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Sample records for weld tests

  1. Laser Welding Test Results with Gas Atmospheres in Welding Chamber

    Energy Technology Data Exchange (ETDEWEB)

    Joung, Chang-Young; Hong, Jin-Tae; Ahn, Sung-Ho; Heo, Sung-Ho; Jang, Seo-Yun; Yang, Tae-Ho [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2015-10-15

    The weld beads of specimens welded under identical conditions in the helium and argon gas were cleaner, more regular, and steadier than those in a vacuum. The penetration depth of the FZ in the vacuum was much deeper than those in the helium and argon gas. To measure the irradiation properties of nuclear fuel in a test reactor, a nuclear fuel test rod instrumented with various sensors must be fabricated with assembly processes. A laser welding system to assemble the nuclear fuel test rod was designed and fabricated to develop various welding technologies of the fuel test rods to joint between a cladding tube and end-caps. It is an air-cooling optical fiber type and its emission modes are a continuous (CW) mode of which the laser generates continuous emission, and pulse (QCW) mode in which the laser internally generates sequences of pulses. We considered the system welding a sample in a chamber that can weld a specimen in a vacuum and inert gas atmosphere, and the chamber was installed on the working plate of the laser welding system. In the chamber, the laser welding process should be conducted to have no defects on the sealing area between a cladding tube and an end-cap.

  2. Microhardness Testing of Aluminum Alloy Welds

    Science.gov (United States)

    Bohanon, Catherine

    2009-01-01

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

  3. Testing and Modeling of Mechanical Characteristics of Resistance Welding Machines

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels;

    2003-01-01

    The dynamic mechanical response of resistance welding machine is very important to the weld quality in resistance welding especially in projection welding when collapse or deformation of work piece occurs. It is mainly governed by the mechanical parameters of machine. In this paper, a mathematical...... for both upper and lower electrode systems. This has laid a foundation for modeling the welding process and selecting the welding parameters considering the machine factors. The method is straightforward and easy to be applied in industry since the whole procedure is based on tests with no requirements...

  4. Friction welding; Magnesium; Finite element; Shear test.

    Directory of Open Access Journals (Sweden)

    Leonardo Contri Campanelli

    2013-06-01

    Full Text Available Friction spot welding (FSpW is one of the most recently developed solid state joining technologies. In this work, based on former publications, a computer aided draft and engineering resource is used to model a FSpW joint on AZ31 magnesium alloy sheets and subsequently submit the assembly to a typical shear test loading, using a linear elastic model, in order to conceive mechanical tests results. Finite element analysis shows that the plastic flow is concentrated on the welded zone periphery where yield strength is reached. It is supposed that “through the weld” and “circumferential pull-out” variants should be the main failure behaviors, although mechanical testing may provide other types of fracture due to metallurgical features.

  5. The ultrasonic testing of the spot welded different steel sheets

    Directory of Open Access Journals (Sweden)

    M. Vural

    2006-08-01

    Full Text Available Purpose: Purpose of this paper is to investigate the applicability of spot welded different steel sheets toultrasonic testing, because resistance spot welding of the steel sheets is widely used in the car bodies andtransport fields and ultrasonic testing is a good way to evaluate the fatique life of the spot welds.Design/methodology/approach: Methodology of this paper is that two different steel sheets (AISI 304 typeaustenitic stainless steel sheet and Galvanized steel sheet were welded to each other by using resistance spotwelding. Some pre-welding tests were made to obtain suitable and optimum weld nugget diameter; and thewelding current vs. nugget diameter curve were obtained. By using this curve and kepting constant weldingparameters such as current, electrode pressure, weld time, etch., fully identical four spot welded specimenshaving 5 mm (±0.2 nugget diameter were obtained. The specimens and nugget diameters were tested by usinga special ultrasonic test apparatus which is designed for spot welded joints.Findings: Findings are that after the first ultrasonic tests, the four identical spot welded sheets which have AISI304 – Galvanized steel sheet combination were subjected to the fatigue test in four different number of cycles.There is no any rupture or fracture in spot welded joints after fatigue tests. The spot welded specimens subjectedto fatigue test were tested in ultrasonic test apparatus to observe the variation in the weld nugget and joint. Theultrasonic test results before fatigue and after fatigue were compared with each other; and the decreasing of theweld nugget diameter were observed while increasing the number of cycles. The results were shown in figuresand discussed.Research limitations/implications: Spot welding of different steel sheets forms different microstructures whichrespond different values to ultrasonic testing. Evaluation of these responses are quiet difficult.Practical implications: Only a few spot welds can be

  6. Identification of the Quality Spot Welding used Non Destructive Test-Ultrasonic Testing: (Effect of Welding Time)

    Science.gov (United States)

    Sifa, A.; Endramawan, T.; Badruzzaman

    2017-03-01

    Resistance Spot Welding (RSW) is frequently used as one way of welding is used in the manufacturing process, especially in the automotive industry [4][5][6][7]. Several parameters influence the process of welding points. To determine the quality of a welding job needs to be tested, either by damaging or testing without damage, in this study conducted experimental testing the quality of welding or identify quality of the nugget by using Non-Destructive Test (NDT) –Ultrasonic Testing (UT), in which the identification of the quality of the welding is done with parameter thickness of worksheet after welding using NDT-UT with use same material worksheet and have more thickness of worksheet, the thickness of the worksheet single plate 1mm, with the capability of propagation Ultrasonic Testing (UT) standard limited> 3 mm [1], welding process parameters such as the time difference between 1-10s and the welding current of 8 KV, visually Heat Affected Zone ( HAZ ) have different results due to the length of time of welding. UT uses a probe that is used with a frequency of 4 MHz, diameter 10 mm, range 100 and the couplant used is oil. Identification techniques using drop 6dB, with sound velocity 2267 m / s of Fe, with the result that the effect of the Welding time affect the size of the HAZ, identification with the lowest time 1s show results capable identified joined through NDT - UT.

  7. 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…

  8. Electrochemical Testing of Gas Tungsten Arc Welded and Reduced Pressure Electron Beam Welded Alloy 22

    Energy Technology Data Exchange (ETDEWEB)

    Day, S D; Wong, F M G; Gordon, S R; Wong, L L; Rebak, R B

    2003-09-07

    Alloy 22 (N06022) is the material selected for the fabrication of the outer shell of the nuclear waste containers for the Yucca Mountain high-level nuclear waste repository site. A key technical issue in the Yucca Mountain waste package program has been the integrity of container weld joints. The currently selected welding process for fabricating and sealing the containers is the traditional gas tungsten arc welding (GTAW) or TIG method. An appealing faster alternative technique is reduced pressure electron beam (RPEB) welding. Standard electrochemical tests were carried on GTAW and RPEB welds as well as on base metal to determine their relative corrosion behavior in SCW at 90 C (alkaline), 1 M HCl at 60 C (acidic) and 1 M NaCl at 90 C (neutral) solutions. Results show that for all practical purposes, the three tested materials had the electrochemical behavior in the three tested solutions.

  9. Testing and Modeling of Machine Properties in Resistance Welding

    DEFF Research Database (Denmark)

    Wu, Pei

    electrode force, and the time of stabilizing does not depend on the level of the force. An additional spring mounted in the welding head improves the machine touching behavior due to a soft electrode application, but this results in longer time of oscillation of the electrode force, especially when......The objective of this work has been to test and model the machine properties including the mechanical properties and the electrical properties in resistance welding. The results are used to simulate the welding process more accurately. The state of the art in testing and modeling machine properties...... in resistance welding has been described based on a comprehensive literature study. The present thesis has been subdivided into two parts: Part I: Mechanical properties of resistance welding machines. Part II: Electrical properties of resistance welding machines. In part I, the electrode force in the squeeze...

