding parameters, such as electrode gap, travel speed, current and voltage, that aid in controlling the aspect ratio of DSS joints, must be optimized to obtain desirable aspect ratio for DSS joints. Hence in this study, the above parameters of ATIG welding for aspect ratio of ASTM/UNS S32205 DSS welds are optimized by using Taguchi orthogonal array (OA) experimental design and other statistical tools such as Analysis of Variance (ANOVA) and Pooled ANOVA techniques. The optimum process parameters are found to be 1 mm electrode gap, 130 mm/min travel speed, 140 A current and 12 V voltage. The aspect ratio and the ferrite content for the DSS joints fabricated using the optimized ATIG parameters are found to be well within the acceptable range and there is no macroscopically evident solidification cracking.

  5. Numerical Simulation of the Friction Stir Welding Process Using Coupled Eulerian Lagrangian Method

    Science.gov (United States)

    Iordache, M.; Badulescu, C.; Iacomi, D.; Nitu, E.; Ciuca, C.

    2016-08-01

    Friction Stir Welding (FSW) is a solid state joining process that relies on frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the combined parts. The experiments are often time consuming and costly. To overcome these problems, numerical analysis has frequently been used in last years. Several simplified numerical models were designed to elucidate various aspects of the complex thermo-mechanical phenomena associated with FSW. This research investigates a thermo-mechanical finite element model based on Coupled Eulerian Lagrangian method to simulate the friction stir welding of the AA 6082-T6 alloy. Abaqus/cae software is used in order to simulate the welding stage of the Friction Stir Welding process. This paper presents the steps of the numerical simulation using the finite elements method, in order to evaluate the boundary conditions of the model and the geometry of the tools by using the Coupled Eulerian Lagrangian method.

  6. Arc Interference Behavior during Twin Wire Gas Metal Arc Welding Process

    Directory of Open Access Journals (Sweden)

    Dingjian Ye

    2013-01-01

    Full Text Available In order to study arc interference behavior during twin wire gas metal arc welding process, the synchronous acquisition system has been established to acquire instantaneous information of arc profile including dynamic arc length variation as well as relative voltage and current signals. The results show that after trailing arc (T-arc is added to the middle arc (M-arc in a stable welding process, the current of M arc remains unchanged while the agitation increases; the voltage of M arc has an obvious increase; the shape of M arc changes, with increasing width, length, and area; the transfer frequency of M arc droplet increases and the droplet itself becomes smaller. The wire extension length of twin arc turns out to be shorter than that of single arc welding.

  7. Effect of Process Parameters of Friction Stir Welded Joint for Similar Aluminium Alloys H30

    Directory of Open Access Journals (Sweden)

    Vanita S. Thete

    2015-05-01

    Full Text Available In this paper the effect of process parameters of friction stir welded joint for similar aluminium alloys H30 was studied. Taper cylindrical with three flutes all made of High speed steel was used for the friction stir welding (FSW aluminium alloy H30 and the tensile test of the welded joint were tested by universal testing method. The optimization done using detailed mathematical model is simulated by Minitab17. In this investigation, an effective approach based on Taguchi method, has been developed to determine the optimum conditions leading to higher tensile strength. Experiments were conducted on varying rotational speed, transverse speed, and axial force using L9 orthogonal array of Taguchi method. The present study aims at optimizing process parameters to achieve high tensile strength.

  8. FUZZY REGRESSION MODEL TO PREDICT THE BEAD GEOMETRY IN THE ROBOTIC WELDING PROCESS

    Institute of Scientific and Technical Information of China (English)

    B.S. Sung; I.S. Kim; Y. Xue; H.H. Kim; Y.H. Cha

    2007-01-01

    Recently, there has been a rapid development in computer technology, which has in turn led todevelop the fully robotic welding system using artificial intelligence (AI) technology. However, therobotic welding system has not been achieved due to difficulties of the mathematical model andsensor technologies. The possibilities of the fuzzy regression method to predict the bead geometry,such as bead width, bead height, bead penetration and bead area in the robotic GMA (gas metalarc) welding process is presented. The approach, a well-known method to deal with the problemswith a high degree of fuzziness, is used to build the relationship between four process variablesand the four quality characteristics, respectively. Using these models, the proper prediction of theprocess variables for obtaining the optimal bead geometry can be determined.

  9. One-knob self-optimizing fuzzy control of CO2 arc welding process

    Institute of Scientific and Technical Information of China (English)

    俞建荣; 蒋力培

    2002-01-01

    A new one-knob self-optimizing fuzzy control system of CO2 arc welding is established based on the synthetic performance evaluation of droplet transfer process. It includes two kinds of self-optimizing fuzzy controllers: the arc voltage controller and the current waveform controller. The fuzzy control principle and the key points of the control patterns are presented. Through on-line detecting, computing of characteristic parameters and one-knob self-optimizing adjusting, the characteristic parameters and welding variables can be adjusted to suitable ranges under the control of the arc voltage controller. Meanwhile the current waveform controller is active in the rear-time stage of the short-circuiting and the instant of re-triggering arc. The experiment results show that the control and its algorithm can improve the synthetic performance of arc welding process apparently.

  10. Exploring the electrodes alignment and mushrooming effects on weld geometry of dissimilar steels during the spot welding process

    Indian Academy of Sciences (India)

    Nachimani Charde

    2014-12-01

    The class two of RWMA electrode caps has very common applicationpurpose for the welding of steels and withstand for high thermal application on wrought cast. It has been experimentally used to weld carbon and stainless steels up to 900 weld attempts using AC waveform, C-type JPC 75 kVA, Japanese made spot welder. So the electrode alignments and resulting mushrooming effects are finally analysed in this research as well as the weld geometry of dissimilar (carbon and stainless) steels. When considering such weld joints, the heat imbalances are very interesting factors on spot welding research and therefore I have simulated the dissimilar weld joints using Ansys 14. Initially, it was simulated and later those results are compared with real welded samples. The common welded regions such as: fusion zones, heat affected zones, heat extended zones and base metals are all well-noticed for carbon steel sides but not for stainless steel sides. Besides, the electrode mushrooming effect on both sides of electrodes are not parallel deterioration and it has some demerits on internal structure indeed. Some of the dissimilar welded samples and electrode caps are eventually underwent metallurgical test to identify the improper alignment.

  11. INTRODUCTION: Nonequilibrium Processes in Plasmas

    Science.gov (United States)

    Petrović, Zoran; Marić, Dragana; Malović, Gordana

    2009-07-01

    This book aims to give a cross section from a wide range of phenomena that, to different degrees, fall under the heading of non-equilibrium phenomenology. The selection is, of course, biased by the interests of the members of the scientific committee and of the FP6 Project 026328 IPB-CNP Reinforcing Experimental Centre for Non-equilibrium Studies with Application in Nano-technologies, Etching of Integrated Circuits and Environmental Research. Some of the papers included here are texts based on selected lectures presented at the Second International Workshop on Non-equilibrium Processes in Plasmas and Environmental Science. However, this volume is not just the proceedings of that conference as it contains a number of papers from authors that did not attend the conference. The goal was to put together a volume that would cover the interests of the project and support further work. It is published in the Institute of Physics journal Journal of Physics: Conference Series to ensure a wide accessibility of the articles. The texts presented here range from in-depth reviews of the current status and past achievements to progress reports of currently developed experimental devices and recently obtained still unpublished results. All papers have been refereed twice, first when speakers were selected based on their reputation and recently published results, and second after the paper was submitted both by the editorial board and individual assigned referees according to the standards of the conference and of the journal. Nevertheless, we still leave the responsibility (and honours) for the contents of the papers to the authors. The papers in this book are review articles that give a summary of the already published work or present the work in progress that will be published in full at a later date (or both). In the introduction to the first volume, in order to show how far reaching, ubiquitous and important non-equilibrium phenomena are, we claimed that ever since the early

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

    Science.gov (United States)

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

    2000-01-01

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

  13. In-process tool force and rotation variation to control sheet thickness change in friction stir welding of magnesium alloys

    Science.gov (United States)

    Buffa, Gianluca; Fratini, Livan; Simoncini, Michela; Forcellese, Archimede

    2016-10-01

    Two different in-process control strategies, developed in order to produce sound joints in AZ31 magnesium alloy by Friction Stir Welding on sheet blanks with a non-uniform thickness, are presented and compared. To this purpose, sheets with dip or hump were machined and welded by either changing the rotational speed or the tool plunging in order to keep constant the vertical force occurring during welding. The mechanical strength of the joints was measured in the zones where the sheets before welding were characterised by different thicknesses. The sheets welded by the two different strategies are characterized by very similar ultimate tensile strength values. Finally, the results showed that the two approaches permit to successfully weld sheets with non-uniform thickness with a reduced loss in the mechanical strength.

  14. Effect of Process Parameters on Tensile Strength of Friction Stir Welded Cast LM6 Aluminium Alloy Joints

    Institute of Scientific and Technical Information of China (English)

    M. Jayaraman; R.Sivasubramanian; V. Balasubramanian

    2009-01-01

    This paper reports the effect of friction stir welding (FSW) process parameters on tensile strength of cast LM6 aluminium alloy. Joints were made by using different combinations of tool rotation speed, welding speed and axial force each at four levels. The quality of weld zone was investigated using macrostructure and microstructure analysis. Tensile strength of the joints were evaluated and correlated with the weld zone hardness and microstructure. The joint fabricated using a rotational speed of 900 r/min, a welding speed of 75 mm/min and an axial force of 3 kN showed superior tensile strength compared with other joints. The tensile strength and microhardness of the welded joints for the optimum conditions were 166 MPa and 64.8 Hv respectively.

  15. Survey of welding processes for field fabrication of 2 1/4 Cr-1 Mo steel pressure vessels. [128 references

    Energy Technology Data Exchange (ETDEWEB)

    Grotke, G.E.

    1980-04-01

    Any evaluation of fabrication methods for massive pressure vessels must consider several welding processes with potential for heavy-section applications. These include submerged-arc and shielded metal-arc, narrow-joint modifications of inert-gas metal-arc and inert-gas tungsten-arc processes, electroslag, and electron beam. The advantage and disadvantages of each are discussed. Electroslag welding can be dropped from consideration for joining of 2 1/4 Cr-1 Mo steel because welds made with this method do not provide the required mechanical properties in the welded and stress relieved condition. The extension of electron-beam welding to sections as thick as 4 or 8 inches (100 or 200 mm) is too recent a development to permit full evaluation. The manual shielded metal-arc and submerged-arc welding processes have both been employed, often together, for field fabrication of large vessels. They have the historical advantage of successful application but present other disadvantages that make them otherwise less attractive. The manual shielded metal-arc process can be used for all-position welding. It is however, a slow and expensive technique for joining heavy sections, requires large amounts of skilled labor that is in critically short supply, and introduces a high incidence of weld repairs. Automatic submerged-arc welding has been employed in many critical applications and for welding in the flat position is free of most of the criticism that can be leveled at the shielded metal-arc process. Specialized techniques have been developed for horizontal and vertical position welding but, used in this manner, the applications are limited and the cost advantage of the process is lost.

  16. Welding distortion control of automobile engine stator by finite element method

    Institute of Scientific and Technical Information of China (English)

    De-jun YAN; Xue-song LIU; Huan-yu XU; Jian-guo YANG; Hong-yuan FANG; Jing-yang LU

    2009-01-01

    In this paper, a thermal elastic-plastic finite element method (FEM) is used to simulate the plasma welding process in order to predict the welding distortion of automobile stator iron core. Six spatial symmetrical welding torches are adopted in the welding process so as to make the iron core rings welded firmly and the distortion symmetric. The effect of rigid clamp on actual welding process is replaced by the contact function between rigid body and deformation element in the MSC software, MARC. The welding process restrained by clamp and deformation analysis after the removal of clamp was successfully simulated. The predictions show good agree-ment with the test results when the rigid clamps are taken into account in the welding simulation, which satisfies the design requirement for manufacture.

  17. Deposição por plasma com arco transferido Hardfacing by plasma transfer arc process

    Directory of Open Access Journals (Sweden)

    Víctor Vergara Díaz

    2010-03-01

    Full Text Available Em virtude do Processo de Soldagem Plasma com Alimentação de Pó ter similaridades com o Processo de Soldagem Plasma com Alimentação de Arame, foi realizado um estudo comparativo entre ambos os processos utilizando-se a liga a base de cobalto comercialmente conhecida como Stellite 6, como material de adição na forma de pó e arame. A pesquisa foi realizada com a expectativa de ser aplicada nas operações de revestimentos de superfícies, em especial em pás de turbinas hidráulicas desgastadas por cavitação. A seleção do material de adição a ser empregado depende da natureza do mecanismo de desgaste encontrado. No Labsolda, a liga Stellite 6 vem sendo uma das mais utilizadas, por apresentar uma excelente resistência ao desgaste erosivo por cavitação. Foi avaliada a influência da vazão de gás de plasma a partir dos valores de diluição, dimensões do cordão, dureza e microestrutura. O Processo de Soldagem Plasma com Alimentação de Pó foi o que produziu o melhor acabamento superficial, menor diluição, melhor molhamento e maior largura. Com isto abre-se uma nova perspectiva para revestimentos metálicos e neste contexto se insere a recuperação por soldagem de partes erodidas de turbinas hidráulicas.The Plasma powder transferred arc welding process, which uses feed stock in the powder form, has similarities with Plasma wire transferred arc welding. This work describes a comparative study of the two processes using a Cobalt-based alloy commercially known as Stellite 6. This Co-based alloy is recognized for its superior cavitation erosion resistance. The aim of this work is to investigate the potential of PTA coatings for the protection and refurbishiment hydraulic turbine blades. Coatings were evaluated for the influence of Plasma gas flow rate on coating dilution, geometry, hardness and microstructure. Coatings processed with the atomized Stellite 6 powder feestock showed a superior surface quality, lower dilution

  18. Study on the high-precision laser welding technology of nuclear fuel elements processing

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Soo Sung; Yang, M. S.; Kim, W. K.; Lee, D. Y

    2001-01-01

    The proper welding method for appendage of bearing pads and spacers of PHWR nuclear fuel elements is considered important in respect to the soundness of weldments and the improvement of the performance of nuclear fuels during the operation in reactor. The probability of welding defects of the appendage parts is mostly apt to occur and it is connected directly with the safty and life prediction of the nuclear reactor in operation. Recently there has been studied all over the world to develope welding technology by laser in nuclear fuel processing, and the appendage of bearing pads and spacers of PHWR nuclear fuel elements. Therefore, the purpose of this study is to investigate the characteristics of the laser welded specimens and make some samples for the appendage of bearing pads of PHWR nuclear fuel elements. This study will be also provide the basic data for the fabrications of the appendage of bearing pads and spacers. Especially the laser welding is supposed to be used in the practical application such as precise materials manufacturing fields. In this respect this technology is not only a basic advanced technology with wide applications but also likely to be used for the development of directly applicable technologies for industries, with high potential benefits derived in the view point of economy and industry.

  19. The effects of microstructural changes caused by welding on microbiologically influenced corrosion: Material and process implications

    Energy Technology Data Exchange (ETDEWEB)

    Walsh, D.W.; Willis, E.R.; Van Diepen, T. [California Polytechnic State Univ., San Luis Obispo, CA (United States). Materials Engineering Dept.

    1995-10-01

    The microbiologically influenced corrosion (MIC) susceptibility of a material is inextricably linked to its microstructure. The thermomechanical cycle associated with welding produces extensive microstructural change in the vicinity of the weld. This work tested the hypothesis that fabrication procedure would alter MIC susceptibility. This study examined the effect of systematic variation in the amounts of cerium, sulfur and silicon on the corrosion susceptibility of welded AISI 8630 material in aqueous, anaerobic solutions. Samples were exposed to both sterile and biologically solutions. Biologically active solutions were invariably more aggressive. The changes in corrosion susceptibility were correlated to the changes in the microstructure of the weld fusion zone, the partially melted zone (PMZ) and the base material, as affected by minor element content. Significant correlations between total numbers of pits/maximum pit depth and minor element content/location of attack were found in this study. The creation of extensive subgrain boundary coupled with solute redistribution in the fusion zone as well as extensive continuous grain boundary films in the partially melted zone foster MIC in these locations. Mitigation strategies treating material selection and weld process/procedure selection are discussed.