  10. Weld Tests Conducted by the Idaho National Laboratory

    Energy Technology Data Exchange (ETDEWEB)

    Larry Zirker; Lance Lauerhass; James Dowalo

    2007-02-01

    During the fiscal year of 2006, the Idaho National Laboratory (INL) performed many tests and work relating to the Mobile Melt-Dilute (MMD) Project components. Tests performed on the Staubli quick disconnect fittings showed promising results, but more tests were needed validate the fittings. Changes were made to the shield plug design—reduced the closure groove weld depth between the top of the canister and the top plate of the shielding plug from 0.5-in to 0.375-in deep. Other changes include a cap to cover the fitting, lifting pintle and welding code citations on the prints. Tests conducted showed stainless steel tubing, with 0.25-in, 0.375-in, and 0.5-in diameters, all with 0.035-in wall thickness, could be pinch seal welded using commercially available resistance welding equipment. Subsequent testing showed that these welds could be real-time inspected with ultrasonic inspection methods.

  11. Electrochemical Testing of Gas Tungsten ARC Welded and Reduced Pressure Electron Beam Welded Alloy 22

    Energy Technology Data Exchange (ETDEWEB)

    S. Daniel Day; Frank M.G. Wong; Steven R. Gordon; Lana L. Wong; Raul B. Rebak

    2006-05-08

    Alloy 22 (N06022) is the material selected for the fabrication of the outer shell of the nuclear waste containers for the Yucca Mountain high-level nuclear waste repository site. A key technical issue in the waste package program has been the integrity of the container weld joints. The currently selected welding process for fabricating and sealing the containers is the traditional gas tungsten arc welding (GTAW) or TIC method. An appealing faster alternative technique is reduced pressure electron beam (RPEB) welding. It was of interest to compare the corrosion properties of specimens prepared using both types of welding techniques. Standard electrochemical tests were carried on GTAW and RPEB welds as well as on base metal (non-welded) to determine their relative corrosion behavior in simulated concentrated water (SCW) at 90 C (alkaline), 1 M HCI at 60 C (acidic) and 1 M NaCl at 90 C (neutral) solutions. Results show that for all practical purposes, the three tested materials had the same electrochemical behavior in the three tested electrolytes.

  12. Low temperature impact testing of welded structural wrought iron

    Science.gov (United States)

    Rogers, Zachary

    During the second half of the 19th century, structural wrought iron was commonly used in construction of bridges and other structures. Today, these remaining structures are still actively in use and may fall under the protection of historic preservation agencies. Continued use and protection leads to the need for inspection, maintenance, and repair of the wrought iron within these structures. Welding can be useful to achieve the appropriate repair, rehabilitation, or replacement of wrought iron members. There is currently very little published on modern welding techniques for historic wrought iron. There is also no pre-qualified method for this welding. The demand for welding in the repair of historic structural wrought iron has led to a line of research investigating shielded metal arc welding (SMAW) of historic wrought iron at the University of Colorado Denver. This prior research selected the weld type and other weld specifications to try and achieve a recognized specific welding procedure using modern SMAW technology and techniques. This thesis continues investigating SMAW of historic wrought iron. Specifically, this thesis addresses the toughness of these welds from analysis of the data collected from performing Charpy V-Notch (CVN) Impact Tests. Temperature was varied to observe the material response of the welds at low temperature. The wrought iron used in testing was from a historic vehicle bridge in Minnesota, USA. This area, and many other areas with wrought iron structures, can experience sustained or fluctuating temperatures far below freezing. Investigating the toughness of welds in historic wrought iron at these temperatures is necessary to fully understand material responses of the existing structures in need of maintenance and repair. It was shown that welded wrought iron is tougher and more ductile than non-welded wrought iron. In regards to toughness, welding is an acceptable repair method. Information on wrought iron, low temperature failure

  13. TIG-dressing of High Strength Butt Welded Connection. Part 2: Physical Testing and Modelling

    NARCIS (Netherlands)

    Van Es, S.H.J.; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2014-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging

  14. TIG-dressing of high strength butt welded connection - Part 2: physical testing and modelling

    NARCIS (Netherlands)

    Es, S.H.J. van; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2013-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging

  15. TIG-dressing of high strength butt welded connection - Part 2: physical testing and modelling

    NARCIS (Netherlands)

    Es, S.H.J. van; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2013-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging fro

  16. TIG-dressing of High Strength Butt Welded Connection. Part 2: Physical Testing and Modelling

    NARCIS (Netherlands)

    Van Es, S.H.J.; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2014-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging fro

  17. Testing and Modeling of Contact Problems in Resistance Welding

    DEFF Research Database (Denmark)

    Song, Quanfeng

    As a part of the efforts towards a professional and reliable numerical tool for resistance welding engineers, this Ph.D. project is dedicated to refining the numerical models related to the interface behavior. An FE algorithm for the contact problems in resistance welding has been developed...... together two or three cylindrical parts as well as disc-ring pairs of dissimilar metals. The tests have demonstrated the effectiveness of the model. A theoretical and experimental study is performed on the contact resistance aiming at a more reliable model for numerical simulation of resistance welding....... The model currently employed is evaluated. It is found that the model may underestimate the constriction resistance because it is based on the assumption of continual contact area. A new model is proposed on the constriction resistance in resistance welding. A parametric study is performed on the contact...

  18. Characterization of Nitinol Laser-Weld Joints by Nondestructive Testing

    Science.gov (United States)

    Wohlschlögel, Markus; Gläßel, Gunter; Sanchez, Daniela; Schüßler, Andreas; Dillenz, Alexander; Saal, David; Mayr, Peter

    2015-12-01

    Joining technology is an integral part of today's Nitinol medical device manufacturing. Besides crimping and riveting, laser welding is often applied to join components made from Nitinol to Nitinol, as well as Nitinol components to dissimilar materials. Other Nitinol joining techniques include adhesive bonding, soldering, and brazing. Typically, the performance of joints is assessed by destructive mechanical testing, on a process validation base. In this study, a nondestructive testing method—photothermal radiometry—is applied to characterize small Nitinol laser-weld joints used to connect two wire ends via a sleeve. Two different wire diameters are investigated. Effective joint connection cross sections are visualized using metallography techniques. Results of the nondestructive testing are correlated to data from destructive torsion testing, where the maximum torque at fracture is evaluated for the same joints and criteria for the differentiation of good and poor laser-welding quality by nondestructive testing are established.

  19. Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing.

    Science.gov (United States)

    Villegas, Irene F; Palardy, Genevieve

    2016-02-11

    This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints.

  20. Material test data of SUS304 welded joints

    Energy Technology Data Exchange (ETDEWEB)

    Asayama, Tai [Japan Nuclear Cycle Development Inst., Oarai, Ibaraki (Japan). Oarai Engineering Center; Kawakami, Tomohiro [Nuclear Energy System Incorporation, Tokyo (Japan)

    1999-10-01

    This report summarizes the material test data of SUS304 welded joints. Numbers of the data are as follows: Tensile tests 71 (Post-irradiation: 39, Others: 32), Creep tests 77 (Post-irradiation: 20, Others: 57), Fatigue tests 50 (Post-irradiation: 0), Creep-fatigue tests 14 (Post-irradiation: 0). This report consists of the printouts from 'the structural material data processing system'. (author)

  1. High Strain Rate Testing of Welded DOP-26 Iridium

    Energy Technology Data Exchange (ETDEWEB)

    Schneibel, J. H. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Miller, R. G. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Carmichael, C. A. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Fox, E. E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Ulrich, G. B. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); George, E. P. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

    2017-08-01

    The iridium alloy DOP-26 is used to produce Clad Vent Set cups that protect the radioactive fuel in radioisotope thermoelectric generators (RTGs) which provide electric power for spacecraft and rovers. In a previous study, the tensile properties of DOP-26 were measured over a wide range of strain rates and temperatures and reported in ORNL/TM-2007/81. While that study established the properties of the base material, the fabrication of the heat sources requires welding, and the mechanical properties of welded DOP-26 have not been extensively characterized in the past. Therefore, this study was undertaken to determine the mechanical properties of DOP-26 specimens containing a transverse weld in the center of their gage sections. Tensile tests were performed at room temperature, 750, 900, and 1090°C and engineering strain rates of 1×10-3 and 10 s-1. Room temperature testing was performed in air, while testing at elevated temperatures was performed in a vacuum better than 1×10-4 Torr. The welded specimens had a significantly higher yield stress, by up to a factor of ~2, than the non-welded base material. The yield stress did not depend on the strain rate except at 1090°C, where it was slightly higher for the faster strain rate. The ultimate tensile stress, on the other hand, was significantly higher for the faster strain rate at temperatures of 750°C and above. At 750°C and above, the specimens deformed at 1×10-3 s-1 showed pronounced necking resulting sometimes in perfect chisel-edge fracture. The specimens deformed at 10 s-1 exhibited this fracture behavior only at the highest test temperature, 1090°C. Fracture occurred usually in the fusion zone of the weld and was, in most cases, primarily intergranular.