  20. Explosive welding: Principles and potentials

    Energy Technology Data Exchange (ETDEWEB)

    Brasher, D.G.; Butler, D.J. [Northwest Technical Industries, Inc., Sequim, WA (United States)

    1995-03-01

    Explosive welding is a solid-state process in which controlled explosive detonations force two or more metals together at high pressures. The resultant composite system is joined with a high-quality metallurgical bond. Explosive welding (or explosive bonding) is a high-pressure process in which contaminant surface films are plastically jetted off the base metals as a result of the collision of two metals. The time duration involved in the explosive welding event is so short that the reaction zone (or heat affected zone) between the constituent metals is microscopic. During the process, the first few atomic layers of each metal become plasma because of the high velocity of the impact (200 to 500 m/s, 660 to 1,640 ft/s.) The angle of collision causes the plasma to jet in front of the collision point, effectively scrub-cleaning both surfaces, and leaving clean metal behind.

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

    Energy Technology Data Exchange (ETDEWEB)

    Hovanski, Yuri; Carsley, John; Carlson, Blair; Hartfield-Wunsch, Susan; Pilli, Siva Prasad

    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.

  2. Effect of plasma processing reactor circuitry on plasma characteristics

    Energy Technology Data Exchange (ETDEWEB)

    Rauf, S.; Kushner, M.J. [Univ. of Illinois, Urbana, IL (United States). Dept. of Electrical and Computer Engineering

    1997-12-31

    It is well known that external circuitry greatly influences the performance of plasma processing reactors. Simulation of external circuits difficult since the time in which the external circuit attains the steady-state is several orders of magnitude longer than typical plasma simulation time scales. In this paper, the authors present a technique to simulate the external circuit concurrently with the plasma, and implement it into the Hybrid Plasma Equipment Model (HPEM). The resulting model is used to investigate the influence of external circuitry on plasma behavior.

  3. Study on fundamental processes of laser welded metals observed with intense x-ray beams

    Science.gov (United States)

    Muramatsu, T.; Daido, H.; Shobu, T.; Takase, K.; Tsukimori, K.; Kureta, M.; Segawa, M.; Nishimura, A.; Suzuki, Y.; Kawachi, T.

    With use of photon techniques including visible light, soft and hard x-rays, precise fundamental laser welding processes in the repair and maintenance of nuclear plant engineering were reviewed mechanistically. We make discussions centered on the usefulness of an intense soft x-ray beams for evaluations of spatial residual strain distribution and welded metal convection behavior including the surface morphology. Numerical results obtained with a general purpose three-dimensional code SPLICE for the simulation of the welding and solidifying phenomena. Then it is concluded that the x-ray beam would be useful as one of the powerful tools for understanding the mechanisms of various complex phenomena with higher accuracy and higher resolution.

  4. EFFECT OF PROCESS PARAMETERS ON THE TENSILE STRENGTH OF FRICTION STIR WELDED DISSIMILAR ALUMINUM JOINTS

    Directory of Open Access Journals (Sweden)

    R. PADMANABAN

    2015-06-01

    Full Text Available Friction stir welding is one of the recent solid state joining processes that has drawn the attention of the metal joining community. In this work the effects of tool rotation speed (TRS and welding speed (WS on the tensile strength of dissimilar friction stir welded AA2024-AA7075 joints are investigated. Response surface methodology is used for developing a mathematical model for the tensile strength of the dissimilar aluminum alloy joints. The model is used to investigate the effect of TRS and WS on the tensile strength of the joints. It is seen that the tensile strength of the joint increases with the increase in TRS up to a limit of 1050 rpm and decreases thereafter. The tensile strength of the joints is also seen increasing with the WS up to 15 mm/min. Further increase in WS results in a reduction of the tensile strength of the joints.

  5. Experimental Investigations on Formability of Aluminum Tailor Friction Stir Welded Blanks in Deep Drawing Process

    Science.gov (United States)

    Kesharwani, R. K.; Panda, S. K.; Pal, S. K.

    2015-02-01

    In the present work, tailor friction stir welded blanks (TFSWBs) were fabricated successfully using 2.0-mm-thick AA5754-H22 and AA5052-H32 sheet metals with optimized tool design and process parameters. Taguchi L9 orthogonal array has been used to design the friction stir welding experiments, and the Grey relational analysis has been applied for the multi objective optimization in order to maximize the weld strength and total elongation reducing the surface roughness and energy consumption. The formability of the TFSWBs and parent materials was evaluated and compared in terms of limiting drawing ratio (LDR) using a conventional circular die. It was found that the formability of the TFSWBs was comparable with that of both the parent materials without failure in the weldment. A modified conical tractrix die (MCTD) was proposed to enhance the LDR of the TFSWBs. It was found that the formability was improved by 27% using the MCTD.

  6. Atomic and molecular processes in fusion plasmas

    Energy Technology Data Exchange (ETDEWEB)

    Janev, R.K. [International Atomic Energy Agency, Vienna (Austria)

    1997-01-01

    The role of atomic and molecular processes in achieving and maintaining the conditions for thermonuclear burn in a magnetically confined fusion plasma is described. Emphasis is given to the energy balance and power and particle exhaust issues. The most important atomic and molecular processes which affect the radiation losses and impurity transport in the core plasma, the neutral particle transport in the plasma edge and the radiative cooling of divertor plasmas are discussed in greater detail. (author)

  7. Friction Welding For Cladding Applications: Processing, Microstructure and Mechanical Properties of Inertia Friction Welds of Stainless Steel to Low Carbon Steel and Evaluation of Wrought and Welded Austenitic Stainless Steels for Cladding Applications in Acidchloride Service

    Science.gov (United States)

    Switzner, Nathan

    Friction welding, a solid-state joining method, is presented as a novel alternative process step for lining mild steel pipe and forged components internally with a corrosion resistant (CR) metal alloy for petrochemical applications. Currently, fusion welding is commonly used for stainless steel overlay cladding, but this method is costly, time-consuming, and can lead to disbonding in service due to a hard martensite layer that forms at the interface due to partial mixing at the interface between the stainless steel CR metal and the mild steel base. Firstly, the process parameter space was explored for inertia friction butt welding using AISI type 304L stainless steel and AISI 1018 steel to determine the microstructure and mechanical properties effects. A conceptual model for heat flux density versus radial location at the faying surface was developed with consideration for non-uniform pressure distribution due to frictional forces. An existing 1 D analytical model for longitudinal transient temperature distribution was modified for the dissimilar metals case and to account for material lost to the flash. Microstructural results from the experimental dissimilar friction welds of 304L stainless steel to 1018 steel were used to discuss model validity. Secondly, the microstructure and mechanical property implications were considered for replacing the current fusion weld cladding processes with friction welding. The nominal friction weld exhibited a smaller heat softened zone in the 1018 steel than the fusion cladding. As determined by longitudinal tensile tests across the bond line, the nominal friction weld had higher strength, but lower apparent ductility, than the fusion welds due to the geometric requirements for neck formation adjacent to a rigid interface. Martensite was identified at the dissimilar friction weld interface, but the thickness was smaller than that of the fusion welds, and the morphology was discontinuous due to formation by a mechanism of solid

  8. Numerical simulation method for weld line development in micro injection molding process

    Institute of Scientific and Technical Information of China (English)

    XIE Lei; ZIEGMANN Gerhard; JIANG Bing-yan

    2009-01-01

    In order to reduce the "trial-mold" risk and cost, numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm (depth)×0.4 mm (width)× 12 mm(length) in test area was selected as the objective part, and polypropylene (PP) as the experimental material. Respectively with specific commercial software (Mold Flow~(R)) and general computational fluid dynamic (CFD) software (Comsol ~(R)Multiphysics), the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process, the specific commercial software for normal injection molding process is not valid to describe the micro flow process, the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle clue to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development, the general CFD software, which is more flexible in user defining function, is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion, as for weld line forming process, the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process; but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.

  9. Mathematical Modeling of Metal Active Gas (MAG) Arc Welding

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    In the present paper, a numerical model for MAG (metal active gas) arc welding of thin plate has been developed. In MAG arc welding, the electrode wire is melted and supplied into the molten pool intermittently. Accordingly, it is assumed on the modeling that the thermal energy enters the base-plates through two following mechanisms, i.e., direct heating from arc plasma and “indirect” heating from the deposited metal. In the second part of the paper, MAG arc welding process is numerically analyzed by using the model, and the calculated weld bead dimension and surface profile have been compared with the experimental MAG welds on steel plate. As the result, it is made clear that the model is capable of predicting the bead profile of thin-plate MAG arc welding , including weld bead with undercutting.

  10. A study of process induced voids in resistance welding of thermoplastic composites

    NARCIS (Netherlands)

    Shi, H.; Fernandez Villegas, I.; Bersee, H.E.N.

    2015-01-01

    Void formation in resistance welding of woven fabric reinforced thermoplastic composites was investigated. Void contents were measured using optical microscopy and digital image process. Un-even void distributions were observed in the joints, and more voids were found in the middle of the joints tha

  11. Experimental comparison of the MIG, friction stir welding, cold metal transfer and hybrid laser-MIG processes for AA 6005-T6 aluminium alloy

    Science.gov (United States)

    Caruso, Serafino; Sgambitterra, Emanuele; Rinaldi, Sergio; Gallone, Antonello; Viscido, Lucio; Filice, Luigino; Umbrello, Domenico

    2016-10-01

    In this study, the mechanical properties of welded joints of AA 6005-T6 aluminum alloy obtained with hybrid laser-MIG and cold metal transfer (CMT) welding were analyzed. The performance of hybrid laser-MIG and CMT welded joints were identified using tensile, bending, shear and fatigue life tests. Taking into account the process conditions and requirements, hybrid laser-MIG and CMT welding processes were compared with friction stir welding (FSW) and conventional metal inert gas (MIG) welding processes, shown in a previous work, to understand the advantages and disadvantages of the processes for welding applications of studied Al alloy. Better tensile, bending and shear strength and fatigue life behavior were obtained with hybrid laser-MIG and FSW welded joints compared with conventional MIG processes.

  12. Qualification Of Kapton Pretreatment Process Using 3M Scotch Weld 2216 For Solar Panel Application

    Science.gov (United States)

    Swamy, B. R.; Krishna, Priya G.; Venkatesh, K.; Nagendra, H. R.; Nanjundaswamy, T. S.

    2011-10-01

    Substrates for solar arrays intended to be used on satellite systems are generally made of aluminum honeycomb structure sandwiched with Carbon Fiber Reinforced Plastic (CFRP) face skin. Two mil thick KaptonTM sheets are co cured on one side of the aluminum /CFRP composite structure while realizing the substrate panels. This Kapton sheet would serve as an insulator over which solar cell blankets are bonded with suitable adhesive for the satellite solar panels. The satellite solar panels demands highest degree of quality and reliability and one of the prime factors in this regards is the bond strength of adhesive which is used to bond the solar cell blankets. Various methods of pretreatments of Kapton surface are in use for increasing the surface energy, which in turn results in improved bond strengths. These methods generally provide roughened surface of the Kapton which is achieved either by abrasive means like scrubbing the surface using fine silica chip, or plasma etching or alternatively by an additive process wherein suitable polyester, phenolic or other resins are coated on to the Kapton surface to achieve the desired results. For spacecraft solar panel applications at ISRO, polyester resin coating on to the Kapton surface was used as pretreatment prior to adhesive application. This process had provided adequate bond strengths between the solar cells and Kapton. Due to issues related to the supply of the polyester resin material from the vendor alternative methods of pretreatments were explored. In this paper, a novel process developed for Kapton pretreatment is described along with results of relevant qualifications for the satellite solar panel application. This newly developed pretreatment process for Kapton successfully adopts an epoxy based material 3M Scotch weld 2216 which is widely used in spacecraft electronic hardware.

  13. Optimization of Process Parameters of Hybrid Laser-Arc Welding onto 316L Using Ensemble of Metamodels

    Science.gov (United States)

    Zhou, Qi; Jiang, Ping; Shao, Xinyu; Gao, Zhongmei; Cao, Longchao; Yue, Chen; Li, Xiongbin

    2016-08-01

    Hybrid laser-arc welding (LAW) provides an effective way to overcome problems commonly encountered during either laser or arc welding such as brittle phase formation, cracking, and porosity. The process parameters of LAW have significant effects on the bead profile and hence the quality of joint. This paper proposes an optimization methodology by combining non-dominated sorting genetic algorithm (NSGA-II) and ensemble of metamodels (EMs) to address multi-objective process parameter optimization in LAW onto 316L. Firstly, Taguchi experimental design is adopted to generate the experimental samples. Secondly, the relationships between process parameters ( i.e., laser power ( P), welding current ( A), distance between laser and arc ( D), and welding speed ( V)) and the bead geometries are fitted using EMs. The comparative results show that the EMs can take advantage of the prediction ability of each stand-alone metamodel and thus decrease the risk of adopting inappropriate metamodels. Then, the NSGA-II is used to facilitate design space exploration. Besides, the main effects and contribution rates of process parameters on bead profile are analyzed. Eventually, the verification experiments of the obtained optima are carried out and compared with the un-optimized weld seam for bead geometries, weld appearances, and welding defects. Results illustrate that the proposed hybrid approach exhibits great capability of improving welding quality in LAW.

  14. Influence of the Surface Layer when the CMT Process Is Used for Welding Steel Sheets Treated by Nitrooxidation

    Directory of Open Access Journals (Sweden)

    I. Michalec

    2012-01-01

    Full Text Available Nitrooxidation is a non-conventional surface treatment method that can provide significantly improved mechanical properties as well as corrosion resistance. However, the surface layer is a major problem during the welding process, and welding specialists face many problems regarding the weldability of steel sheets. This paper deals with the properties of a nitrooxidized surface layer, and evaluates ways of welding steel sheets treated by nitrooxidation using a Cold Metal Transfer (CMT process. The limited heat input and the controlled metal transfer, which are considered as the main advantage of the CMT process, have a negative impact on weld joint quality. An excessive amount of porosity is observed,probably due to the high content of nitrogen and oxygen in the surface layer of the material and the fast cooling rate of the weld pool.

  15. Effect of Ti-Al on microstructures and mechanical properties of plasma arc in-situ welded joint of SiCp/Al MMCs

    Institute of Scientific and Technical Information of China (English)

    LEI Yu-cheng; ZHANG Zhen; NIE Jia-jun; CHEN Xi-zhang

    2008-01-01

    The effect of Ti-Al on microstructures and mechanical properties of SiCp/Al MMC joints produced by plasma arc in-situ weld-alloying was investigated, in which argon-nitrogen mixture was used as plasma gases and Ti-Al alloy as filling composite. The results show that the formation of needle-like harmful phase Al4C3 is effectively prevented in the weld by in-situ weld-alloying/plasma arc welding with Ti-Al alloy sheet filler whose titanium content is more than 20%. The fluidity of molten pool is improved, and stable molten pool is gained for the addition of the Ti-Al alloy. The mechanical properties of welded joint are effectively enhanced by the compact-grain structure and the new reinforced composites such as Al3Ti, TiN, AlN and TiC welded joint. The test results of mechanical property show that the maximum tensile strength of welded joint gained by adding Ti-60Al alloy is up to 235 MPa. The factors influencing the tensile strength were also investigated.

  16. Thermal Stir Welding Development at Marshall Space Flight Center

    Science.gov (United States)

    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.

  17. Repair welding of cast iron coated electrodes

    Science.gov (United States)

    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.

  18. Alternating-Polarity Arc Welding

    Science.gov (United States)

    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.

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

    Directory of Open Access Journals (Sweden)

    Eber Huanca Cayo

    2012-05-01

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

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

    Science.gov (United States)

    Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

    2012-01-01

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

  1. A Study on the Effect of Different Activating Flux on A-TIG Welding Process of Incoloy 800H

    Directory of Open Access Journals (Sweden)

    Sridhar S.P.