  2. TIG-dressing of High Strength Butt Welded Connection. Part 2: Physical Testing and Modelling

    OpenAIRE

    Van Es, S.H.J.; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2014-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging from S460 to S1100 in the TIG-dressed condition. The test results are compared with modelled fatigue strength according to the notch stress theory and similar specimens in the as-welded condition. The...

  3. Development of Welding and Instrumentation Technology for Nuclear Fuel Test Rod

    Energy Technology Data Exchange (ETDEWEB)

    Joung, Chang Young; Ahn, Sung Ho; Heo, Sung Ho; Hong, Jin Tae; Kim, Ka Hye [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2013-10-15

    It is necessary to develop various types of welding, instrumentation and helium gas filling techniques that can conduct TIG spot welding exactly at a pin-hole of the end-cap on the nuclear fuel rod to fill up helium gas. The welding process is one of the most important among the instrumentation processes of the nuclear fuel test rod. To manufacture the nuclear fuel test rod, a precision welding system needs to be fabricated to develop various welding technologies of the fuel test rod jointing the various sensors and end-caps on a fuel cladding tube, which is charged with fuel pellets and component parts. We therefore designed and fabricated an orbital TIG welding system and a laser welding system. This paper describes not only some experiment results from weld tests for the parts of a nuclear fuel test rod, but also the contents for the instrumentation process of the dummy fuel test rod installed with the C-type T. C. A dummy nuclear fuel test rod was successfully fabricated with the welding and instrumentation technologies acquired with various tests. In the test results, the round welding has shown a good weldability at both the orbital TIG welding system and the fiber laser welding system. The spot welding to fill up helium gas has shown a good welding performance at a welding current of 30A, welding time of 0.4 sec and gap of 1 mm in a helium gas atmosphere. The soundness of the nuclear fuel test rod sealed by a mechanical sealing method was confirmed by helium leak tests and microstructural analyses.

  4. Sturdy on Orbital TIG Welding Properties for Nuclear Fuel Test Rod

    Energy Technology Data Exchange (ETDEWEB)

    Joung, Changyoung; Hong, Jintae; Kim, Kahye; Huh, Sungho [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2014-05-15

    We developed a precision TIG welding system that is able to weld the seam between end-caps and a fuel cladding tube for the nuclear fuel test rod and rig. This system can be mainly classified into an orbital TIG welder (AMI, M-207A) and a pressure chamber. The orbital TIG welder can be independently used, and it consists of a power supply unit, a microprocessor, water cooling unit, a gas supply unit and an orbital weld head. In this welder, the power supply unit mainly supplies GTAW power for a welding specimen and controls an arc starting of high frequency, supping of purge gas, arc rotation through the orbital TIG welding head, and automatic timing functions. In addition, the pressure chamber is used to make the welded surface of the cladding specimen clean with the inert gas filled inside the chamber. To precisely weld the cladding tube, a welding process needs to establish a schedule program for an orbital TIG welding. Therefore, the weld tests were performed on a cladding tube and dummy rods under various conditions. This paper describes not only test results on parameters of the purge gas flow rates and the chamber gas pressures for the orbital TIG welding, but also test results on the program establishment of an orbital TIG welding system to weld the fuel test rods. Various welding tests were performed to develop the orbital TIG welding techniques for the nuclear fuel test rod. The width of HAZ of a cladding specimen welded with the identical power during an orbital TIG welding cycle was continuously increased from a welded start-point to a weld end-point because of heat accumulation. The welding effect of the PGFR and CGP shows a relatively large difference for FSS and LSS. Each hole on the cladding specimens was formed in the 1bar CGP with the 20L/min PGFR but not made in the case of the PGFR of 10L/min in the CGP of 2bar. The optimum schedule program of the orbital TIG welding system to weld the nuclear fuel test rod was established through the program

  5. Eddy current testing system for bottom mounted instrumentation welds

    Directory of Open Access Journals (Sweden)

    Kobayashi Noriyasu

    2015-01-01

    Full Text Available The capability of eddy current testing (ECT for the bottom mounted instrumentation (BMI weld area of reactor vessel in a pressurized water reactor was demonstrated by the developed ECT system and procedure. It is difficult to position and move the probe on the BMI weld area because the area has complexly curved surfaces. The space coordinates and the normal vectors at the scanning points were calculated as the scanning trajectory of probe based on the measured results of surface shape on the BMI mock-up. The multi-axis robot was used to move the probe on the mock-up. Each motion-axis position of the robot corresponding to each scanning point was calculated by the inverse kinematic algorithm. In the mock-up test, the probe was properly contacted with most of the weld surfaces. The artificial stress corrosion cracking of approximately 6 mm in length and the electrical-discharge machining slit of 0.5 mm in length, 1 mm in depth and 0.2 mm in width given on the weld surface were detected. From the probe output voltage, it was estimated that the average probe tilt angle on the surface under scanning was 2.6°.

  6. Welding for testability: An approach aimed at improving the ultrasonic testing of thick-walled austenitic and dissimilar metal welds

    Energy Technology Data Exchange (ETDEWEB)

    Wagner, Sabine; Dugan, Sandra [Materials Testing Institute University of Stuttgart (MPA), Pfaffenwaldring 32, 70569 Stuttgart (Germany); Barth, Martin; Schubert, Frank; Köhler, Bernd [Fraunhofer Institute for Nondestructive Testing, Dresden Branch (IZFP-D), Maria-Reiche-Str. 2, 01109 Dresden (Germany)

    2014-02-18

    Austenitic and dissimilar welds in thick walled components show a coarse grained, dendritic microstructure. Therefore, ultrasonic testing has to deal with beam refraction, scattering and mode conversion effects. As a result, the testing techniques typically applied for isotropic materials yield dissatisfying results. Most approaches for improvement of ultrasonic testing have been based on modeling and improved knowledge of the complex wave propagation phenomena. In this paper, we discuss an alternative approach: is it possible to use a modified welding technology which eliminates the cause of the UT complications, i.e. the large-grained structure of the weld seams? Various modification parameters were tested, including: TIG current pulsing, additional DC and AC magnetic fields, and also additional external vibrations during welding. For all welds produced under different conditions, the grain structure of the weld seam was characterized by optical and GIUM microstructure visualizations on cross sections, wave field propagation measurements, and ultrasonic tests of correct detectability of flaws. The mechanical properties of the welds were also tested.

  7. Statistical tools for weld defect evaluation in radiographic testing

    Energy Technology Data Exchange (ETDEWEB)

    Nacereddine, N.; Tridi, M. [LTSI, Centre de Recherche en Soudage et Controle, Alger (Algeria); Hamami, L. [Ecole National Polytechnique, Alger (Algeria). Dept. Electronique; Ziou, D. [Sherbrooke Univ., Quebec (Canada). DMI, Faculte des Sciences

    2006-07-01

    A reliable detection of defects in welded joints is one of the most important tasks in non-destructive testing by radiography, since the human factor still has a decisive influence on the evaluation of defects on the film. An incorrect classification may disapprove a piece in good conditions or approve a piece with discontinuities exceeding the limit established by the applicable standards. The progresses in computer science and the artificial intelligence techniques have allowed the welded joint quality interpretation to be carried out by using pattern recognition tools, making the system of the weld inspection more reliable, reproducible and faster. In this work, we develop and implement algorithms based on statistical approaches for segmentation and classification of the weld defects. Because of the complex nature of the considered images and so that the extracted defect area represents the most accurately possible the real defect, and that the detected defect corresponds as well as possible to its real class, the choice of the algorithms must be very judicious. In order to achieve this, a comparative study of the various segmentation and classification methods was performed to demonstrate the advantages of the ones in comparison with the others giving to the most optimal combinations. (orig.)