    2016-09-01

    Full Text Available This study investigates the effect of different activating flux such as V2O5, TiO2, MoO3, Cr2O3, and Al2O3 on A-TIG welding process of Incoloy 800H. The influence of the flux on the depth of penetration and on mechanical and metallurgical characteristics of the weld were studied and compared with autogeneous TIG welds which were welded with the same process parameters and conditions. The use of TiO2 flux gave full depth of penetration and the use of V2O5, Cr2O3 flux gave increased penetration as compared to autogeneous TIG welds while the use of Al2O3 and MoO3 led to the detoriation of the effect.

  2. Effect of Welding Processes and Consumables on Tensile and Impact Properties of High Strength Quenched and Tempered Steel Joints

    Institute of Scientific and Technical Information of China (English)

    G Magudeeswaran; V Balasubramanian; G Madhusudhan Reddy; T S Balasubramanian

    2008-01-01

    Quenched and tempered steels are prone to hydrogen induced cracking in the heat affected gone after welding.The use of austenitic stainless steel consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase.In this investigation,an attempt was made to determine a suitable consumable to replace expensive austenitic consumables.Two different consumables,namely,austenitic stainless steel and lOW hydrogen ferritic steel,were used to fabricate the joints by shielded metal arc welding(SMAW)and flux cored arc welding(FCAW)processes.The joints fabricated by using low hydrogen ferritic steel consumables showed superior transverse tensile properties,whereas joints fabricated by using austenitic stainless steel consumables exhibited better impact toughness,irrespective of the welding process used.The SMAW joints exhibited superior mechanical and impact properties,irrespective of the consumables used,than their FCAW counterparts.

  3. Review of laser hybrid welding

    DEFF Research Database (Denmark)

    Bagger, Claus

    2004-01-01

    In this artucle an overview og the hybrid welding process is given. After a short historic overview, a review of the fundamental phenomenon taking place when a laser (CO2 or Nd:YAG) interacts in the same molten pool as a more conventional source of energy, e.g. tungsten in-active gas, plasma...

  4. Review of laser hybrid welding

    DEFF Research Database (Denmark)

    Bagger, Claus

    2004-01-01

    In this artucle an overview og the hybrid welding process is given. After a short historic overview, a review of the fundamental phenomenon taking place when a laser (CO2 or Nd:YAG) interacts in the same molten pool as a more conventional source of energy, e.g. tungsten in-active gas, plasma...

  5. Testing of New Materials and Computer Aided Optimization of Process Parameters and Clamping Device During Predevelopment of Laser Welding Processes

    Science.gov (United States)

    Weidinger, Peter; Günther, Kay; Fitzel, Martin; Logvinov, Ruslan; Ilin, Alexander; Ploshikhin, Vasily; Hugger, Florian; Mann, Vincent; Roth, Stephan; Schmidt, Michael

    The necessity for weight reduction in motor vehicles in order to save fuel consumption pushes automotive suppliers to use materials of higher strength. Due to their excellent crash behavior high strength steels are increasingly applied in various structures. In this paper some predevelopment steps for a material change from a micro alloyed to dual phase and complex phase steels of a T-joint assembly are displayed. Initially the general weldability of the materials regarding pore formation, hardening in the heat affected zone and hot cracking susceptibility is discussed. After this basic investigation, the computer aided design optimization of a clamping device is shown, in which influences of the clamping jaw, the welding position and the clamping forces upon weld quality are presented. Finally experimental results of the welding process are displayed, which validate the numerical simulation.

  6. Neural network modeling for weld shape process of P-GMAW

    Institute of Scientific and Technical Information of China (English)

    Yan Zhihong; Wu Lin; Zhang Guangjun; Gao Hongming

    2007-01-01

    Weld shape control is a fundamental issue in automatic welding. In this paper, a double side visual system is established for pulsed gas metal arc welding (P-GMAW), and both topside and backside weld pool images can be captured and stored continuously in real time. By analyzing the weld shape regulation with the molten metal volume, some topside weld pool characterized parameters (WPCPs) are proposed for determining penetration in butt welding of thin mild steel. Moreover, some BP network models are established to predict backside weld pool width with welding parameters and WPCPs as inputs.

  7. Characterization of airborne particles generated from metal active gas welding process.

    Science.gov (United States)

    Guerreiro, C; Gomes, J F; Carvalho, P; Santos, T J G; Miranda, R M; Albuquerque, P

    2014-05-01

    This study is focused on the characterization of particles emitted in the metal active gas welding of carbon steel using mixture of Ar + CO2, and intends to analyze which are the main process parameters that influence the emission itself. It was found that the amount of emitted particles (measured by particle number and alveolar deposited surface area) are clearly dependent on the distance to the welding front and also on the main welding parameters, namely the current intensity and heat input in the welding process. The emission of airborne fine particles seems to increase with the current intensity as fume-formation rate does. When comparing the tested gas mixtures, higher emissions are observed for more oxidant mixtures, that is, mixtures with higher CO2 content, which result in higher arc stability. These mixtures originate higher concentrations of fine particles (as measured by number of particles by cm(3) of air) and higher values of alveolar deposited surface area of particles, thus resulting in a more severe worker's exposure.

  8. Dissimilar steel welding and overlay covering with nickel based alloys using SWAM (Shielded Metal Arc Welding) and GTAW (Gas Tungsten Arc Welding) processes in the nuclear industry

    Energy Technology Data Exchange (ETDEWEB)

    Arce Chilque, Angel Rafael [Centro Tecnico de Engenharia e Inovacao Empresarial Ltda., Belo Horizonte, MG (Brazil); Bracarense, Alexander Queiroz; Lima, Luciana Iglesias Lourenco [Federal University of Minas Gerais (UFMG), Belo Horizonte, MG (Brazil); Quinan, Marco Antonio Dutra; Schvartzman, Monica Maria de Abreu Mendonca [Nuclear Technology Development Centre (CDTN/CNEN-MG), Belo Horizonte, MG (Brazil); Marconi, Guilherme [Federal Center of Technological Education (CEFET-MG), Belo Horizonte, MG (Brazil)

    2009-07-01

    This work presents the welding of dissimilar ferritic steel type A508 class 3 and austenitic stainless steel type AISI 316 L using Inconel{sup R} 600 (A182 and A82) and overlay covering with Inconel{sup R} 690 (A52) as filler metal. Dissimilar welds with these materials without defects and weldability problems such as hot, cold, reheat cracking and Ductility Dip Crack were obtained. Comparables mechanical properties to those of the base metal were found and signalized the efficiency of the welding procedure and thermal treatment selected and used. This study evidences the importance of meeting compromised properties between heat affected zone of the ferritic steel and the others regions presents in the dissimilar joint, to elaborate the dissimilar metal welding procedure specification and weld overlay. Metallographic studies with optical microscopy and Vickers microhardness were carried out to justified and support the results, showing the efficiency of the technique of elaboration of dissimilar metal welding procedure and overlay. The results are comparables and coherent with the results found by others. Some alternatives of welding procedures are proposed to attain the efficacy. Further studies are proposed like as metallographic studies of the fine microstructure, making use, for example, of scanning electron microscope (SEM adapted with an EDS) to explain looking to increase the resistance to primary water stress corrosion (PWSCC) in nuclear equipment. (author)

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

    Science.gov (United States)

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

    2017-03-01

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

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

    Science.gov (United States)

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

    2017-02-01

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

  11. Plasma chemistry study of PLAD processes

    Energy Technology Data Exchange (ETDEWEB)

    Qin Shu; Brumfield, Kyle; Liu, Lequn Jennifer; Hu, Yongjun Jeff; McTeer, Allen; Hsu, Wei Hui; Wang Maoying [Nanya Technology Inc., Santa Clara, CA 95054 (United States); Micron Technology Inc., Boise, ID 83707 (United States)

    2012-11-06

    Plasma doping (PLAD) shows very different impurity profiles compared to the conventional beam-line-based ion implantations due to its non-mass separation property and plasma environment. There is no simulation for PLAD process so far due to a lack of a dopant profile model. Several factors determine impurity profiles of PLAD process. The most significant factors are: plasma chemistry and deposition/etching characteristics of multi-ion species plasmas. In this paper, we present plasma chemistry and deposition/etching characteristics of PLAD processes versus co-gas dilutions. Four dopant plasmas including B{sub 2}H{sub 6}, BF{sub 3}, AsH{sub 3}, and PH{sub 3}, and two non-dopant plasmas including CH{sub 4} and GeH{sub 4} are studied and demonstrated.

  12. Nova tocha de plasma híbrida para o processamento de materiais New hybrid plasma torch for materials processing

    Directory of Open Access Journals (Sweden)

    Richard Thomas Lermen

    2012-12-01

    Full Text Available O principal objetivo deste artigo foi apresentar um novo dispositivo para o processamento de materiais. Ele consiste em uma tocha de plasma híbrida, a qual é caracterizada pela formação simultânea de dois arcos plasma em apenas um dispositivo, gerando jato (de plasma com elevada densidade de energia. A tocha foi submetida aos seguintes testes experimentais: de funcionamento para verificar possíveis problemas de projeto e seus limites de operação; de caracterização, consistindo em determinar o comprimento do jato de plasma; de sua viabilidade para processamento de materiais (soldagem e corte. Com base nestes testes iniciais, alguns problemas de isolamento elétrico e térmico foram encontrados e resolvidos. Quanto aos resultados dos testes de caracterização, os parâmetros de funcionamento da tocha de plasma híbrida apresentaram influência significativa sobre o comprimento do jato de plasma. Os resultados obtidos nos testes de processamento de materiais foram satisfatórios, ou seja, é possível realizar soldagem e corte com esta tocha de plasma híbrida.The main aim of this paper was to present a new device for materials processing. It consist of a hybrid plasma torch which is characterized by the simultaneous formation of two plasma arcs in one device only, generating a (plasma jet with high energy density. The torch was submitted to the following trials: of operation to identify possible design problems and its operational torch limits; of characterization, consisting in plasma jet length determination; and of viability for materials processing (welding and cutting. Based on these initial trials, some electrical and thermal insulation problems were found and solved. Concerning the results of the characterization trials, the hybrid plasma torch parameters had a significant influence over the plasma jet length. The results obtained in the materials processing trials were satisfactory, i.e., it is possible to carry out welding and

  13. Comparison of deposited surface area of airborne ultrafine particles generated from two welding processes.

    Science.gov (United States)

    Gomes, J F; Albuquerque, P C; Miranda, Rosa M; Santos, Telmo G; Vieira, M T

    2012-09-01

    This article describes work performed on the assessment of the levels of airborne ultrafine particles emitted in two welding processes metal-active gas (MAG) of carbon steel and friction-stir welding (FSW) of aluminium in terms of deposited area in alveolar tract of the lung using a nanoparticle surface area monitor analyser. The obtained results showed the dependence from process parameters on emitted ultrafine particles and clearly demonstrated the presence of ultrafine particles, when compared with background levels. The obtained results showed that the process that results on the lower levels of alveolar-deposited surface area is FSW, unlike MAG. Nevertheless, all the tested processes resulted in important doses of ultrafine particles that are to be deposited in the human lung of exposed workers.

  14. Research on Welding Processes of Armor Steels%装甲钢焊接技术研究进展

    Institute of Scientific and Technical Information of China (English)

    谭俊; 张勇

    2013-01-01

    装甲钢是一种用于作战装备的保护性合金材料,装甲钢的焊接是装甲钢结构的主要连接方式.从装甲钢的裂纹类别、特点以及其形成原因出发,介绍了装甲钢焊接材料、焊接工艺和提高焊接接头性能的措施.主要包括奥氏体焊条、铁素体焊条及奥氏体/铁素体双向焊条;电弧焊、CO2气体保护焊、熔化极气体保护焊、修复装甲钢裂纹的铝热焊、机器人焊,激光焊等焊接工艺;焊后热处理、超声波冲击法、焊趾砂轮打磨法与钨极电弧焊法.并在装甲钢焊接技术研究现状分析的基础上,提出装甲钢焊接技术今后的改进措施与发展方向.%The armor steel is a kind of protective alloy material which is used in a variety of combat equipment. The welding is a main joining method of armor steel structure. On the base of crack category, characteristics and formation causes of armor steel, the welding materials and welding processes of armor steel, and the measures taken to improve the properties of welded joint were introduced. Those include austenite welding electrode, ferrite and austenite/ferrite dual phase welding electrodes, the processes of arc welding, CO2 gas protection welding and thermit welding of armor steel crack repairing, and the measures taken to improve the properties of the welded joint of heat treatment after welding, ultrasonic impact, toe grinding and tungsten arc welding. The improving measures and development direction of armor steel welding were put forward by analyzing the armor steel welding processes.

  15. Investigation in the use of plasma arc welding and alternative feedstock delivery method in additive manufacture

    Science.gov (United States)

    Alhuzaim, Abdullah F.

    The work conducted for this thesis was to investigate the use of plasma arc welding (PAW) and steel shot as a means of additive manufacturing. A robotic PAW system and automatic shot feeder were used to manufacture linear walls approximately 100 mm long by 7 mm wide and 20 mm tall. The walls were built, layer-by-layer, on plain carbon steel substrate by adding individual 2.5 mm diameter plain carbon steel shot. Each layer was built, shot-by-shot, using a pulse of arc current to form a molten pool on the deposit into which each shot was deposited and melted. The deposition rate, a measure of productivity, was approximately 50 g/hour. Three walls were built using the same conditions except for the deposit preheat temperature prior to adding each new layer. The deposit preheat temperature was controlled by allowing the deposit to cool after each layer for an amount of time called the inter-layer wait time. The walls were sectioned and grain size and hardness distribution were measured as a function of wall height. The results indicated that, for all specimens, deposit grain size increased and hardness decreased as wall height increased. Furthermore, average grain size decreased and hardness increased as interlayer wait time increased. An analytical heat flow model was developed to study the influence of interlayer wait time on deposit temperature and therefore grain size and hardness. The results of the model indicated that as wall height increased, the rate of deposit heat removal by conduction to the substrate decreased leading to a higher preheat temperature after a fixed interlayer wait time causing grain size to increase as wall height increased. However, the model results also show that as wall height increased, the deposit surface area from which heat energy is lost via convection and radiation increased. The model also demonstrated that the use of a means of forced convection to rapidly remove heat from the deposit could be an effective way to boost

  16. Atmospheric Pressure Plasma Process And Applications

    Energy Technology Data Exchange (ETDEWEB)

    Peter C. Kong; Myrtle

    2006-09-01

    This paper provides a general discussion of atmospheric-pressure plasma generation, processes, and applications. There are two distinct categories of atmospheric-pressure plasmas: thermal and nonthermal. Thermal atmospheric-pressure plasmas include those produced in high intensity arcs, plasma torches, or in high intensity, high frequency discharges. Although nonthermal plasmas are at room temperatures, they are extremely effective in producing activated species, e.g., free radicals and excited state atoms. Thus, both thermal and nonthermal atmosphericpressure plasmas are finding applications in a wide variety of industrial processes, e.g. waste destruction, material recovery, extractive metallurgy, powder synthesis, and energy conversion. A brief discussion of recent plasma technology research and development activities at the Idaho National Laboratory is included.