  8. Forming Tests for Laser Welded Blanks

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove; Rasmussen, Mads

    1998-01-01

    In this paper different means for testing the formability of new material combinations used as tailored blanks in the automotive industry are presented. The following forming techniques will be described and their benefits and drawbacks presented :Limiting Dome Height test (LDH)Limiting Drawing...

  9. Standard practice for ultrasonic testing of the Weld Zone of welded pipe and tubing

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2010-01-01

    1.1 This practice describes general ultrasonic testing procedures for the detection of discontinuities in the weld and adjacent heat affected zones of welded pipe and tubing by scanning with relative motion between the search unit and pipe or tube. When contact or unfocused immersion search units are employed, this practice is intended for tubular products having specified outside diameters ≥2 in. (≥50 mm) and specified wall thicknesses of 1/8to 11/16 in. (3 to 27 mm). When properly focused immersion search units are employed, this practice may also be applied to material of smaller diameter and thinner wall. Note 1—When contact or unfocused immersion search units are used, precautions should be exercised when examining pipes or tubes near the lower specified limits. Certain combinations of search unit size, frequency, thin–wall thicknesses, and small diameters could cause generation of unwanted sound waves that may produce erroneous examination results. 1.2 All surfaces of material to be examined in ...

  10. Field application of phased array ultrasonic testing for structural weld overlay on dissimilar welds of pressurizer nozzles

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Jin Hoi; Kim, Yong Sik [Korea Hydro and Nuclear Power Company Ltd., Central Research Institute, Daejeon (Korea, Republic of)

    2015-08-15

    Weld overlay was first used in power plants in the US in the early 1980s as an interim method of repairing the welds of flawed piping joints. Weld overlaid piping joints in nuclear power plants must be examined periodically using ultrasonic examination technology. Portable phased array ultrasonic technology has recently become available. Currently, the application of preemptive weld overlays as a mitigation technique and/as a method to improve the examination surface condition for more complex configurations is becoming more common. These complex geometries may require several focused conventional transducers for adequate inspection of the overlay, the original weld, and the base material. Alternatively, Phased array ultrasonic probes can be used to generate several inspection angles simultaneously at various focal depths to provide better and faster coverage than that possible by conventional methods. Thus, this technology can increase the speed of examinations, save costs, and reduce radiation exposure. In this paper, we explain the general sequence of the inspection of weld overlay and the results of signal analysis for some PAUT (phased array ultrasonic testing) signals detected in on-site inspections.

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

    Science.gov (United States)

    2010-09-01

    2 Welding The material used in this study was quenched and tempered martensitic HY80 steel which conforms to MIL-S-1621 [2]. The testing...Canada Fibre Laser Welding of HY-80 Steel Proceedure Development and Testing Christopher Bayley DLP Neil Aucoin DLP Xinjin Cao NRC IAR AMTC Technical...Memorandum DRDC Atlantic TM 2009-187 September 2010 This page intentionally left blank. Fibre Laser Welding of HY-80 Steel Procedure

  12. Systemic inflammatory responses following welding inhalation challenge test

    Directory of Open Access Journals (Sweden)

    Paula Kauppi

    2015-01-01

    Conclusions: Exposure to MS and SS welding fume resulted in a mild systemic inflammatory response. The particle concentration from the breathing zones correlated with the measurements inside the welding face shields.

  13. Root causes for failures in flattening test in high frequency induction welded steel pipe mill

    Energy Technology Data Exchange (ETDEWEB)

    Babakri, Khalid Ali [Saudi Steel Pipe Company, Dammam, (Saudi Arabia)

    2010-07-01

    The flattening test is used to test weld integrity in high frequency induction welded (HFIW) steel pipe mills. The flattening test failures happen mostly with the formation of oxides in the weld area during HFIZ process. This study investigated the root causes for failure in flattening test due to improper process control in the HFIW steel pipe mill. Several flattening tests have been carried out on API 5L X60 steel pipes with various chemical compositions and various procedures (height of the ductility test). A microstructure analysis was also established (EDAX analysis). Based on the experimental data, it is found that the mills can improve flattening test performance by applying various policies. It is proposed that the acceptance criteria in the international specifications related to the test of weld ductility be modified. The reasonable height for measuring weld ductility is usually at two thirds of the specified outside diameter of the pipe.

  14. Development of Fabrication Procedure and Welding Performance Test for ITER HCCR TBM

    Energy Technology Data Exchange (ETDEWEB)

    Yoon, J. S.; Lee, E. H.; Kim, S. K.; Lee, D. W.; Shin, K. I.; Jin, H. G. [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of); Cho, S. [National Fusion Research Institute, Daejeon (Korea, Republic of)

    2014-05-15

    Korea has developed and plans to test a Helium Cooled Ceramic Reflector (HCCR) Test Blanket Module (TBM) in the ITER. The HCCR TBM is composed of four sub-modules and a back manipulator (BM). Each sub-module is composed of a first wall (FW), a breeding box with a seven-layer breeding zone (BZ), and side walls (SW) with a cooling path. The front surface of the sub-module is 231 mm in width and 835 mm in height. The test specimens of the ARAA were prepared to test the weldability for tungsten inert gas (TIG) welding and electron beam (EB) welding. To establish and optimize the welding procedure in an EB weld from ARRA material, the variation in the bead width and penetration depth according to the welding current and welding speed were investigated. To verify the weldability and fabrication procedure for a complex structure such as the breeding zone, a small box with a cooling channel is being fabricated using the ARAA steel under development. A fabrication procedure of a HCCR TBM submodule was designed for a first wall, breeding zone including the side wall, and assembled sub-module by welding the first wall and breeding zone box. A plate for the test specimen to evaluate the welding characteristics was fabricated based on the optimized E-beam welding results.

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

    Science.gov (United States)

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

    2017-03-01

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

  16. NUMERICAL SIMULATION OF ULTRASONIC NONDESTRUCTIVE TESTING FOR WELDS

    Institute of Scientific and Technical Information of China (English)

    H.D. Chen; Y.W. Wang; J. Xue

    2004-01-01

    A computer simulation technique for ultrasonic propagation is utilized for the simulation of ultrasonic nondestructive testing (NDT). In this paper, one goal of the simulation is to compute ultrasonic field radiated by arbitrary transducers into pieces under examination. The other simulates a testing experiment. The simulation approach is based on the model for the computation of the ultrasonic field in isotropic media radiated from actual NDT transducers. After the field is known, remaining to be modeled is the interaction between this field and the scatters (defect) and the echo structure. The model of beam-defect interaction is based on the Kirchhoff's diffraction approximations theory applied to elastodynamics. We assumed that the incident wave fronts on the defect are plane in the case of a focused immersed transducer and material is isotropic and homogeneous. The simulating results demonstrate that the model in ultrasonic NDT of welds is practical in further research and useful in optimizing testing configurations.

  17. Field Testing Pulsed Power Inverters in Welding Operations to Control Heavy Metal Emissions

    Science.gov (United States)

    2009-12-01

    FINAL REPORT Field Testing Pulsed Power Inverters in Welding Operations to Control Heavy Metal Emissions ESTCP Project WP-200212...PROGRAM ELEMENT NUMBER Field Testing Pulsed Power Inverters in Welding Operations to Control Heavy Metal Emissions 6. AUTHOR(S) 5d. PROJECT

  18. SRF test facility for the superconducting LINAC ``RAON'' — RRR property and e-beam welding

    Science.gov (United States)

    Jung, Yoochul; Hyun, Myungook; Joo, Jongdae; Joung, Mijoung

    2015-02-01

    Equipment, such as a vacuum furnace, high pressure rinse (HPR), eddy current test (ECT) and buffered chemical polishing (BCP), are installed in the superconducting radio frequency (SRF) test facility. Three different sizes of cryostats (diameters of 600 mm for a quarter wave resonator (QWR), 900 mm for a half wave resonator (HWR), and 1200 mm for single spoke resonator 1&2 (SSR 1&2)) for vertical RF tests are installed for testing cavities. We confirmed that as-received niobium sheets (ASTM B393, RRR300) good electrical properties because they showed average residual resistance ratio (RRR) values higher than 300. However, serious RRR degradation occurred after joining two pieces of Nb by e-beam welding because the average RRR values of the samples were ˜179, which was only ˜60% of as-received RRR value. From various e-beam welding experiments in which the welding current and a speed at a fixed welding voltage were changed, we confirmed that good welding results were obtained at a 53 mA welding current and a 20-mm/s welding speed at a fixed welding voltage of 150 kV.

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

    Science.gov (United States)

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

    2016-03-01

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

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

    Science.gov (United States)

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

    2016-03-01

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

  1. 46 CFR 54.20-5 - Welding qualification tests and production testing (modifies UW-26, UW-28, UW-29, UW-47, and UW-48).

    Science.gov (United States)

    2010-10-01

    ... 46 Shipping 2 2010-10-01 2010-10-01 false Welding qualification tests and production testing... OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING PRESSURE VESSELS Fabrication by Welding § 54.20-5 Welding qualification tests and production testing (modifies UW-26, UW-28, UW-29, UW-47, and UW-48)....

  2. Testing the susceptibility of CANDU fuel bundle endcap/endplate welds to delayed hydride cracking

    Energy Technology Data Exchange (ETDEWEB)

    Shek, G.K.; Wasiluk, B.S. [Kinectrics Inc., Toronto, Ontario (Canada); Lampman, T. [Nuclear Safety Solutions Inc., Toronto, Ontario (Canada); Freire-Canosa, J. [Nuclear Waste Management Organization, Toronto, Ontario (Canada)

    2008-07-01

    Among degradation mechanisms that could potentially impact CANDU fuel bundle integrity during long-term dry storage, Delayed Hydride Cracking (DHC) of the bundle endcap/endplate welds was identified as posing the most likely risk. An apparatus developed and tested on non-irradiated CANDU fuel bundle endcap/endplate welds showed DHC could be operative at welds with about 10 ppm hydrogen at 130 C. Further testing of welds with 40 ppm hydrogen at 150 C gave K{sub IH} values of 7.6 to 13.6 MPa{radical}m. Preliminary stress calculations indicate the K{sub I} values at the welds during dry storage are significantly lower than the found K{sub IH} values. (author)

  3. Different types of cracking of P91 steel weld joints after long-term creep tests

    Energy Technology Data Exchange (ETDEWEB)

    Jandova, D.; Kasl, J.; Chvostova, E. (SKODA VYZKUM s.r.o., Plzen (Czech Republic))

    2010-05-15

    This paper deals with creep testing and microstructural investigation of trial weld joints prepared of wrought and cast 9Cr-1Mo-V steels using GTAW & SMAW method. Creep testing was carried out at temperature range from 525 degC to 625 degC, the longest time to rupture of 45 811 hrs was achieved. The creep strengths of weld joints for 100 000 hrs were calculated. Different types of cracking were observed in dependency on conditions of creep test and the type of weld joint. Type 1 and Type 2 fractures occurred at high applied stress at relatively low temperatures in the tube weld joint and also in two speciments of the cast plate weld joint after creep test at the lowest temperature and the highest temperature. All other fractures were of the Type 4. Causes of different fracture location in tested weld joints were elucidated on the base of substructure evolution in individual zones - the weld metal, the heat affected zone and the base material. Two processes occur simultaneously, which result in the creep damage: (i) softening of solid solution as a result of Laves phase precipitation and (ii) formation and coalescence of cavities in the soft fine grained parts of heat affected zone. (orig.)

  4. Susceptibility testing for welding of AlMg alloys intended for extrusion

    Directory of Open Access Journals (Sweden)

    J. Borowski

    2016-07-01

    Full Text Available The objective of research was to determine the weldability, using Tungsten Inert Gas (TIG of extruded sections made of hard-deformable 5xxx series aluminum alloys with differing magnesium content, i.e. AlMg3, AlMg4,5, AlMg5, AlMg7. Welded joints were obtained as a result of a welding process consisting of several steps. Only welds characterized by very good appearance and quality were selected for tests. As a result of conducted research, TIG welding parameters were determined for sections with a thickness of 8 mm. It was observed that alloys of differing Mg content are characterized by high weldability and do not exhibit a significant reduction of the yield point. Moreover, joints exhibit uniform hardness distribution in the welded joint and heat-affected zone. Tensile strength is reduced.

  5. Development of Mechanical Sealing and Laser Welding Technology to Instrument Thermocouple for Nuclear Fuel Test Rod

    Energy Technology Data Exchange (ETDEWEB)

    Joung, Chang-Young; Ahn, Sung-Ho; Hong, Jin-Tae; Kim, Ka-Hye; Huh, Sung-Ho [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2015-05-15

    Zircaloy-4 of the nuclear fuel test rod, AISI 316L of the mechanical sealing parts, and the MI (mineral insulated) cable at a thermocouple instrumentation are hetero-metals, and are difficult to weld to dissimilar materials. Therefore, a mechanical sealing method to instrument the thermocouple should be conducted using two kinds of sealing process as follows: One is a mechanical sealing process using Swagelok, which is composed of sealing components that consists of an end-cap, a seal tube, a compression ring and a Swagelok nut. The other is a laser welding process used to join a seal tube, and an MI cable, which are made of the same material. The mechanical sealing process should be sealed up with the mechanical contact compressed by the strength forced between a seal tube and an end-cap, and the laser welding process should be conducted to have no defects on the sealing area between a seal tube and an MI cable. Therefore, the mechanical sealing and laser welding techniques need to be developed to accurately measure the centerline temperature of the nuclear fuel test rod in an experimental reactor. The mechanical sealing and laser welding tests were conducted to develop the thermocouple instrumentation techniques for the nuclear fuel test rod. The optimum torque value of a Swagelok nut to seal the mechanical sealing part between the end-cap and seal tube was established through various torque tests using a torque wrench. The optimum laser welding conditions to seal the welding part between a seal tube and an MI cable were obtained through various welding tests using a laser welding system.

  6. Combined Cycle Fatigue Testing with Ultrasonic Frequency Component of S350 Steel Welded Joint

    Institute of Scientific and Technical Information of China (English)

    柳阳; 王东坡; 邓彩艳; 吴良晨; 尹丹青; 龚宝明

    2014-01-01

    A combined cycle fatigue (CCF) testing system with ultrasonic frequency component was developed to evaluate the CCF properties of S350 steel welded joints in this study. The fatigue testing results indicated that the S-N curves of CCF did not have fatigue limit, which agreed with those of pure high frequency fatigue of welded joints. The S-N curves showed that the CCF strength of welded joints dropped greatly with the increasing interaction between high and low frequency fatigue loading. An approximation design method of CCF was presented using amplitude envelope as the stress range.

  7. Use of Metallographic Analysis and Strength Testing to Improve Ultrasonic Phased-Array Evaluation of Resistance SPOT Welds

    Science.gov (United States)

    Hopkins, Deborah L.

    2008-02-01

    Results are summarized for a series of experiments in which one hundred spot welds were inspected using a high-frequency phased-array ultrasonic probe, and then sectioned, polished and etched to reveal the microstructure of the welds. The ultrasonic and metallographic results are analyzed in conjunction with the results of strength tests and the size of the weld buttons obtained from destructive tear-down of the welded samples.