  17. Innovative Tools Advance Revolutionary Weld Technique

    Science.gov (United States)

    2009-01-01

    The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe

  18. Multi-response optimization of process parameters for TIG welding of Incoloy 800HT by Taguchi grey relational analysis

    Directory of Open Access Journals (Sweden)

    Arun Kumar Srirangan

    2016-06-01

    Full Text Available Incoloy 800HT which was selected as one of the prominent material for fourth generation power plant can exhibit appreciable strength, good resistance to corrosion and oxidation in high temperature environment. This study focuses on the multi-objective optimization using grey relational analysis for Incoloy 800HT welded with tungsten inert arc welding process with N82 filler wire of diameter 1.2 mm. The welding input parameters play a vital role in determining desired weld quality. The experiments were conducted according to L9 orthogonal array. The input parameter chosen were the welding current, Voltage and welding speed. The output response for quality targets chosen were the ultimate tensile strength and yield strength (at room temperature, 750 °C and impact toughness. Grey relational analysis was applied to optimize the input parameters simultaneously considering multiple output variables. The optimal parameters combination was determined as A2B1C2 i.e. welding current at 110 A, voltage at 10 V and welding speed at 1.5 mm/s. ANOVA method was used to assess the significance of factors on the overall quality of the weldment. The output of the mechanical properties for best and least grey relational grade was validated by the metallurgical characteristics:

  19. Parametric Optimization Of Gas Metal Arc Welding Process By Using Grey Based Taguchi Method On Aisi 409 Ferritic Stainless Steel

    Science.gov (United States)

    Ghosh, Nabendu; Kumar, Pradip; Nandi, Goutam

    2016-10-01

    Welding input process parameters play a very significant role in determining the quality of the welded joint. Only by properly controlling every element of the process can product quality be controlled. For better quality of MIG welding of Ferritic stainless steel AISI 409, precise control of process parameters, parametric optimization of the process parameters, prediction and control of the desired responses (quality indices) etc., continued and elaborate experiments, analysis and modeling are needed. A data of knowledge - base may thus be generated which may be utilized by the practicing engineers and technicians to produce good quality weld more precisely, reliably and predictively. In the present work, X-ray radiographic test has been conducted in order to detect surface and sub-surface defects of weld specimens made of Ferritic stainless steel. The quality of the weld has been evaluated in terms of yield strength, ultimate tensile strength and percentage of elongation of the welded specimens. The observed data have been interpreted, discussed and analyzed by considering ultimate tensile strength ,yield strength and percentage elongation combined with use of Grey-Taguchi methodology.

  20. Multi-response optimization of process parameters in friction stir welded AM20 magnesium alloy by Taguchi grey relational analysis

    Directory of Open Access Journals (Sweden)

    Prakash Kumar Sahu

    2015-03-01

    Full Text Available The purpose of this paper is to optimize the process parameter to get the better mechanical properties of friction stir welded AM20 magnesium alloy using Taguchi Grey relational analysis (GRA. The considered process parameters are welding speed, tool rotation speed, shoulder diameter and plunging depth. The experiments were carried out by using Taguchi's L18 factorial design of experiment. The processes parameters were optimized and ranked the parameters based on the GRA. The percentage influence of each process parameter on the weld quality was also quantified. A validation experimental run was conducted using optimal process condition, which was obtained from the analysis, to show the improvement in mechanical properties of the joint. This study also shows the feasibility of the GRA with Taguchi technique for improvement in welding quality of magnesium alloy.

  1. Mechanical properties of API X80 steel pipe joints welded by Flux Core Arc Weld Process; Propriedades mecanicas de juntas de tubos de aco API X80 soldadas com arame tubulares

    Energy Technology Data Exchange (ETDEWEB)

    Ordonez, Robert E. Cooper; Silva, Jose Hilton F.; Trevisan, Roseana E. [Universidade Estadual de Campinas, SP (Brazil). Faculdade de Engenharia Mecanica. Dept. de Engenharia de Fabricacao

    2003-07-01

    Flux Core Arc Welding processes (FCAW) are beginning to be applied in pipeline welds, however, very limited experimental data regarding mechanical properties of pipeline weld joints with these processes are available in the literature. In this paper, the effects of preheat temperature and type of FCAW on mechanical properties (microhardness and tensile strength) of API X80 weld joint steel are presented. FCAW processes with gas protection and self-shielded were used. Multipasses welding were applied in 30'' diameter and 0,625'' thickness tubes. Influence factors were: FCAW type and preheat temperature. Acceptance criteria of welded joints were evaluated by API 1104 standard for tensile strength test and ASTM E384-99 for microhardness test. The results obtained showed that FCAW type and preheat temperature have no influence on mechanical properties of API X80 joint steel. (author)

  2. Cold plasma processing to improve food safety

    Science.gov (United States)

    Cold plasma is an antimicrobial process being developed for application as a food processing technology. This novel intervention is the subject of an expanding research effort by groups around the world. A variety of devices can be used to generate cold plasma and apply it to the food commodity bein...

  3. Utlrasonic welding of thermoplastic composites with flat energy directors: Influence of the thickness of the energy director on the welding process

    NARCIS (Netherlands)

    Palardy, G.; Fernandez Villegas, I.

    2015-01-01

    This paper presents a detailed experimental examination of the influence of the thickness of flat energy directors (ED) on the ultrasonic welding (USW) process for carbon fibre/polyetherimide composites. Three thicknesses of flat ED were compared: 0.06 mm, 0.25 mm and 0.50 mm. Power and displacement

  4. Ultrasonic welding of thermoplastic composites with flat energy directors: Influence of the thickness of the energy director on the welding process

    NARCIS (Netherlands)

    Palardy, G.; Fernandez Villegas, I.

    2015-01-01

    This paper presents a detailed experimental examination of the influence of the thickness of flat energy directors (ED) on the ultrasonic welding (USW) process for carbon fibre/polyetherimide composites. Three thicknesses of flat ED were compared: 0.06 mm, 0.25 mm and 0.50 mm. Power and displacement

  5. Spectral analysis of the process emission during laser welding of AISI 304 stainless steel with disk and Nd:YAG laser

    NARCIS (Netherlands)

    Konuk, A.R.; Aarts, R.G.K.M.; Huis in 't Veld, A.J.

    2009-01-01

    Optical emissions from the laser welding process can be obtained relatively easy in real-time. Such emissions come from the melt pool, keyhole, or plume during welding. Therefore it is very beneficial to establish a clear relation between characteristics of these emissions and the resulting weld qua

  6. Spectral analysis of the process emission during laser welding of AISI 304 stainless steel with disk and Nd:YAG laser

    NARCIS (Netherlands)

    Konuk, A.R.; Aarts, R.G.K.M.; Huis in 't Veld, A.J.

    2009-01-01

    Optical emissions from the laser welding process can be obtained relatively easy in real-time. Such emissions come from the melt pool, keyhole, or plume during welding. Therefore it is very beneficial to establish a clear relation between characteristics of these emissions and the resulting weld

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

    Science.gov (United States)

    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

  8. Toward Improving the Type IV Cracking Resistance in Cr-Mo Steel Weld Through Thermo-Mechanical Processing

    Science.gov (United States)

    Shassere, Benjamin A.; Yamamoto, Yukinori; Babu, Sudarsanam Suresh

    2016-05-01

    Detailed microstructure characterization of Grade 91 (Modified 9Cr-1Mo, ASTM A387) steel subjected to a thermo-mechanical treatment process was performed to rationalize the cross-weld creep properties. A series of thermo-mechanical processing in the austenite phase region, followed by isothermal aging at temperatures at 973 K to 1173 K (700 °C to 900 °C), was applied to the Grade 91 steel to promote precipitation kinetics of MX (M: Nb and V, X: C and N) in the austenite matrix. Detailed characterization of the base metals after standard tempering confirmed the presence of fine MX dispersion within the tempered martensitic microstructure in steels processed at/and above 1073 K (800 °C). Relatively low volume fraction of M23C6 precipitates was observed after processing at 1073 K (800 °C). The cross-weld creep strength after processing was increased with respect to the increase of MX dispersion, indicating that these MX precipitates maintained during weld thermal cycles in the fine-grained heat-affected zone region and thereby contribute to improved creep resistant of welds in comparison to the welds made with the standard "normalization and tempering" processes. The steels processed in this specific processing condition showed improved cross-weld creep resistance and sufficient room temperature toughness. The above data are also analyzed based on existing theories of creep deformation based on dislocation climb mechanism.

  9. Considerations of metal joining processes for space fabrication, construction and repair

    Science.gov (United States)

    Russell, C.; Poorman, R.; Jones, C.; Nunes, A.; Hoffman, D.

    A comprehensive evaluation is conducted of candidate processes for metalworking in orbital (vacuum-microgravity) conditions. Attention is given to electron-beam welding, brazing, gas-tungsten arc welding, laser welding, plasma arc welding, and gas-metal arc welding. It is established that several of these processes will be required to cover all foreseeable requirements. Microgravity effects are considered minor, and efforts are being concentrated on problems associated with vacuum conditions and with process-operator safety.

  10. Experimental and Simulation Studies on Cold Welding Sealing Process of Heat Pipes

    Science.gov (United States)

    Li, Yong; Chen, Shengle; Huang, Jinlong; Yan, Yuying; Zeng, Zhixin

    2017-03-01

    Sealing quality strongly affects heat pipe performance, but few studies focus on the process of heat pipe sealing. Cold welding sealing technology based on a stamping process is applied for heat pipe sealing. The bonding mechanism of the cold welding sealing process (CWSP) is investigated and compared with the experimental results obtained from the bonding interface analysis. An orthogonal experiment is conducted to observe the effects of various parameters, including the sealing gap, sealing length, sealing diameter, and sealing velocity on bonding strength. A method with the utilization of saturated vapor pressure inside a copper tube is proposed to evaluate bonding strength. A corresponding finite element model is developed to investigate the effects of sealing gap and sealing velocity on plastic deformation during the cold welding process. Effects of various parameters on the bonding strength are determined and it is found that the sealing gap is the most critical factor and that the sealing velocity contributes the least effect. The best parameter combination (A 1 B 3 C 1 D 3, with a 0.5 mm sealing gap, 6 mm sealing length, 3.8 mm sealing diameter, and 50 mm/s sealing velocity) is derived within the experimental parameters. Plastic deformation results derived from the finite element model are consistent with those from the experiment. The instruction for the CWSP of heat pipes and the design of sealing dies of heat pipes are provided.

  11. Effect of Welding Processes on Tensile and Impact Properties, Hardness and Microstructure of AISI 409M Ferritic Stainless Joints Fabricated by Duplex Stainless Steel Filler Metal

    Institute of Scientific and Technical Information of China (English)

    A K Lakshminarayanan; K Shanmugam; V Balasubramanian

    2009-01-01

    The effect of welding processes such as shielded metal arc welding, gas metal arc welding and gas tungsten arc welding on tensile and impact properties of the ferritic stainless steel conforming to AISI 409M grade is studied. Rolled plates of 4 mm thickness were used as the base material for preparing single pass butt welded joints. Tensile and impact properties, microhardness, microstructure and fracture surface morphology of the welded joints have been evaluated and the results are compared. From this investigatio.n, it is found that gas tungsten arc welded joints of ferritic stainless steel have superior tensile and impact properties compared with shielded metal are and gas metal arc welded joints and this is mainly due to the presence of finer grains in fusion zone and heat affected zone.

  12. Microheterogeneous Structure of Local Melted Zones in the Process of Explosive Welding

    Science.gov (United States)

    Greenberg, Bella A.; Ivanov, Mikhail A.; Inozemtsev, Alexei V.; Patselov, Alexander M.; Pushkin, Mark S.; Vlasova, Alisa M.

    2015-08-01

    The dispersed structures formed in the process of explosive welding and solidification after melting were investigated in areas near the interface. It was shown that melting can be initiated by particles flying away as a result of granulating fragmentation. This is the fastest process during explosive welding, which is similar to fragmentation in conventional explosions with the formation of fragments but occurring in the presence of a barrier. The reaction between the particles and their environment may lead to local heating sufficient for melting. This is confirmed by the observation of numerous particles of the refractory phase within the local melted zones. In the absence of mutual solubility of the initial phases, the solidified local melted zones are to a certain extent analogous to colloidal solutions of immiscible liquids. Correlations between the typical temperatures were obtained that determine the conditions for the formation of various types of colloidal solutions.

  13. Modeling of Thermo-Electro-Mechanical Manufacturing Processes Applications in Metal Forming and Resistance Welding

    CERN Document Server

    Nielsen, C V; Alves, L M; Bay, N; Martins, P A F

    2013-01-01

    Modeling of Thermo-Electro-Mechanical Manufacturing Processes with Applications in Metal Forming and Resistance Welding provides readers with a basic understanding of the fundamental ingredients in plasticity, heat transfer and electricity that are necessary to develop and proper utilize computer programs based on the finite element flow formulation.   Computer implementation of a wide range of theoretical and numerical subjects related to mesh generation, contact algorithms, elasticity, anisotropic constitutive equations, solution procedures and parallelization of equation solvers is comprehensively described.   Illustrated and enriched with selected examples obtained from industrial applications, Modeling of Thermo-Electro-Mechanical Manufacturing Processes with Applications in Metal Forming and Resistance Welding works to diminish the gap between the developers of finite element computer programs and the professional engineers with expertise in industrial joining technologies by metal forming and resista...

  14. Optimization of the welding process of high alloyed steels and improvement of corrosion behaviour of welded joints; Optimierung des Schweissprozesses hochlegierter Staehle und Verbesserung der Korrosionsbestaendigkeit der Schweissverbindungen

    Energy Technology Data Exchange (ETDEWEB)

    Schilling, K.; Goellner, J. [Otto-von-Guericke-Universitaet Magdeburg, IWW, PF 4120, D-39016 Magdeburg (Germany); Ryspaev, T.; Reiter, R.; Wesling, V. [Technische Universitaet Clausthal, Agricolastrasse 2, D-38678 Clausthal-Zellerfeld (Germany)

    2005-03-01

    The optimization of welding processes is necessary to obtain a good durability of the welded joints connected with a minimization of the corrosion performance. Welding processes represent a considerable influence of the material. The formation of precipitations, strong structure changes, increasing of the residual stress and not at all undefined surface layers are possible. All these changes have a great influence on the corrosion behaviour. Particularly tempering tarnish changes the passive layer which is decisive for the corrosion resistance. But also surface treatment methods can influence the corrosion behaviour. Therefore both the welding process and an ''after-care'' coordinated with the respective welding process had to be optimized. The optimization of the welding process was carried out by variation of the energy per unit length and the use of different protective gases. For a selection of a surface treatment method it has to be taken into account that an obvious remove of the tempering tarnish doesn't lead to an improvement in the corrosion behaviour. Traces of the working tool which can have a negative effect on the corrosion behaviour often remain on the surface. The influence of these different parameters on the corrosion property could be proved by electrochemical and surface analytical examinations. The investigations were carried out at specimens of two typical representatives of high alloyed austenitic steels and at welded joints, which had different surface treatments. (Abstract Copyright [2005], Wiley Periodicals, Inc.) [German] Die Optimierung von Schweissprozessen ist erforderlich, um eine gute Haltbarkeit der Schweissverbindungen und eine Minimierung der Korrosionsneigung zu erzielen. Schweissprozesse stellen eine erhebliche Beeinflussung fuer den Werkstoff dar. Es kann dabei zu Ausscheidungen bzw. zu starken Gefuegeveraenderungen, zur Erhoehung der Eigenspannungen und nicht zuletzt zu Schichtbildungen kommen. All

  15. Atomic processes in optically thin plasmas

    Science.gov (United States)

    Kaastra, Jelle S.; Gu, Liyi; Mao, Junjie; Mehdipour, Missagh; Raassen, Ton; Urdampilleta, Igone

    2016-10-01

    The Universe contains a broad range of plasmas with quite different properties depending on distinct physical processes. In this contribution we give an overview of recent developments in modeling such plasmas with a focus on X-ray emission and absorption. Despite the fact that such plasmas have been investigated already for decades, and that overall there is a good understanding of the basic processes, there are still areas, where improvements have to be made that are important for the analysis of astrophysical plasmas. We present recent work on the update of atomic parameters in the codes that describe the emission from collisional plasmas, where older approximations are being replaced now by more accurate data. Further we discuss the development of models for photo-ionised plasmas in the context of outflows around supermassive black holes and models for charge transfer that are needed for analyzing the data from the upcoming ASTRO-H satellite.

  16. Effects of the Hot Isostatic Pressing Process on Crack Healing of the Laser Repair-Welded CM247LC Superalloy

    Directory of Open Access Journals (Sweden)

    Keng-Tu Hsu

    2016-10-01

    Full Text Available This study investigated the effects of the hot isostatic pressing process on the crack healing, microstructure, and mechanical properties of the laser repair-welded CM247LC precipitation-hardened superalloy. To ensure the strength of the repair-welded area, this study used the direct re-melting approach, and simulated the repair welding with the filler addition, which has a chemical composition matching that of the base superalloy. As expected, different types of cracks, including the solidification crack in the weld fusion zone and various types of liquidation cracks in the heat-affected zone, were observed. Through a proper hot isostatic pressing healing process, all cracks in the weld fusion zone and the heat-affected zone of the repair-welded pieces were healed. At the same time, some nano- and micro-sized carbides tended to form discontinuously along the healed crack trace. A micro-hardness test was conducted in the repair-welded area, and the results were similar to that of the as-cast material.

  17. Secondary electron emission from plasma processed accelerating cavity grade niobium

    Science.gov (United States)

    Basovic, Milos

    by different techniques. Specifically, this work provides the results of SEY from the plasma cleaned cavity grade niobium (Nb) samples. Pure niobium is currently the material of choice for the fabrication of Superconducting Radio Frequency (SRF) cavities. The effect of plasma processing with two different gases will be examined in two groups of samples. The first group of samples is made from cavity grade niobium. The second group of samples is made from the same material, but include a welded joint made by electron beam welding, since in niobium SRF cavities the peak electric and magnetic field are seen in close proximity to the welded joints. Both groups of samples will be exposed to nitrogen (N2) and a mixture of argon with oxygen (Ar/O2) plasma. It is the goal of this research to determine the SEY on these two groups of samples before and after plasma processing as a function of the energy of primary electrons. The SEY as a function of the angle of incidence of the primary electrons is tested on the samples treated with Ar/O2 plasma.

  18. Secondary Electron Emission from Plasma Processed Accelerating Cavity Grade Niobium

    Energy Technology Data Exchange (ETDEWEB)

    Basovic, Milos [Old Dominion Univ., Norfolk, VA (United States)

    2016-05-01

    by different techniques. Specifically, this work provides the results of SEY from the plasma cleaned cavity grade niobium (Nb) samples. Pure niobium is currently the material of choice for the fabrication of Superconducting Radio Frequency (SRF) cavities. The effect of plasma processing with two different gases will be examined in two groups of samples. The first group of samples is made from cavity grade niobium. The second group of samples is made from the same material, but include a welded joint made by electron beam welding, since in niobium SRF cavities the peak electric and magnetic field are seen in close proximity to the welded joints. Both groups of samples will be exposed to nitrogen (N2) and a mixture of argon with oxygen (Ar/O2) plasma. It is the goal of this research to determine the SEY on these two groups of samples before and after plasma processing as a function of the energy of primary electrons. The SEY as a function of the angle of incidence of the primary electrons is tested on the samples treated with Ar/O2 plasma.

  19. Effect of ultrasound on plasma arc and experimental research on welding%超声对等离子电弧的影响及焊接试验研究

    Institute of Scientific and Technical Information of China (English)

    范成磊; 谢伟峰; 杨春利; 林三宝; 孙清洁; 范阳阳

    2015-01-01

    With the development of modern industry, the application of ultrasound in materials processing is getting more and more widespread and important. There are many ultrasonund-welding methods, all of those have improved welding quality and production efficiency to a certain degree, and enhance the adaptability of welding. An ultrasonic-arc technique, utilizing external ultrasonic source to regulate plasma arc (welding heat source), is described in detail in this paper. The arc test shows that the shape of the arc modulated by ultrasound is conical instead of bell-shaped, and this compression effect is very obvious. While in the welding test, with ultrasound, the size of welding droplet is smaller than that without ultrasound, and the transition frequency is significantly increased. By using this method, some of the shortcomings in ordinary arc welding can be overcomed, such as arc energy divergence, the low quality of welds and low welding efficiency.%随着现代工业生产技术的发展,超声波在材料加工领域应用越来越广泛,相继出现了多种超声波与焊接相结合的方式,在一定程度上提高了焊接质量和生产效率,增强了焊接的适应性。详细介绍了一种超声电弧技术,即利用外加超声源调控等离子电弧作为相应热源进行焊接的技术。电弧试验研究显示,受超声调制的等离子电弧呈规则的圆锥形,压缩明显,电弧中心区压力增大。在焊接试验中,发现施加超声后,焊接熔滴尺寸更小,过渡频率明显增加,焊缝的熔宽和熔深都不同程度增加。利用该方法可以克服普通电弧焊接熔深浅、电弧能量不集中、焊接效率低等缺点。

  20. ROLE OF FCA WELDING PROCESS PARAMETERS ON BEAD PROFILE, ANGULAR AND BOWING DISTORTION OF FERRITIC STAINLESS STEEL SHEETS

    Directory of Open Access Journals (Sweden)

    VENKATESAN M. V.

    2014-02-01

    Full Text Available This paper discusses the influence of flux cored arc welding (FCAW process parameters such as welding current, travel speed, voltage and CO2 shielding gas flow rate on bead profile, bowing distortion and angular distortion of 409 M ferritic stainless steel sheets of 2 mm thickness. The bowing and angular distortions of the welded plates were measured using a simple device called profile tracer and Vernier bevel protractor respectively. The study revealed that the FCAW process parameters have significant effect on bead profile, and distortion. The relationship between bead profile and distortions were analyzed. Most favorable process parameters that give uniform bead profile and minimum distortion for the weld are recommended for fabrication.

  1. Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology

    Directory of Open Access Journals (Sweden)

    Ramanjaneyulu Kadaganchi

    2015-09-01

    Full Text Available The heat treatable aluminum–copper alloy AA2014 finds wide application in the aerospace and defence industry due to its high strength-to-weight ratio and good ductility. Friction stir welding (FSW process, an emerging solid state joining process, is suitable for joining this alloy compared to fusion welding processes. This work presents the formulation of a mathematical model with process parameters and tool geometry to predict the responses of friction stir welds of AA 2014-T6 aluminum alloy, viz yield strength, tensile strength and ductility. The most influential process parameters considered are spindle speed, welding speed, tilt angle and tool pin profile. A four-factor, five-level central composite design was used and a response surface methodology (RSM was employed to develop the regression models to predict the responses. The mechanical properties, such as yield strength (YS, ultimate tensile strength (UTS and percentage elongation (%El, are considered as responses. Method of analysis of variance was used to determine the important process parameters that affect the responses. Validation trials were carried out to validate these results. These results indicate that the friction stir welds of AA 2014-T6 aluminum alloy welded with hexagonal tool pin profile have the highest tensile strength and elongation, whereas the joints fabricated with conical tool pin profile have the lowest tensile strength and elongation.

  2. Linear Friction Welding Process Model for Carpenter Custom 465 Precipitation-Hardened Martensitic Stainless Steel

    Science.gov (United States)

    Grujicic, M.; Yavari, R.; Snipes, J. S.; Ramaswami, S.; Yen, C.-F.; Cheeseman, B. A.

    2014-06-01

    An Arbitrary Lagrangian-Eulerian finite-element analysis is combined with thermo-mechanical material constitutive models for Carpenter Custom 465 precipitation-hardened martensitic stainless steel to develop a linear friction welding (LFW) process model for this material. The main effort was directed toward developing reliable material constitutive models for Carpenter Custom 465 and toward improving functional relations and parameterization of the workpiece/workpiece contact-interaction models. The LFW process model is then used to predict thermo-mechanical response of Carpenter Custom 465 during LFW. Specifically, temporal evolutions and spatial distribution of temperature within, and expulsion of the workpiece material from, the weld region are examined as a function of the basic LFW process parameters, i.e., (a) contact-pressure history, (b) reciprocation frequency, and (c) reciprocation amplitude. Examination of the results obtained clearly revealed the presence of three zones within the weld, i.e., (a) Contact-interface region, (b) Thermo-mechanically affected zone, and (c) heat-affected zone. While there are no publicly available reports related to Carpenter Custom 465 LFW behavior, to allow an experiment/computation comparison, these findings are consistent with the results of our ongoing companion experimental investigation.

  3. Welding of Al6061and Al6082-Cu composite by friction stir processing

    Science.gov (United States)

    Iyer, R. B.; Dhabale, R. B.; Jatti, V. S.

    2016-09-01

    Present study aims at investigating the influence of process parameters on the microstructure and mechanical properties such as tensile strength and hardness of the dissimilar metal without and with copper powder. Before conducting the copper powder experiments, optimum process parameters were obtained by conducting experiments without copper powder. Taguchi's experimental L9 orthogonal design layout was used to carry out the experiments without copper powder. Threaded pin tool geometry was used for conducting the experiments. Based on the experimental results and Taguchi's analysis it was found that maximum tensile strength of 66.06 MPa was obtained at 1400 rpm spindle speed and weld speed of 20 mm/min. Maximum micro hardness (92 HV) was obtained at 1400 rpm spindle speed and weld speed of 16 mm/min. At these optimal setting of process parameters aluminium alloys were welded with the copper powder. Experimental results demonstrated that the tensile strength (96.54 MPa) and micro hardness (105 HV) of FSW was notably affected by the addition of copper powder when compared with FSW joint without copper powder. Tensile failure specimen was analysed using Scanning Electron Microscopy in order to study the failure mechanism.

  4. A plasma process monitor/control system

    Energy Technology Data Exchange (ETDEWEB)

    Stevenson, J.O.; Ward, P.P.; Smith, M.L. [Sandia National Labs., Albuquerque, NM (United States); Markle, R.J. [Advanced Micro Devices, Inc., Austin, TX (United States)

    1997-08-01

    Sandia National Laboratories has developed a system to monitor plasma processes for control of industrial applications. The system is designed to act as a fully automated, sand-alone process monitor during printed wiring board and semiconductor production runs. The monitor routinely performs data collection, analysis, process identification, and error detection/correction without the need for human intervention. The monitor can also be used in research mode to allow process engineers to gather additional information about plasma processes. The plasma monitor can perform real-time control of support systems known to influence plasma behavior. The monitor can also signal personnel to modify plasma parameters when the system is operating outside of desired specifications and requires human assistance. A notification protocol can be selected for conditions detected in the plasma process. The Plasma Process Monitor/Control System consists of a computer running software developed by Sandia National Laboratories, a commercially available spectrophotometer equipped with a charge-coupled device camera, an input/output device, and a fiber optic cable.

  5. Vision-based detection of MAG weld pool

    Institute of Scientific and Technical Information of China (English)

    Gao Jinqiang; Wu Chuansong; Zhang Min; Zhao Yanhua

    2007-01-01

    Weld pool contains significant information about the welding process. The weld pool images of MAG welding are detected by LaserStrobe system. An algorithm for extracting weld pool edge is proposed according to the characteristics of MAG weld pool images. The maximum weld pool length and width are calculated. The measurement data can be used to verify the results of welding process simulation and to provide a good foundation for automatic control of MAG welding process.

  6. Elucidation of laser welding phenomena and factors affecting weld penetration and welding defects

    Science.gov (United States)

    Katayama, Seiji; Kawahito, Yousuke; Mizutani, Masami

    The behavior and effect of a plasma plume on the weld penetration are greatly different between CO2 laser welding and YAG, disk or fiber laser welding. The effects of the power and the power density on the weld penetration are elucidated. Spattering leading to the formation of underfilled weld beads is controlled by inclining the laser beam. Porosity is formed from bubbles generated from the tip of the keyhole at low welding speed or from the middle part of the keyhole at high laser power density. Cracking easily occurs in pulsed spot welding of aluminum alloys.

  7. Surface studies of plasma processed Nb samples

    Energy Technology Data Exchange (ETDEWEB)

    Tyagi, Puneet V. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Doleans, Marc [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Hannah, Brian S. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Afanador, Ralph [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Stewart, Stephen [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Mammosser, John [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Howell, Matthew P [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Saunders, Jeffrey W [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Degraff, Brian D [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Kim, Sang-Ho [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS)

    2015-01-01

    Contaminants present at top surface of superconducting radio frequency (SRF) cavities can act as field emitters and restrict the cavity accelerating gradient. A room temperature in-situ plasma processing technology for SRF cavities aiming to clean hydrocarbons from inner surface of cavities has been recently developed at the Spallation Neutron Source (SNS). Surface studies of the plasma-processed Nb samples by Secondary ion mass spectrometry (SIMS) and Scanning Kelvin Probe (SKP) showed that the NeO2 plasma processing is very effective to remove carbonaceous contaminants from top surface and improves the surface work function by 0.5 to 1.0 eV.

  8. Space plasma physics: I - Stationary processes

    Science.gov (United States)

    Hasegawa, Akira; Sato, Tetsuya

    1989-01-01

    The physics of stationary processes in space plasmas is examined theoretically in an introduction intended for graduate students. The approach involves the extensive use of numerical simulations. Chapters are devoted to fundamental principles, small-amplitude waves, and the stationary solar plasma system; typical measurement data and simulation results are presented graphically.

  9. Developments in Plasma Processes for Extractive Metallurgy

    Science.gov (United States)

    Gauvin, W. H.; Drouet, M. G.; Munz, R. J.

    1987-12-01

    With the recent availability of commercial plasma-generating devices capable of reliable performance at powers as high as 30 MW, the applications of plasma technology in high-temperature extractive metallurgy are rapidly increasing. Some of the more promising process developments are reviewed in this paper, as are newer reactor designs.

  10. Welded solar cell interconnection

    Science.gov (United States)

    Stofel, E. J.; Browne, E. R.; Meese, R. A.; Vendura, G. J.

    1982-01-01

    The efficiency of the welding of solar-cell interconnects is compared with the efficiency of soldering such interconnects, and the cases in which welding may be superior are examined. Emphasis is placed on ultrasonic welding; attention is given to the solar-cell welding machine, the application of the welding process to different solar-cell configurations, producibility, and long-life performance of welded interconnects. Much of the present work has been directed toward providing increased confidence in the reliability of welding using conditions approximating those that would occur with large-scale array production. It is concluded that there is as yet insufficient data to determine which of three methods (soldering, parallel gap welding, and ultrasonic welding) provides the longest-duration solar panel life.

  11. Effect of heat input on dilution and heat affected zone in submerged arc welding process

    Indian Academy of Sciences (India)

    Hari Om; Sunil Pandey

    2013-12-01

    Submerged arc welding (SAW) is a fusion joining process, known for its high deposition capabilities. This process is useful in joining thick section components used in various industries. Besides joining, SAW can also be used for surfacing applications. Heat Affected Zone (HAZ) produced within the base metal as a result of tremendous heat of arc is of big concern as it affects the performance of welded/surfaced structure in service due to metallurgical changes in the affected region. This work was carried out to investigate the effect of polarity and other SAW parameters on HAZ size and dilution and to establish their correlations. Influence of heat input on dilution and heat affected zone was then carried out. Four levels of heat input were used to study their effect on % dilution and HAZ area at both the electrode positive and electrode negative polarities. Proper management of heat input in welding is important, because power sources can be used more efficiently if one knows how the same heat input can be applied to get the better results. Empirical models have been developed using statistical technique.

  12. 低温制冷机冷头焊接工艺研究%Welding process of cryocooler cold - head

    Institute of Scientific and Technical Information of China (English)

    席有民; 平丽浩; 钱吉裕

    2012-01-01

    冷头是低温制冷机的关键零部件,是制冷机的重要结构件,同时也是制冷机与热载荷的接口部位.文中对冷头的焊接工艺进行研究,提出一种爆炸焊复合材料与激光焊结合的冷头焊接工艺.%Cold - head is a key part in cryocooler. It is not only an important structure part, but also the interface between cryocooler and heat load. In this paper, we studied on the welding process of cold - head, and then put forward a welding process which integrated composive - welding composite material and laser welding.

  13. Profiling stainless steel welding processes to reduce fume emissions, hexavalent chromium emissions and operating costs in the workplace.