  8. Flexural testing of weld site and HVOF coating characteristics

    CERN Document Server

    Yilbas, Bekir Sami; Sahin, Ahmet

    2014-01-01

    This book provides fundamental understanding and practical application of characteristics of flexural motion in the assessment of the weld size and coating thickness. Some formulations of heat transfer and flexural motion are introduced while displacement and load correlation are used to estimate elastic modules and the size of the heat affected zone as well as the coating thickness. The case studies presented give a practical understanding of weld size and coating thickness characterizations.

  9. The Welding Process of the Small In-pile Testing Fuel Assembly

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    The small in-pile testing fuel assembly is designed for high performance fuel assembly study. It has two parts of which are four fuel element with double layer cladding and a detect system for measurement of testing pressure and temperature. The fuel element is composed of UO2 pellets, the stainless steel cladding and end caps. The detect system is direct contact with the fuel element by electron beam welding. In the fabrication of the assembly, some special welding technologies are

  10. Long-term creep testing and microstructure evaluation of P91 steel weld joints

    Energy Technology Data Exchange (ETDEWEB)

    Jandova, D.; Kasl, J.; Kanta, V. [SKODA VYZKUM s.r.o., Plzen (Czech Republic)

    2007-06-15

    Trial weld joints were made from wrought and cast modified 9Cr-lMo-V steel using GTAW and SMAW methods. Creep testing was carried out at temperature range from 525 deg C to 625 deg C and stresses from 50 to 240 MPa. Time to rupture of welds made from tube segments and cast plates reached almost 30 000 hours and 20 000 hours respectively. Creep strength was evaluated according the Larson-Miller parametric equation and microstructure was investigated using both light and electron microscopy. Creep rupture strength of both weld joints tested at temperatures below 600 deg C falls into the {+-}20% scatter band of the creep rupture strength of the parent material. At 600 deg C and 625 deg C the creep strength dropped by 27% and 30% for the plate weld and the tube weld respectively. All ruptures occurred in fine grain and intercritically reheated heat affected zones either in the parent material or in the weld metal. Observation of thin foils prepared from selected regions of the weld joints revealed differences in precipitation processes and the structure recovery causing decrease of dislocation density in some regions. Fine ferritic grains with low density of fine carbonitride precipitate occurred in critical localities. Soft grains were deformed and cavities at grain boundaries initiated the crack propagation. (orig.)

  11. Metallographic studies of electron beam welded copper plates. EBSD studies of the cross-sections and determination of EBSD reference curves by EB-welded tensile test samples

    Energy Technology Data Exchange (ETDEWEB)

    Karhula, T. [Tampere Univ. of Technology (Finland)

    2013-07-15

    This work is part of Posiva's spent nuclear fuel disposal canister sealing development. Posiva has welded series of plate welding experiments at Patria Aviation Facilities. At Tampere University of Technology, Department of Materials Science (TUT DMS) metallographic and electron microscopy studies of electron beam welded copper samples have been carried out. In this report a part of the welding test program is analyzed. The results of the cross-sections of the test welds X436-X440 and X453-X458 are presented here together with the methods used. These two sets of welds were conducted to study the effects of welding speed, annealing temperature and the presence of cosmetic pass. The aim of this study was to estimate the residual stresses present in the EB-welds using electron backscatter diffraction (EBSD) technique. For this task various EBSD reference curves with tensile test samples were constructed: the recrystallized, substructured and deformed fractions of grains, the occurrence of 1.5 deg C and 2.5 deg C misorientations, the average of mean intra-grain misorientation AMIS, and the hardness could be related to the applied strain. It was found that the hardness was higher if there was a cosmetic pass on the weld. The welding speed and the annealing temperature did not seem to have a noticeable effect on the measured properties. The estimated residual stresses were mainly very low, in the range 27-34 MPa. In the values estimated based on the hardness reference curve, the maximum residual stress was 58.7 MPa (in X455A). (orig.)

  12. Characterization of Friction Stir Welded Tubes by Means of Tube Bulge Test

    Science.gov (United States)

    D'Urso, G.; Longo, M.; Giardini, C.

    2011-05-01

    Mechanical properties of friction stir welded joints are generally evaluated by means of conventional tensile test. This testing method might provide insufficient information because maximum strain obtained in tensile test before necking is small; moreover, the application of tensile test is limited when the joint path is not linear or even when the welds are executed on curved surfaces. Therefore, in some cases, it would be preferable to obtain the joints properties from other testing methods. Tube bulge test can be a valid solution for testing circumferential or longitudinal welds executed on tubular workpieces. The present work investigates the mechanical properties and the formability of friction stir welded tubes by means of tube bulge tests. The experimental campaign was performed on tubular specimens having a thickness of 3 mm and an external diameter of 40 mm, obtained starting from two semi-tubes longitudinally friction stir welded. The first step, regarding the fabrication of tubes, was performed combining a conventional forming process and friction stir welding. Sheets in Al-Mg-Si-Cu alloy AA6060 T6 were adopted for this purpose. Plates having a dimension of 225×60 mm were bent (with a bending axis parallel to the main dimension) in order to obtain semi-tubes. A particular care was devoted to the fabrication of forming devices (punch and die) in order to minimize the springback effects. Semi-tubes were then friction stir welded by means of a CNC machine tool. Some preliminary tests were carried out by varying the welding parameters, namely feed rate and rotational speed. A very simple tool having flat shoulder and cylindrical pin was used. The second step of the research was based on testing the welded tubes by means of tube bulge test. A specific equipment having axial actuators with a conical shape was adopted for this study. Some analyses were carried out on the tubes bulged up to a certain pressure level. In particular, the burst pressure and the

  13. 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.

  14. Analysis of the Charpy V-notch test for welds

    DEFF Research Database (Denmark)

    Tvergaard, Viggo; Needleman, A.

    2000-01-01

    softening accounted for. The onset of cleavage is taken to occur when a critical value of the maximum principal stress is attained. The effect of weld strength undermatch or overmatch is investigated for a comparison material, and analyses are also carried out based on experimentally determined flow...... temperature on stress triaxiality. (C) 2000 Elsevier Science Ltd. All rights reserved....

  15. Mechanical Test on Irradiated Welding X80/X02 Steel

    Institute of Scientific and Technical Information of China (English)

    LIU; Xin-peng; ZHANG; Chang-yi; NING; Guang-sheng; TONG; Zhen-feng; YANG; Wen

    2015-01-01

    The dedicated X80base metal,welding metal and X80/X02HAZ metal are irradiated in experimental reactor in order to evaluate the mechanical properties on the special condition.The cumulative irradiate dose(E>1 MeV)is 4×1016 cm-2,and irradiating temperature is below

  16. Rapid ultrasonic C-scan test for spot welding based on image interpolation

    Institute of Scientific and Technical Information of China (English)

    刘静; 徐国成; 史延利; 周广浩; 谷晓鹏

    2014-01-01

    In this paper,ultrasonic C-scan test ofspot welds for stainless steel has been studied.It is concluded that large scanning step length contributes to high testing efficiency,however,the low-resolution C-scan image generated cannot be used to assess spot welding quality reliably.Based on bicubic image interpolation,the C-scan image in low resolution with the large step length 1 000μm is subdivided and reconstructed.By this means,the C-scan image resolution is greatly enhanced and testing results obtained are satisfactory,realizing rapid assessment ofspot welds.The results ofrapid ultrasonic C-scan test fit the actual metallographic measured value well.Mean value ofnormal distribution oferror statistics is 0.006 67,and the standard deviation is 0.087 1 1 .Rapid ultrasonic C-scan test based on image interpolation is of high accuracy and excellent stability.

  17. A Comparison Between Mechanical And Electrochemical Tests on Ti6Al4V Welded By LBW

    Science.gov (United States)

    Serroni, G.; Bitondo, C.; Astarita, A.; Scala, A.; Gloria, A.; Prisco, U.; Squillace, A.; Bellucci, F.