    Science.gov (United States)

    Keane, Michael; Siert, Arlen; Stone, Samuel; Chen, Bean T

    2016-01-01

    Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium (Cr(6+)). Elemental manganese, nickel, chromium, iron emissions per unit length of weld, and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered, and analyzed by inductively coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr(6+). GMAW processes used were Surface Tension Transfer, Regulated Metal Deposition, Cold Metal Transfer, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr(6+) ranged from 50-7800 µg/min, and Cr(6+) generation rates per g electrode ranged from 1-270 µg/g. Elemental Cr generation rates spanned 13-330 µg/g. Manganese emission rates ranged from 50-300 µg/g. Nickel emission rates ranged from 4-140 µg/g. Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as five times the cost of a typical SMAW welding machine. The results show that all of the GMAW processes in this

  14. Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

    Science.gov (United States)

    Ren, Weiju

    2014-11-11

    A method of welding including forming a filler material of a first oxide dispersoid metal, the first oxide dispersoid material having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersoid metals; positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersoid metal; and friction welding the filler material, the first metal structure and the second metal structure to provide a weld.

  15. Handbook of Plastic Welding

    DEFF Research Database (Denmark)

    Islam, Aminul

    The purpose of this document is to summarize the information about the laser welding of plastic. Laser welding is a matured process nevertheless laser welding of micro dimensional plastic parts is still a big challenge. This report collects the latest information about the laser welding of plasti...... as a knowledge handbook for laser welding of plastic components. This document should provide the information for all aspects of plastic laser welding and help the design engineers to take all critical issues into consideration from the very beginning of the design phase....

  16. Image processing of ESPI based on measurement the welding dynamic displacement fields

    Institute of Scientific and Technical Information of China (English)

    陶军; 李冬青; 范成磊; 刘忠国

    2004-01-01

    A dual-beam electronic speckle pattern interferometry (ESPI) system was adopted to get speckle patterns for the measurement of welding dynamic displacement fields. The mathematical model of this system was described, based on which methods of the ESPI pattern image processing were discussed. Gray transformation and histogram equalization were used to enhance the contrast of speckle patterns. A discrete cosine image processing method was carried out and an exponent low-pass filter was chosen to reduce multiplicative noise in speckle patterns. Speckle grain noise can be eliminated effectively after these processes.

  17. 热丝TIG焊方法最新研究进展%Research on Development of Hot-wire TIG Welding Process

    Institute of Scientific and Technical Information of China (English)

    赵福海; 华学明; 叶欣; 吴毅雄

    2011-01-01

    综述了各类热丝TIG焊方法的特点及其技术与工艺难点,并着重阐述了近些年来研究较多的脉冲加热热丝TIG焊、窄间隙热丝TIG焊、超高速热丝TIG焊的研究进展.%The characteristics of hot-wire welding process and the principles and technical difficulties of many kinds of hot-wire welding process were briefly introduced. The research progress of several advanced hot- wire welding processes in recent years, including pulse-heated hot-wire TIG welding process, narrow gap hot-wire TIG welding process and ultra-high-speed hot-wire welding process was introduced.

  18. A Review: Welding Of Dissimilar Metal Alloys by Laser Beam Welding & Friction Stir Welding Techniques

    Directory of Open Access Journals (Sweden)

    Ms. Deepika Harwani

    2014-12-01

    Full Text Available Welding of dissimilar metals has attracted attention of the researchers worldwide, owing to its many advantages and challenges. There is no denial in the fact that dissimilar welded joints offer more flexibility in the design and production of the commercial and industrial components. Many welding techniques have been analyzed to join dissimilar metal combinations. The objective of this paper is to review two such techniques – Laser welding and Friction stir welding. Laser beam welding, a high power density and low energy-input process, employs a laser beam to produce welds of dissimilar materials. Friction stir welding, a solid-state joining process, is also successfully used in dissimilar welding applications like aerospace and ship building industries. This paper summarizes the trends and advances of these two welding processes in the field of dissimilar welding. Future aspects of the study are also discussed.

  19. The Tungsten Inert GAS (TIG) Process of Welding Aluminium in Microgravity: Technical and Economic Considerations

    Science.gov (United States)

    Ferretti, S.; Amadori, K.; Boccalatte, A.; Alessandrini, M.; Freddi, A.; Persiani, F.; Poli, G.

    2002-01-01

    The UNIBO team composed of students and professors of the University of Bologna along with technicians and engineers from Alenia Space Division and Siad Italargon Division, took part in the 3rd Student Parabolic Flight Campaign of the European Space Agency in 2000. It won the student competition and went on to take part in the Professional Parabolic Flight Campaign of May 2001. The experiment focused on "dendritic growth in aluminium alloy weldings", and investigated topics related to the welding process of aluminium in microgravity. The purpose of the research is to optimise the process and to define the areas of interest that could be improved by new conceptual designs. The team performed accurate tests in microgravity to determine which phenomena have the greatest impact on the quality of the weldings with respect to penetration, surface roughness and the microstructures that are formed during the solidification. Various parameters were considered in the economic-technical optimisation, such as the type of electrode and its tip angle. Ground and space tests have determined the optimum chemical composition of the electrodes to offer longest life while maintaining the shape of the point. Additionally, the power consumption has been optimised; this offers opportunities for promoting the product to the customer as well as being environmentally friendly. Tests performed on the Al-Li alloys showed a significant influence of some physical phenomena such as the Marangoni effect and thermal diffusion; predictions have been made on the basis of observations of the thermal flux seen in the stereophotos. Space transportation today is a key element in the construction of space stations and future planetary bases, because the volumes available for launch to space are directly related to the payload capacity of rockets or the Space Shuttle. The research performed gives engineers the opportunity to consider completely new concepts for designing structures for space applications

  20. In-process monitoring and adaptive control for gap in micro butt welding with pulsed YAG laser

    Science.gov (United States)

    Kawahito, Yousuke; Kito, Masayuki; Katayama, Seiji

    2007-05-01

    A gap is one of the most important issues to be solved in laser welding of a micro butt joint, because the gap results in welding defects such as underfilling or a non-bonded joint. In-process monitoring and adaptive control has been expected as one of the useful procedures for the stable production of sound laser welds without defects. The objective of this research is to evaluate the availability of in-process monitoring and adaptive control in micro butt welding of pure titanium rods with a pulsed neodymium : yttrium aluminium garnet (Nd : YAG) laser beam of a 150 µm spot diameter. It was revealed that a 45 µm narrow gap was detected by the remarkable jump in a reflected light intensity due to the formation of the molten pool which could bridge the gap. Heat radiation signal levels increased in proportion to the sizes of molten pools or penetration depths for the respective laser powers. As for adaptive control, the laser peak power was controlled on the basis of the reflected light or the heat radiation signals to stably produce a sound deeply penetrated weld reduced underfilling. In the case of a 100 µm gap, the underfilling was greatly reduced by half smaller than those made with a conventional rectangular pulse shape in seam welding as well as spot welding with a pulsed Nd : YAG laser beam. Consequently, the adaptive control of the laser peak power on the basis of in-process monitoring could reduce the harmful effects due to a gap in micro butt laser welding with a pulsed laser beam.

  1. In-process monitoring and adaptive control for gap in micro butt welding with pulsed YAG laser

    Energy Technology Data Exchange (ETDEWEB)

    Kawahito, Yousuke; Kito, Masayuki; Katayama, Seiji [Joining and Welding Research Institute (JWRI), Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047 (Japan)

    2007-05-07

    A gap is one of the most important issues to be solved in laser welding of a micro butt joint, because the gap results in welding defects such as underfilling or a non-bonded joint. In-process monitoring and adaptive control has been expected as one of the useful procedures for the stable production of sound laser welds without defects. The objective of this research is to evaluate the availability of in-process monitoring and adaptive control in micro butt welding of pure titanium rods with a pulsed neodymium : yttrium aluminium garnet (Nd : YAG) laser beam of a 150 {mu}m spot diameter. It was revealed that a 45 {mu}m narrow gap was detected by the remarkable jump in a reflected light intensity due to the formation of the molten pool which could bridge the gap. Heat radiation signal levels increased in proportion to the sizes of molten pools or penetration depths for the respective laser powers. As for adaptive control, the laser peak power was controlled on the basis of the reflected light or the heat radiation signals to stably produce a sound deeply penetrated weld reduced underfilling. In the case of a 100 {mu}m gap, the underfilling was greatly reduced by half smaller than those made with a conventional rectangular pulse shape in seam welding as well as spot welding with a pulsed Nd : YAG laser beam. Consequently, the adaptive control of the laser peak power on the basis of in-process monitoring could reduce the harmful effects due to a gap in micro butt laser welding with a pulsed laser beam.

  2. Robotic and automatic welding development at the Marshall Space Flight Center

    Science.gov (United States)

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

    1988-01-01

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

  3. Fundamental Processes in Plasmas. Final report

    Energy Technology Data Exchange (ETDEWEB)

    O' Neil, Thomas M.; Driscoll, C. Fred

    2009-11-30

    This research focuses on fundamental processes in plasmas, and emphasizes problems for which precise experimental tests of theory can be obtained. Experiments are performed on non-neutral plasmas, utilizing three electron traps and one ion trap with a broad range of operating regimes and diagnostics. Theory is focused on fundamental plasma and fluid processes underlying collisional transport and fluid turbulence, using both analytic techniques and medium-scale numerical simulations. The simplicity of these systems allows a depth of understanding and a precision of comparison between theory and experiment which is rarely possible for neutral plasmas in complex geometry. The recent work has focused on three areas in basic plasma physics. First, experiments and theory have probed fundamental characteristics of plasma waves: from the low-amplitude thermal regime, to inviscid damping and fluid echoes, to cold fluid waves in cryogenic ion plasmas. Second, the wide-ranging effects of dissipative separatrices have been studied experimentally and theoretically, finding novel wave damping and coupling effects and important plasma transport effects. Finally, correlated systems have been investigated experimentally and theoretically: UCSD experients have now measured the Salpeter correlation enhancement, and theory work has characterized the 'guiding center atoms of antihydrogen created at CERN.

  4. Saturn Plasma Sources and Associated Transport Processes

    Science.gov (United States)

    Blanc, M.; Andrews, D. J.; Coates, A. J.; Hamilton, D. C.; Jackman, C. M.; Jia, X.; Kotova, A.; Morooka, M.; Smith, H. T.; Westlake, J. H.

    2015-10-01

    This article reviews the different sources of plasma for Saturn's magnetosphere, as they are known essentially from the scientific results of the Cassini-Huygens mission to Saturn and Titan. At low and medium energies, the main plasma source is the H2O cloud produced by the "geyser" activity of the small satellite Enceladus. Impact ionization of this cloud occurs to produce on the order of 100 kg/s of fresh plasma, a source which dominates all the other ones: Titan (which produces much less plasma than anticipated before the Cassini mission), the rings, the solar wind (a poorly known source due to the lack of quantitative knowledge of the degree of coupling between the solar wind and Saturn's magnetosphere), and the ionosphere. At higher energies, energetic particles are produced by energy diffusion and acceleration of lower energy plasma produced by the interchange instabilities induced by the rapid rotation of Saturn, and possibly, for the highest energy range, by contributions from the CRAND process acting inside Saturn's magnetosphere. Discussion of the transport and acceleration processes acting on these plasma sources shows the importance of rotation-induced radial transport and energization of the plasma, and also shows how much the unexpected planetary modulation of essentially all plasma parameters of Saturn's magnetosphere remains an unexplained mystery.

  5. A cooperative control strategy of resistance spot welding process by combining the constant current control with the DRC method

    Institute of Scientific and Technical Information of China (English)

    Li Guizhong; Wang Changzheng; Kong Meng; Guo Caiguang

    2009-01-01

    The modeling control method based on the dynamic resistance characteristics of good nuggets, that is the DRC method, is an improvement on the dynamic resistance threshold method for the quality control of resistance spot welding. But there is still a control blind area in the initial four cycles. For this reason, the quality of every weld nugget could not be fully ensured. Thus a new fuzzy cooperative control method is put forward. It uses a multi-information time-control mechanism by combining the constant current control technology with the DRC method in a relay way. This whole-process control strategy has led to a good control effect and produced the dual-identicul results in the weld nugget quality and the welding time.

  6. OPTIMIZATION OF PROCESS PARAMETERS TO MINIMIZE ANGULAR DISTORTION IN GAS TUNGSTEN ARC WELDED STAINLESS STEEL 202 GRADE PLATES USING PARTICLE SWARM OPTIMIZATION

    Directory of Open Access Journals (Sweden)

    R. SUDHAKARAN

    2012-04-01

    Full Text Available This paper presents a study on optimization of process parameters using particle swarm optimization to minimize angular distortion in 202 grade stainless steel gas tungsten arc welded plates. Angular distortion is a major problem and most pronounced among different types of distortion in butt welded plates. The process control parameters chosen for the study are welding gun angle, welding speed, plate length, welding current and gas flow rate. The experiments were conducted using design of experiments technique with five factor five level central composite rotatable design with full replication technique. A mathematical model was developed correlating the process parameters with angular distortion. A source code was developed in MATLAB 7.6 to do the optimization. The optimal process parameters gave a value of 0.0305° for angular distortion which demonstrates the accuracy of the model developed. The results indicate that the optimized values for the process parameters are capable of producing weld with minimum distortion.

  7. Hydrogen Plasma Processing of Iron Ore

    Science.gov (United States)

    Sabat, Kali Charan; Murphy, Anthony B.

    2017-06-01

    Iron is currently produced by carbothermic reduction of oxide ores. This is a multiple-stage process that requires large-scale equipment and high capital investment, and produces large amounts of CO2. An alternative to carbothermic reduction is reduction using a hydrogen plasma, which comprises vibrationally excited molecular, atomic, and ionic states of hydrogen, all of which can reduce iron oxides, even at low temperatures. Besides the thermodynamic and kinetic advantages of a hydrogen plasma, the byproduct of the reaction is water, which does not pose any environmental problems. A review of the theory and practice of iron ore reduction using a hydrogen plasma is presented. The thermodynamic and kinetic aspects are considered, with molecular, atomic and ionic hydrogen considered separately. The importance of vibrationally excited hydrogen molecules in overcoming the activation energy barriers, and in transferring energy to the iron oxide, is emphasized. Both thermal and nonthermal plasmas are considered. The thermophysical properties of hydrogen and argon-hydrogen plasmas are discussed, and their influence on the constriction and flow in the of arc plasmas is considered. The published R&D on hydrogen plasma reduction of iron oxide is reviewed, with both the reduction of molten iron ore and in-flight reduction of iron ore particles being considered. Finally, the technical and economic feasibility of the process are discussed. It is shown that hydrogen plasma processing requires less energy than carbothermic reduction, mainly because pelletization, sintering, and cokemaking are not required. Moreover, the formation of the greenhouse gas CO2 as a byproduct is avoided. In-flight reduction has the potential for a throughput at least equivalent to the blast furnace process. It is concluded that hydrogen plasma reduction of iron ore is a potentially attractive alternative to standard methods.

  8. Hydrogen Plasma Processing of Iron Ore

    Science.gov (United States)

    Sabat, Kali Charan; Murphy, Anthony B.

    2017-03-01

    Iron is currently produced by carbothermic reduction of oxide ores. This is a multiple-stage process that requires large-scale equipment and high capital investment, and produces large amounts of CO2. An alternative to carbothermic reduction is reduction using a hydrogen plasma, which comprises vibrationally excited molecular, atomic, and ionic states of hydrogen, all of which can reduce iron oxides, even at low temperatures. Besides the thermodynamic and kinetic advantages of a hydrogen plasma, the byproduct of the reaction is water, which does not pose any environmental problems. A review of the theory and practice of iron ore reduction using a hydrogen plasma is presented. The thermodynamic and kinetic aspects are considered, with molecular, atomic and ionic hydrogen considered separately. The importance of vibrationally excited hydrogen molecules in overcoming the activation energy barriers, and in transferring energy to the iron oxide, is emphasized. Both thermal and nonthermal plasmas are considered. The thermophysical properties of hydrogen and argon-hydrogen plasmas are discussed, and their influence on the constriction and flow in the of arc plasmas is considered. The published R&D on hydrogen plasma reduction of iron oxide is reviewed, with both the reduction of molten iron ore and in-flight reduction of iron ore particles being considered. Finally, the technical and economic feasibility of the process are discussed. It is shown that hydrogen plasma processing requires less energy than carbothermic reduction, mainly because pelletization, sintering, and cokemaking are not required. Moreover, the formation of the greenhouse gas CO2 as a byproduct is avoided. In-flight reduction has the potential for a throughput at least equivalent to the blast furnace process. It is concluded that hydrogen plasma reduction of iron ore is a potentially attractive alternative to standard methods.

  9. Two-dimensional time-dependent modelling of fume formation in a pulsed gas metal arc welding process

    Science.gov (United States)

    Boselli, M.; Colombo, V.; Ghedini, E.; Gherardi, M.; Sanibondi, P.

    2013-06-01

    Fume formation in a pulsed gas metal arc welding (GMAW) process is investigated by coupling a time-dependent axi-symmetric two-dimensional model, which takes into account both droplet detachment and production of metal vapour, with a model for fume formation and transport based on the method of moments for the solution of the aerosol general dynamic equation. We report simulative results of a pulsed process (peak current = 350 A, background current 30 A, period = 9 ms) for a 1 mm diameter iron wire, with Ar shielding gas. Results showed that metal vapour production occurs mainly at the wire tip, whereas fume formation is concentrated in the fringes of the arc in the spatial region close to the workpiece, where metal vapours are transported by convection. The proposed modelling approach allows time-dependent tracking of fumes also in plasma processes where temperature-time variations occur faster than nanoparticle transport from the nucleation region to the surrounding atmosphere, as is the case for most pulsed GMAW processes.

  10. Some Studies of Optimal Process Parameters For Solid Wire Gas Metal Arc Welding Using Neural Network Technique And Simulation Using Ansys

    Directory of Open Access Journals (Sweden)

    Saritprava Sahoo

    2013-08-01

    Full Text Available GMAW (Gas Metal Arc Welding is an arc welding process which is widely used in industry to join the metals. In this present work we have investigated the effect of varying welding parameters on the weld bead quality of Mild Steel flat having 12mm thickness. The chosen input parameters for the study are Welding Voltage, Welding Current and the travel speed of welding torch. The output parameters chosen are Weld Bead Width, Weld Bead Height, Depth of Penetration and Depth of Heat Affected Zone (HAZ. The four levels of experimental set-ups for each of the input parameters are considered and other process parameters are kept constant for the study. Hence the total numbers of experimental set-ups are 64 and the corresponding values of output parameters are found. As this is a Multi-Response Problem, it is being optimized to Single-Response Problem using Weighted Principal Components (WPC Method. Artificial Neural Networks (sANN, Error Back Propagation Procedure is being used for the prediction of optimal process parameters for GMAW process in this present work. The finite element analysis of residual stresses in butt welding of two similar plates is performed with the ANSYS software.

  11. 脉冲变极性等离子弧焊接系统及其特征信号分析%Pulse Variable Polarity Plasma Arc Welding System and Analysis of Its Characteristic Signals

    Institute of Scientific and Technical Information of China (English)

    春兰; 韩永全; 陈芙蓉; 洪海涛

    2014-01-01

    A double-inverter variable polarity plasma arc(VPPA) welding system with high-low frequency modulation, controlled by single chip microcomputer is introduced and its characteristics of output signal with different conditions of adding high-low frequency pulse are tested and analyzed. Its welding test is performed and the results show the system runs well. It is analyzed from the time and frequency domain of the characteristic signals that compare with 1 kHz, when pulse frequency increases to 2 kHz the slope of pulse reduces 1.2 times and higher harmonic increases 1.4 times. The welding experiment results show that it can get better welding gap than typical VPPA welding and obtain uniform ripple welding line when process parameters including high frequency pulse, positive and negative polarity currents etc. are chosen appropriately. After examination of the weld microstructure, it is found that the pulse VPPA could obtain finer weld grains than typical VPPA. Because of improving quality of welding, the welding procedure is significant for high-intensity Al-alloy welding in aerospace.%研制基于单片机控制的具有高低频调制脉冲功能的双逆变变极性等离子弧(Variable polarity plasma arc,VPPA)焊接系统,检测并分析叠加不同高低频脉冲参数条件下该焊接系统输出信号的特征,并对系统进行实际焊接试验,结果表明系统运行良好。从特征信号的时域及频域分析发现,当高频脉冲频率提高到2 kHz时,与1 kHz相比较,脉冲上下降沿斜率降低1.2倍,高次谐波量增加1.4倍。由焊接试验结果得出,当高频脉冲频率及正反极性电流等工艺参数选择合适时,可以得到比典型VPPA焊接更加优越的焊缝成形,获得具有均匀鱼鳞纹的理想焊缝。从焊缝显微组织的分析发现,脉冲VPPA焊接工艺得到的焊缝晶粒比典型VPPA焊缝晶粒细小,因此该焊接工艺对进一步提高航空航天高强铝合金焊接质量具有重要意义。

  12. Diode laser welding of ABS: Experiments and process modeling

    CERN Document Server

    Ilie, Mariana; Mattei, Simone; Cicala, Eugen; Stoica, Virgil; 10.1016/j.optlastec.2008.10.005

    2010-01-01

    The laser beam weldability of acrylonitrile/butadiene/styrene (ABS) plates is determined by combining both experimental and theoretical aspects. In modeling the process, an optical model is used to determine how the laser beam is attenuated by the first material and to obtain the laser beam profile at the interface. Using this information as the input data to a thermal model, the evolution of the temperature field within the two components can be estimated. The thermal model is based on the first principles of heat transfer and utilizes the temperature variation laws of material properties. Corroborating the numerical results with the experimental results, some important insights concerning the fundamental phenomena that govern the process could be extracted. This approach proved to be an efficient tool in determining the weldability of polimeric materials and assures a significant reduction of time and costs with the experimental exploration.

  13. Pulsed Plasma Methods in Materials Processing

    Science.gov (United States)

    Rej, D. J.

    1996-05-01

    Plasmas are routinely used to synthesize advanced materials, because of their ability to produce reactant species that enable a wide variety of chemical reactions. For example, in microelectronics manufacturing, plasmas are used to etch, clean, ash photoresist, implant, deposit, polymerize, and metalize. The use of pulsed power may extend the utility of plasma processing. Pulsed devices such as coaxial plasma guns, cathodic arcs, pseudosparks have been employed to synthesize materials ranging from novel steel alloys and high-temperature superconductors to diamond coatings. In this talk, we will highlight plasma immersion ion implantation and deposition, methods that improve conventional steady-state chemical and physical vapor deposition techniques. Pulsed power enables energetic ion bombardment before plasma deposition to promote better film adhesion through the formation of a graded interface. Ion bombardment during deposition reduces residual stress in the deposited film, thereby enabling formation of thick layers. Also, pulsed plasma sources have advantages over steady-state devices in that they conserve electrical power and can produce high-density, fully-dissociated plasmas. As an example, we will review recent experiments on the formation of adherent diamond-like carbon films deposited onto relatively large batches of automotive components.

  14. Plasma characterization studies for materials processing

    Energy Technology Data Exchange (ETDEWEB)

    Pfender, E.; Heberlein, J. [Univ. of Minnesota, Minneapolis, MN (United States)

    1995-12-31

    New applications for plasma processing of materials require a more detailed understanding of the fundamental processes occurring in the processing reactors. We have developed reactors offering specific advantages for materials processing, and we are using modeling and diagnostic techniques for the characterization of these reactors. The emphasis is in part set by the interest shown by industry pursuing specific plasma processing applications. In this paper we report on the modeling of radio frequency plasma reactors for use in materials synthesis, and on the characterization of the high rate diamond deposition process using liquid precursors. In the radio frequency plasma torch model, the influence of specific design changes such as the location of the excitation coil on the enthalpy flow distribution is investigated for oxygen and air as plasma gases. The diamond deposition with liquid precursors has identified the efficient mass transport in form of liquid droplets into the boundary layer as responsible for high growth, and the chemical properties of the liquid for the film morphology.

  15. Development of a vacuum control system for plasma welding chamber%等离子焊箱真空控制系统研制

    Institute of Scientific and Technical Information of China (English)

    张乃禄; 李洋; 许道玉; 李选锋; 刘中磊

    2012-01-01

    在钛及钛合金熔炼生产中,真空等离子焊接是电极制备的重要工序,而真空等离子焊接的真空度对铸锭的质量影响很大.针对真空等离子焊箱真空控制系统的工艺和控制要求,研制基于工控机+PLC(S7-300) +INFICON PCG410-S真空计的集散控制系统,实现了对真空泵组、电磁阀、真空压力和枪抽空进行实时监测与控制优化.生产实际应用表明,该系统在提高抽真空效率,降低漏率,确保高质量钛及钛合金电极生产方面效果显著,具有一定的应用前景.%In smelting titanium and its alloy, vacuum plasma welding is an important process for electrode preparation, and the vacuum degree influences the ingot quality greatly. According to the requirements of technology and control system of vacuum plasma welding chamber, the distributed control system was built based on IPC, PLC ( S7-300 ) and INFICON PCG410-S vacuum gauge, which realized real-time monitoring and control optimization of the vacuum pump, electromagnetic valve, vacuum pressure and vacuum-pumping of gun. The practical application indicates that the system play a good role in improving the efficiency of vacuum pumping, reducing the leakage rate, and ensuring the production of high quality of titanium and titanium alloy electrodes, which has certain application prospects.

  16. Cluster processes in gases and plasmas

    CERN Document Server

    Smirnov, Boris M

    2009-01-01

    Boris M. Smirnov received his Ph.D. in physics from Leningrad State University in 1968. After working in different research positions, he finally accepted a post as head of one of the divisions of the Institute for High Temperatures at the Russian Academy of Sciences in Moscow in 1986. Professor Smirnov is the author and co-author of approximately 50 books as well as 400 research articles in plasma physics, atomic physics, and atomic clusters. He is Vice Chairman of the National Council for Low Temperature Plasma and Chairman ofa Section on Elementary Processes in Plasma. Professor Smirnov`s r

  17. Ultrasonic Plasma Spray--A New Plasma Spray Process

    Institute of Scientific and Technical Information of China (English)

    LU Zhi-qing; ZHANG Hua-tang; WEN Xiong-wei; LI Lu-ming

    2004-01-01

    The method of arc- ultrasonic is introduced into plasma spray process. The process of spray ZrO2-NiCoCr AlY thermal barrier coatings (TBCs) using air plasma spray (APS) process is studied. A exciting source which can be adjusted from audio frequency to several hundred thousand Hertz is designed successfully. The ultrasonic exciting source is coupled with conventional DC spraying power supply. A few ultrasonic frequencies are selected in the testing. Several parts of the coatings with the coupling arc- ultrasonic are compared with the coatings without it. The results show: with 50 kHz and 80 kHz ultrasound, the coating qualities are improved, whereas 30 kHz has an opposite effect.

  18. Optimization of submerged arc welding process parameters using quasi-oppositional based Jaya algorithm

    Energy Technology Data Exchange (ETDEWEB)

    Rao, R. Venkata; Rai, Dhiraj P. [Sardar Vallabhbhai National Institute of Technology, Gujarat (India)

    2017-05-15

    Submerged arc welding (SAW) is characterized as a multi-input process. Selection of optimum combination of process parameters of SAW process is a vital task in order to achieve high quality of weld and productivity. The objective of this work is to optimize the SAW process parameters using a simple optimization algorithm, which is fast, robust and convenient. Therefore, in this work a very recently proposed optimization algorithm named Jaya algorithm is applied to solve the optimization problems in SAW process. In addition, a modified version of Jaya algorithm with oppositional based learning, named “Quasi-oppositional based Jaya algorithm” (QO-Jaya) is proposed in order to improve the performance of the Jaya algorithm. Three optimization case studies are considered and the results obtained by Jaya algorithm and QO-Jaya algorithm are compared with the results obtained by well-known optimization algorithms such as Genetic algorithm (GA), Particle swarm optimization (PSO), Imperialist competitive algorithm (ICA) and Teaching learning based optimization (TLBO).

  19. Atmospheric plasma processes for environmental applications

    OpenAIRE

    Shapoval, Volodymyr

    2012-01-01

    Plasma chemistry is a rapidly growing field which covers applications ranging from technological processing of materials, including biological tissues, to environmental remediation and energy production. The so called atmospheric plasma, produced by electric corona or dielectric barrier discharges in a gas at atmospheric pressure, is particularly attractive for the low costs and ease of operation and maintenance involved. The high concentrations of energetic and chemically active species (e.g...

  20. Atmospheric plasma processes for environmental applications

    OpenAIRE

    Shapoval, Volodymyr

    2012-01-01

    Plasma chemistry is a rapidly growing field which covers applications ranging from technological processing of materials, including biological tissues, to environmental remediation and energy production. The so called atmospheric plasma, produced by electric corona or dielectric barrier discharges in a gas at atmospheric pressure, is particularly attractive for the low costs and ease of operation and maintenance involved. The high concentrations of energetic and chemically active species (e.g...

  1. Plasma processing of superconducting radio frequency cavities

    Science.gov (United States)

    Upadhyay, Janardan

    The development of plasma processing technology of superconducting radio frequency (SRF) cavities not only provides a chemical free and less expensive processing method, but also opens up the possibility for controlled modification of the inner surfaces of the cavity for better superconducting properties. The research was focused on the transition of plasma etching from two dimensional flat surfaces to inner surfaces of three dimensional (3D) structures. The results could be applicable to a variety of inner surfaces of 3D structures other than SRF cavities. Understanding the Ar/Cl2 plasma etching mechanism is crucial for achieving the desired modification of Nb SRF cavities. In the process of developing plasma etching technology, an apparatus was built and a method was developed to plasma etch a single cell Pill Box cavity. The plasma characterization was done with the help of optical emission spectroscopy. The Nb etch rate at various points of this cavity was measured before processing the SRF cavity. Cylindrical ring-type samples of Nb placed on the inner surface of the outer wall were used to measure the dependence of the process parameters on plasma etching. The measured etch rate dependence on the pressure, rf power, dc bias, temperature, Cl2 concentration and diameter of the inner electrode was determined. The etch rate mechanism was studied by varying the temperature of the outer wall, the dc bias on the inner electrode and gas conditions. In a coaxial plasma reactor, uniform plasma etching along the cylindrical structure is a challenging task due to depletion of the active radicals along the gas flow direction. The dependence of etch rate uniformity along the cylindrical axis was determined as a function of process parameters. The formation of dc self-biases due to surface area asymmetry in this type of plasma and its variation on the pressure, rf power and gas composition was measured. Enhancing the surface area of the inner electrode to reduce the

  2. Electrical-thermal interaction simulation for resistance spot welding nugget process of mild steel and stainless steel

    Institute of Scientific and Technical Information of China (English)

    王春生; 韩凤武; 陆培德; 赵熹华; 陈勇; 邱冬生

    2002-01-01

    A three-dimensional finite difference electrical-thermal model for resistance spot welding nugget process of mild steel and stainless steel is introduced. A simulation method of the interaction of electrical and thermal factors is presented. Meanwhile, calculation method of contact resistance and treatment method of heater structure is provided. The influence of the temperature dependent material properties and various cooling boundary conditions on welding process was also taken into account in the model. A method for improving the mild steel and stainless steel joint was analyzed in numerical simulation process. Experimental verification shows that the model prediction agrees well with the practice. The model provides a useful theoretic tool for the analysis of the process of resistance spot welding of mild steel and stainless steel.

  3. An Evaluation of Signal Processing Tools for Improving Phased Array Ultrasonic Weld Inspection

    Energy Technology Data Exchange (ETDEWEB)

    Ramuhalli, Pradeep; Cinson, Anthony D.; Crawford, Susan L.; Harris, Robert V.; Diaz, Aaron A.; Anderson, Michael T.

    2011-03-24

    Cast austenitic stainless steel (CASS) commonly used in U.S. nuclear power plants is a coarse-grained, elastically anisotropic material. The coarse-grained nature of CASS makes ultrasonic inspection of in-service components difficult. Recently, low-frequency phased array ultrasound has emerged as a candidate for the CASS piping weld inspection. However, issues such as low signal-to-noise ratio and difficulty in discriminating between flaw and non-flaw signals remain. This paper discusses the evaluation of a number of signal processing algorithms for improving flaw detection in CASS materials. The full paper provides details of the algorithms being evaluated, along with preliminary results.