    2011-05-01

    Titanium and its alloys are nowadays widely used in many sectors: in the medical field (orthopedic and dental ones), in the architectural field, in the chemical plants field and in aeronautic. In this last field it is more and more used both for its contribution to make lightweight and time durable structures and for its compatibility with new materials, first of all Carbon Fiber Reinforced Plastics (CFRP). To this aim, lots of researches are now focusing on new and emerging technologies capable to make titanium objects and, at the same time, reducing the scrap, since titanium alloys for aeronautic application are very expensive. This paper examines Grade 5 Titanium Alloy (Ti6Al4V) welded by Laser Beam (LBW) in butt-joint configuration. The source was Nd:YAG laser, moreover two inert gases were used, in order to provide a shield both on the top and on the bottom of the weld bead. The joints were studied by varying two process parameters: welding speed and power of the laser beam. It was not possible to realize a full experimental plan, due to technological limits in making titanium laser beam welds. The joints were tested to measure their mechanical properties and the corrosion resistance. The process parameters do not significantly affect the maximum static strength of the joints. Microscopic analysis showed that welds made with high power and low welding speed have a uniform weld bead, and no macroscopic defect occurs. Fatigue test results, instead, show a marked influence of the morphology of the weld bead: the occurrence of some defects, such as the undercut, both on the top and on the bottom of the weld bead, dramatically reduced fatigue resistance of the joints. Corrosion resistance was studied using the electrochemical micro cell technique, which allows to distinguish electrochemical properties of each zone of the weld bead, even when, as in this case, they are very narrow. By a general point of view, it has been demonstrated that the joints showing the best

  18. Standard test method for guided bend test for ductility of welds

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2002-01-01

    1.1 This test method covers a guided bend test for the determination of soundness and ductility of welds in ferrous and nonferrous products. Defects, not shown by X rays, may appear in the surface of a specimen when it is subjected to progressive localized overstressing. This guided bend test has been developed primarily for plates and is not intended to be substituted for other methods of bend testing. 1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard. Note 1—For additional information see Terminology E 6, and American Welding Society Standard D 1.1. 1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

  19. Nondestructive testing of austenitic casting and dissimilar metal welds; Kaksimetalliliitosten ja austeniittisten valujen testaustekniikoiden vertailu

    Energy Technology Data Exchange (ETDEWEB)

    Lahdenperae, K. [VTT Manufacturing Technology, Espoo (Finland)

    1995-01-01

    The publication is a literature study of nondestructive testing of dissimilar metal welds and cast austenitic components in PWR and BWR plants. A major key to the successful testing is a realistic mockup made of the materials to be tested. The inspectors must also be trained and validated using suitable mockups. (42 refs., 27 figs., 10 tabs.).

  20. Reproducibility of pop-ins in laboratory testing of welded joints

    Directory of Open Access Journals (Sweden)

    Berejnoi C.

    2000-01-01

    Full Text Available The pop-in phenomenon, quite common in fracture mechanics tests of welded joints, corresponds to a brittle crack initiation grown from a local brittle zone (LBZ that is arrested in reaching the higher toughness material that surrounds this LBZ. A methodology to obtain a high percentage of pop-in occurrence in laboratory testing is necessary to study the pop-in significance. Such a method is introduced in this work and includes the consumable combination and welding procedures for the SMAW welding process to generate artificial LBZ. In order to find out the influence of the loading state upon the pop-in phenomenon, laboratory CTOD tests were performed using two specimen configurations: some single edge-notched specimens were loaded on a three-point bending (SE(B fixture while others were tested in tensile load (SE(T. A higher frequency of pop-in occurrence was observed in the SE(B geometry.

  1. 单面焊双面成型的焊接工艺试验%Test on Welding Procedure of Single-side Welding Double-side Molding

    Institute of Scientific and Technical Information of China (English)

    孙壮

    2013-01-01

    Regarding to the features of the single-side welding double-side molding technique, the welding test a-dopted the process of mix gas shield solid wire welding to conduct backing welding , and CO2 gas shield flux cored wire welding to carry out filler and finish welding , which obtained satisfied effect .It could ensure the weld has sound flux penetrability and good shape and quality .%  针对单面焊双面成型技术的特点,焊接试验采用实心焊丝混合气体保护焊进行打底焊,药芯焊丝CO2气体保护焊进行填充、盖面焊的方法,达到了满意的效果,保证了根部焊缝的熔透性,焊缝成型美观,质量高。

  2. Transport currents measured in ring samples: test of superconducting weld

    Science.gov (United States)

    Zheng, H.; Claus, H.; Chen, L.; Paulikas, A. P.; Veal, B. W.; Olsson, B.; Koshelev, A.; Hull, J.; Crabtree, G. W.

    2001-02-01

    The critical current densities in bulk melt-textured YBa 2Cu 3O x and across superconducting “weld” joints are measured using scanning Hall probe measurements of the trapped magnetic field in ring samples. With this method, critical current densities are obtained without the use of electrical contacts. Large persistent currents are induced in ring samples at 77 K, after cooling in a 3 kG field. These currents can be determined from the magnetic field they produce. At 77 K a supercurrent exceeding 2000 A (about 10 4 A/cm 2) was induced in a 2 cm diameter ring; this current produces a magnetic field exceeding 1.5 kG in the bore of the ring. We demonstrate that when a ring is cut, and the cut is repaired by a superconducting weld, the weld joint can transmit the same high supercurrent as the bulk.

  3. Initial testing for the recommendation of improved gas metal arc welding procedures for HY-80 steel plate butt joints at Norfolk Naval Shipyard

    OpenAIRE

    Rice, Veronika J.

    2015-01-01

    Approved for public release; distribution is unlimited Hull cut welding proficiency is an essential skill maintained by personnel at naval shipyards. This thesis explores arc weld theory to develop ideal submarine hull butt joint designs and recommends preliminary testing to be used to develop improved butt joint welding procedures at Norfolk Naval Shipyard. Pulsed gas metal arc welding (GMAW-P) is the ideal process for shipboard hull welding applications, theoretically. Butt joint samples...

  4. Reproducibility of pop-ins in laboratory testing of welded joints

    OpenAIRE

    Berejnoi C.; Perez Ipiña J.E.; Llorente C.L.

    2000-01-01

    The pop-in phenomenon, quite common in fracture mechanics tests of welded joints, corresponds to a brittle crack initiation grown from a local brittle zone (LBZ) that is arrested in reaching the higher toughness material that surrounds this LBZ. A methodology to obtain a high percentage of pop-in occurrence in laboratory testing is necessary to study the pop-in significance. Such a method is introduced in this work and includes the consumable combination and welding procedures for the SMAW we...

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

    Energy Technology Data Exchange (ETDEWEB)

    Moran, Traci L.; Anderson, Michael T.; Cinson, Anthony D.; Crawford, Susan L.; Nove, Carol A.

    2014-08-01

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

  6. International Round-Robin Test Results for Dissimilar Metal Weld (DMW)

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Sung Sik; Kim, Kyung Jo; Jung, Hae Dong [Korea Institute of Nuclear Safety, Daejeon (Korea, Republic of)

    2009-10-15

    In nuclear power plant, there are many joints to connect pipes, nozzles and structural components. Most of them are welding joint, and it may be a weak point for leakage and cracks. Some cracks were found in dissimilar metal welds (DMW), which are connected with major components of nuclear power plants. Usually, the dissimilar metal welds are consisted of Alloy 600, carbon steel and stainless steel. Since 2000s, most of the cracks are found in welds, especially dissimilar metal welds such as pressurizer safety relief nozzle, reactor head penetration, reactor bottom mounted instrumentation (BMI), and reactor nozzles. Since the cracks are revealed as a primary water stress corrosion cracking (PWSCC), the reliability of non destructive evaluation (NDE) technique becomes more important. To cope with the NDE reliability, PINC (program for inspection of nickel alloy components) international cooperation was organized. The aim of the project was 1) to fabricate representative NDE mock-ups with flaws to simulate PWSCCs, 2) to identify and quantitatively assess NDE methods for accurately detecting, sizing and characterizing PWSCCs, 3) to document the range of locations and morphologies of PWSCCs and 4) to incorporate results with other results of ongoing PWSCC research programs, as appropriate. In this study, as part of the PINC project, international RRT (round robin test) results for DMW will be introduced.