  4. Wave formation process upon explosive welding: electron microscopic observations and imitating experiments

    CERN Document Server

    Greenberg, B A; Inozemtsev, A V; Pushkin, M S; Patselov, A M; Elkina, O A; Kuzmin, S V; Lysak, V I

    2016-01-01

    A sequence of the interface transition states was investigated. A transition state has been found, during which cusps look like splashes. Images of the splashes for different joints have been obtained. The processes of self-organization of the splashes into a quasi-wave surface and a perfect wavy surface have been revealed. Simulations experiments have been conducted. Heterogeneity and the interface bending of one of the contacting materials have been detected. They imitate the heterogeneity on the interface arising upon explosive welding.

  5. 轮带裂纹的修复补焊工艺%Repairing Welding Process of the Crack in Rotary Kiln

    Institute of Scientific and Technical Information of China (English)

    生利英

    2012-01-01

    The repairing welding process for the cracks in rotary kiln was introduced. Practices prove that, taking the process measures, such as preheating before welding, CO2 gas shielded arc welding and Lincoln flux cored wire, annealing after welding and multiple penetration testing and ultrasonic exploration welding process, can guarantee to achieve the desired effect after welding in rotary kiln.%介绍回转窑轮带裂纹修复补焊工艺.实践证明,通过采取焊前预热,CO2tAr气体保护焊和林肯药芯焊丝,焊后退火及焊接过程中多次渗透探伤和超声波探伤等焊接工艺,可以保证补焊后轮带达到预期使用效果.

  6. Artificial neural network modeling studies to predict the friction welding process parameters of Incoloy 800H joints

    Directory of Open Access Journals (Sweden)

    K. Anand

    2015-09-01

    Full Text Available The present study focuses on friction welding process parameter optimization using a hybrid technique of ANN and different optimization algorithms. This optimization techniques are not only for the effective process modelling, but also to illustrate the correlation between the input and output responses of the friction welding of Incoloy 800H. In addition the focus is also to obtain optimal strength and hardness of joints with minimum burn off length. ANN based approaches could model this welding process of INCOLOY 800H in both forward and reverse directions efficiently, which are required for the automation of the same. Five different training algorithms were used to train ANN for both forward and reverse mapping and ANN tuned force approach was used for optimization. The paper makes a robust comparison of the performances of the five algorithms employing standard statistical indices. The results showed that GANN with 4-9-3 for forward and 4-7-3 for reverse mapping arrangement could outperform the other four approaches in most of the cases but not in all. Experiments on tensile strength (TS, microhardness (H and burn off length (BOL of the joints were performed with optimised parameter. It is concluded that this ANN model with genetic algorithm may provide good ability to predict the friction welding process parameters to weld Incoloy 800H.

  7. Resistance Upset Welding of ODS Steel Fuel Claddings—Evaluation of a Process Parameter Range Based on Metallurgical Observations

    Directory of Open Access Journals (Sweden)

    Fabien Corpace

    2017-08-01

    Full Text Available Resistance upset welding is successfully applied to Oxide Dispersion Strengthened (ODS steel fuel cladding. Due to the strong correlation between the mechanical properties and the microstructure of the ODS steel, this study focuses on the consequences of the welding process on the metallurgical state of the PM2000 ODS steel. A range of process parameters is identified to achieve operative welding. Characterizations of the microstructure are correlated to measurements recorded during the welding process. The thinness of the clad is responsible for a thermal unbalance, leading to a higher temperature reached. Its deformation is important and may lead to a lack of joining between the faying surfaces located on the outer part of the join which can be avoided by increasing the dissipated energy or by limiting the clad stick-out. The deformation and the temperature reached trigger a recrystallization phenomenon in the welded area, usually combined with a modification of the yttrium dispersion, i.e., oxide dispersion, which can damage the long-life resistance of the fuel cladding. The process parameters are optimized to limit the deformation of the clad, preventing the compactness defect and the modification of the nanoscale oxide dispersion.

  8. A MULTI-COUPLED FINITE ELEMENT ANALYSIS OF RESISTANCE SPOT WELDING PROCESS

    Institute of Scientific and Technical Information of China (English)

    Hou Zhigang; Wang Yuanxun; Li Chunzhi; Chen Chuanyao

    2006-01-01

    A two-dimensional axisymmetric finite element model is developed to analyze the transient thermal and mechanical behaviors of the Resistance Spot Welding (RSW) process using commercial software ANSYS. Firstly a direct-coupled electrical-thermal Finite Element Analysis(FEA) is performed to analyze the transient thermal characteristics of the RSW process. Then based on the thermal results a sequential coupled thermo-elastic-plastic analysis is conducted to determine the mechanical features of the RSW process. The thermal history of the whole process and the temperature distribution of the weldment are obtained through the analysis.The mechanical features, including the distributions of the contact pressure at both the faying surface and the electrode-workpiece interface, the stress and strain distributions in the weldment and their changes during the RSW process, the deformation of the weldment and the electrode displacement are also calculated.

  9. A method to simulate multilayer welding process: Node dynamic relaxation method

    Institute of Scientific and Technical Information of China (English)

    Gao Jiashuang; Yang Jianguo; Fang Hongyuan; Hu Junfeng; Wang Tao

    2009-01-01

    A new method called node dynamic relaxation is proposed to simulate multilayer welding. A two dimensional plane strain model for multilayer welding is simulated and the results show that mesh distortion can be decreased, and it is also found that the node dynamic relaxation is a kind of method to calculate welding deformation accurately by comparing experiment results with simulation results.

  10. The full penetration hole as a stochastic process: controlling penetration depth in keyhole laser-welding processes

    Science.gov (United States)

    Blug, A.; Abt, F.; Nicolosi, L.; Heider, A.; Weber, R.; Carl, D.; Höfler, H.; Tetzlaff, R.

    2012-07-01

    Although laser-welding processes are frequently used in industrial production the quality control of these processes is not satisfactory yet. Until recently, the "full penetration hole" was presumed as an image feature which appears when the keyhole opens at the bottom of the work piece. Therefore it was used as an indicator for full penetration only. We used a novel camera based on "cellular neural networks" which enables measurements at frame rates up to 14 kHz. The results show that the occurrence of the full penetration hole can be described as a stochastic process. The probability to observe it increases near the full penetration state. In overlap joints, a very similar image feature appears when the penetration depth reaches the gap between the sheets. This stochastic process is exploited by a closed-loop system which controls penetration depth near the bottom of the work piece ("full penetration") or near the gap in overlap joints ("partial penetration"). It guides the welding process at the minimum laser power necessary for the required penetration depth. As a result, defects like spatters are reduced considerably and the penetration depth becomes independent of process drifts such as feeding rate or pollution on protection glasses.

  11. Space plasma physics stationary processes

    CERN Document Server

    Hasegawa, Akira

    1989-01-01

    During the 30 years of space exploration, important discoveries in the near-earth environment such as the Van Allen belts, the plasmapause, the magnetotail and the bow shock, to name a few, have been made. Coupling between the solar wind and the magnetosphere and energy transfer processes between them are being identified. Space physics is clearly approaching a new era, where the emphasis is being shifted from discoveries to understanding. One way of identifying the new direction may be found in the recent contribution of atmospheric science and oceanography to the development of fluid dynamics. Hydrodynamics is a branch of classical physics in which important discoveries have been made in the era of Rayleigh, Taylor, Kelvin and Helmholtz. However, recent progress in global measurements using man-made satellites and in large scale computer simulations carried out by scientists in the fields of atmospheric science and oceanography have created new activities in hydrodynamics and produced important new discover...

  12. Recent Corrosion Research Trends in Weld Joints

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Hwan Tae; Kil, Sang Cheol [Korea Institute of Science and Technology Information, Seoul (Korea, Republic of); Hwang, Woon Suk [Inha University, Incheon (Korea, Republic of)

    2007-04-15

    The increasing interest in the corrosion properties of weld joints in the corrosive environment is placing stringent demands on the manufacturing techniques and performance requirements, and the manufacture employs the high quality and efficiency welding process to produce welds. Welding plays an important role in the fabrication of chemical plants, nuclear power plant, ship construction, and this has led to an increasing attention to the corrosion resistant weld joints. This paper covers recent technical trends of welding technologies for corrosion resistance properties including the COMPENDEX DB analysis of welding materials, welding process, and welding fabrications

  13. Signal processing methods for MFE plasma diagnostics

    Energy Technology Data Exchange (ETDEWEB)

    Candy, J.V.; Casper, T.; Kane, R.

    1985-02-01

    The application of various signal processing methods to extract energy storage information from plasma diamagnetism sensors occurring during physics experiments on the Tandom Mirror Experiment-Upgrade (TMX-U) is discussed. We show how these processing techniques can be used to decrease the uncertainty in the corresponding sensor measurements. The algorithms suggested are implemented using SIG, an interactive signal processing package developed at LLNL.

  14. Welded Kimberlite?

    Science.gov (United States)

    van Straaten, B. I.; Kopylova, M. G.; Russell, J. K.; Scott Smith, B. H.

    2009-05-01

    Welding of pyroclastic deposits generally involves the sintering of hot glassy vesicular particles and requires the presence of a load and/or high temperatures. Welding can occur on various scales as observed in large welded pyroclastic flows, in small-volume agglutinated spatter rims, or as in coalesced clastogenic lava flows. In all these examples welding occurs mainly by reduction or elimination of porosity within the vesicular clasts and/or inter-clast pore space. The end result of welding in pyroclastic deposits is to produce dense, massive, coherent deposits. Here, we present a possible new end-member of the welding process: welding of non- vesicular pyroclasts in intra-crater kimberlite deposits. Kimberlite melt is a low-viscosity liquid carrying abundant crystals. Because of this, kimberlite eruptions generally produce non-vesicular pyroclasts. During welding, these pyroclast cannot deform by volume reduction to form typical fiamme. As a result, welding and compaction in kimberlites proceeds via the reduction of inter-clast pore space alone. The lack of porous pyroclasts limits the maximum amount of volumetric strain within pyroclastic kimberlite deposits to about 30%. This value is substantially lower than the limiting values for welding of more common felsic pyroclastic flows. The lower limit for volumetric strain in welded kimberlite deposits severely restricts the development of a fabric. In addition, pyroclastic kimberlite deposits commonly feature equant-shaped pyroclasts, and equant-shaped crystals. This, in turn, limits the visibility of the results of compaction and pore space reduction, as there are few deformable markers and elongate rigid markers that are able to record the strain during compaction. These features, together with the low viscosity of kimberlite magma and the stratigraphic position of these kimberlite deposits within the upper reaches of the volcanic conduit, call for careful interpretation of coherent-looking rocks in these

  15. Spot Welding Parameter Optimization to Improve Weld Characteristics for Dissimilar Metals

    OpenAIRE

    Aravinthan Arumugam; MohdAmizi Nor

    2015-01-01

    Abstract Resistance spot welding is a process which is widely used in the automotive industry to join steel parts of various thicknesses and types. The current practice in the automotive industry in determining the welding schedule which will be used in the welding process is based on welding table or experiences. This however may not be the optimum welding schedule that will give the best spot weld quality. This work concentrates on the parameter optimization when spot welding steels with di...

  16. The effect of welding fixtures on welding distortions

    OpenAIRE

    2007-01-01

    Purpose: of this paper is to examine the effect of welding fixture used to prevent the distortions duringcooling process utilizing a robot controlled gas metal arc welding method on cooling rate and distortions ofwelded structures.Design/methodology/approach: Using a specially designed welding fixture for a welded steel structure, sixdifferent types of AISI 1020 steel specimens are tested in three different welding speeds and two differentcooling conditions either at fixture or without using ...

  17. Treatment of welding electrode manufacturing plant wastewater using coagulation/flocculation-nanofiltration as a hybrid process

    Directory of Open Access Journals (Sweden)

    H. A. Golestani

    2011-03-01

    Full Text Available High water consumption and water scarcity make industrial wastewater reuse necessary, especially in those industries characterized by polluted effluents such as welding electrode manufacturing industries. The present paper investigates the coupling of coagulation-flocculation with nanofiltration (NF to recycle water and reuse it in the process. First, the effect of different concentrations of a mixture of alum (Al2(SO43.18H2O and ferric chloride (FeCl3 on the pretreatment process was closely studied. Then the NF process was applied for complementary treatment. The NF results show that, by increasing both flow rate and transmembrane pressure (TMP, permeate flux is increased. The NF results also show that the COD value decreases below 2 mg/l, TDS rejection approaches 82%, turbidity decreases below 1 NTU and the hardness is lower than the factory constraint (100 mg/l as CaCO3, allowing the reuse of the treated wastewater in the process.

  18. Nonthermal Radiation Processes in Interplanetary Plasmas

    Science.gov (United States)

    Chian, A. C. L.

    1990-11-01

    RESUMEN. En la interacci6n de haces de electrones energeticos con plasmas interplanetarios, se excitan ondas intensas de Langmuir debido a inestabilidad del haz de plasma. Las ondas Langmuir a su vez interaccio nan con fluctuaciones de densidad de baja frecuencia para producir radiaciones. Si la longitud de las ondas de Langmujr exceden las condicio nes del umbral, se puede efectuar la conversi5n de modo no lineal a on- das electromagneticas a traves de inestabilidades parametricas. As se puede excitar en un plasma inestabilidades parametricas electromagneticas impulsadas por ondas intensas de Langmuir: (1) inestabilidades de decaimiento/fusi5n electromagnetica impulsadas por una bomba de Lang- muir que viaja; (2) inestabilidades dobles electromagneticas de decai- miento/fusi5n impulsadas por dos bombas de Langrnuir directamente opues- tas; y (3) inestabilidades de dos corrientes oscilatorias electromagne- ticas impulsadas por dos bombas de Langmuir de corrientes contrarias. Se concluye que las inestabilidades parametricas electromagneticas in- ducidas por las ondas de Langmuir son las fuentes posibles de radiacio- nes no termicas en plasmas interplanetarios. ABSTRACT: Nonthermal radio emissions near the local electron plasma frequency have been detected in various regions of interplanetary plasmas: solar wind, upstream of planetary bow shock, and heliopause. Energetic electron beams accelerated by solar flares, planetary bow shocks, and the terminal shock of heliosphere provide the energy source for these radio emissions. Thus, it is expected that similar nonthermal radiation processes may be responsible for the generation of these radio emissions. As energetic electron beams interact with interplanetary plasmas, intense Langmuir waves are excited due to a beam-plasma instability. The Langmuir waves then interact with low-frequency density fluctuations to produce radiations near the local electron plasma frequency. If Langmuir waves are of sufficiently large

  19. Vision of the Arc for Quality Documentation and for Closed Loop Control of the Welding Process

    DEFF Research Database (Denmark)

    Kristiansen, Morten; Kristiansen, Ewa; Jensen, Casper Houmann;

    2014-01-01

    For gas metal arc welding a vision system was developed, which was robust to monitor the position of the arc. The monitoring documents the welding quality indirectly and a closed loop fuzzy control was implemented to control an even excess penetration. For welding experiments on a butt......-joint with a V-groove with varying root gapthe system demonstrated increased welding quality compared to the system with no control. The system was implemented with a low cost vision system, which makes the system interesting to apply in industrial welding automation systems....

  20. 挖掘机动臂单边V形坡口角焊缝的焊接工艺与应用%Welding Processes and Applications Excavator Boom Unilateral V-shaped Bevel Welds

    Institute of Scientific and Technical Information of China (English)

    宋秀山

    2014-01-01

    The study of the excavator boom unilateral V-shaped groove welding process to solve the lack of penetration, cracks, slag and other welding defects in the welding process unilateral V-shaped groove that appears to improve the boom overall reliability.%通过对挖掘机动臂单边V形坡口焊接工艺的研究,解决了在焊接过程中单边V形坡口出现的未焊透、裂纹、夹渣等焊接缺陷,提高了动臂的整体可靠性。