  7. Upset welded 304L and 316L vessels for storage tests

    Energy Technology Data Exchange (ETDEWEB)

    Kanne, W.R. Jr.

    1996-04-01

    Two sets of vessels for tritium storage tests were fabricated using upset welding. A solid-state resistance upset weld was used to join the two halves of each vessel at the girth. The vessels differ from production reservoirs in design, material, and fabrication process. One set was made from forged 304L stainless steel and the other from forged 316L stainless steel. Six vessels of each type were loaded with a tritium mix in November 1995 and placed in storage at 71 C. This memo describes and documents the fabrication of the twelve vessels.

  8. Specifying and testing weld neck flanges for better quality

    Energy Technology Data Exchange (ETDEWEB)

    Weirich, A.B. [Saudi Aramco, Dhahran (Saudi Arabia)

    1996-07-01

    Field failures and persistent defects have impelled users to demand improved reliability in weld neck flanges. This paper explains why and how to specify for better quality. The answers are straightforward: Specify clearly -- Quality begins with improved raw stock, is assured by good manufacturing practices, and is warranted by appropriate quality controls. Be reasonable, specifications must be commercially viable in today`s competitive environment. Inspect the merchandise: Quality cannot be assured without effective enforcement. To think otherwise is unrealistic, regardless how good the procurement specifications may be. Review purchasing policies: When suppliers of quality products are identified, restricted purchases should be instituted. Quicker deliveries and a reliable supply of good quality product are assured as manufacturers maintain upgraded inventories in anticipation of repeat business.

  9. Development of phased array ultrasonic testing in lieu of radiography for testing complete joint penetration (CJP) welds

    Science.gov (United States)

    Haldipur, P.; Boone, Shane D.

    2014-04-01

    The past decade has seen new, emerging innovation of Ultrasonic Testing (UT). Specifically, multiple manufacturers have produced Phased Array Ultrasonic Testing (PAUT) systems. The PAUT systems embed a matrix of multiple (some up to 128) single transducers into one probe used for scanning elastic materials. Simultaneously exciting multiple transducers offers distinct advantages; depending on the sequencing of transducer excitation, the ultrasonic beam could be steered within the material and multiple beams help develop extra dimensional data to assist with visualization of possible flaws including the discontinuity size, shape and location. Unfortunately, there has not been broad acceptance of PAUT in the bridge fabrication industry because it is currently not a recognized inspection technology in AWS D1.5. One situation in which the technology would excel would be inspection of Complete Joint Penetration (CJP) butt welds. Currently, AWS D1.5 required CJP welds subjected to tensile or reversal stresses only be inspected by Radiographic Testing (RT). However, discontinuities normally seen by RT can also be seen with PAUT. Until specification language is adopted into D1.5, there will continue to be hesitancy to use PAUT for the inspection of CJP butt welds. Developmental work must first be performed to develop the acceptance criteria and the specification language. The developmental work from the inspections carried out on butt-weld specimens and transition butt-weld specimens are presented in this paper. Specific scan plans were developed using the ES-Beam simulation software for each of the test specimens. In depth analysis of PAUT data obtained to determine exact location and sizing information of the defects was performed. The results also present the comparison of results from PAUT to those obtained using conventional UT and radiography.

  10. Deformation Characterization of Friction-Stir-Welded Tubes by Hydraulic Bulge Testing

    Science.gov (United States)

    Pang, Q.; Hu, Z. L.; Pan, X.; Zuo, X. Q.

    2014-10-01

    In this article, the large-diameter thin-walled aluminum alloy tubes were produced using a hybrid process combining friction-stir welding (FSW) and spinning. For this novel process, rolled aluminum alloy sheets with a thickness about 2-3 times the wall thickness of target tube, were FSW to form cylinders, and then the cylinders were subjected to spinning to get thin-walled aluminum alloy tubes. Both experimental and simulation study were conducted to investigate the deformation characterization of the FSW tube during hydraulic bulge testing, and the stress and strain states and thickness distribution of the FSW tube were investigated. It was found that the common defects of FSW tube can be significantly improved by specific welding devices. The ductility of the tube is considerably improved with nearly two times higher bulge ratio than as-spun tube after annealing treatment at 300°C. But the annealed tube still shows a high nonuniform wall thickness distribution due to the inhomogeneous deformation characteristics. With increasing deformation of the tube, the gap between the hoop and axial stress for the weld and base metal (BM) decreases. However, the hoop and axial stress of the weld are always greater than those of the BM at the same pressure.

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

    Science.gov (United States)

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

    2010-01-01

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

  12. Phased array ultrasonic testing of dissimilar metal welds using geometric based referencing delay law technique

    Science.gov (United States)

    Han, Taeyoung; Schubert, Frank; Hillmann, Susanne; Meyendorf, Norbert

    2015-03-01

    Phased array ultrasonic testing (PAUT) techniques are widely used for the non-destructive testing (NDT) of austenitic welds to find defects like cracks. However, the propagation of ultrasound waves through the austenitic material is intricate due to its inhomogeneous and anisotropic nature. Such a characteristic leads beam path distorted which causes the signal to be misinterpreted. By employing a reference block which is cutout from the mockup of which the structure is a dissimilar metal weld (DMW), a new method of PAUT named as Referencing Delay Law Technique (RDLT) is introduced. With the RDLT, full matrix capture (FMC) was used for data acquisition. To reconstruct the images, total focusing method (TFM) was used. After the focal laws were calculated, PAUT was then performed. As a result, the flaws are more precisely positioned with significantly increased signal-to-noise ratio (SNR).

  13. Development of a suitable weld geometry for pressure resistance welding of the leader test assembly (LTA's) 16NGF fuel assembly fuel rod at Angra-1 Nuclear Power Plant

    Energy Technology Data Exchange (ETDEWEB)

    Junqueira, Fabio da Silva; Silva, Josue Ribeiro, E-mail: fabiojunqueira@inb.gov.br, E-mail: josueribeiro@inb.gov.br [Industrias Nucleares do Brasil (GEPRDN/INB), Rio de Janeiro, RJ (Brazil). Gerencia do Produto

    2013-07-01

    The purpose of this work is to develop suitable weld geometry for pressure resistance welding of the zircaloy-4 end plug to the special zirconium alloy cladding tube, Ø 9,14mm, for demonstration at Angra-1 Nuclear Plant. Weld geometry development was carried out in two steps: at the first one, the influence caused by the variation of the welding process key parameters, the axial compression strength of the end plug against the cladding tube, projection of the cladding tube into the welding chamber and the welding current have been evaluated; at the second step, the influence of the variation of end-plug weld geometry area was checked. For the combination of welding parameters, the technique of factorial design was used. Results from mechanical and metallographic tests have indicated a strong and direct influence of weld geometry dimensional variation on the weld mechanical resistance, and a modest influence in relation to the range of key parameters used to carry out tests. (author)

  14. Corrosion Verification Test for the Welds of CEFR Sodium Storage Tank and Sodium Drainage Under the First-Grade Accident

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    The main purpose of this test is to observe and analyze the compatibility between the welds and hightemperature sodium at the simulated realistic working conditions of CEFR sodium storage tank andsodium drainage under the first-grade accident. The observation and analysis are focused on theintergranular corrosion at the weld and its heat affection region, in order to provide the test basis for thesafe operation and analysis of CEFR.

  15. Analysis and Testing of a Tapered End Connection for Laser Welded Steel Sandwich Panels

    Science.gov (United States)

    2009-08-15

    1951, Elastic Constants for Corrugated Core Sandwich Plates. Technical Note 2289. National Aeronautics and Space Administration ( NASA ). 19. Lok...Assoc. Professor of Mechanical Engineering, University of Maine (Co-I) Grant No: N00014-05-1 -0735 ATS subcontract No: UM-591 Report No. C-2004-015...RPT-04 August 15,2009 20090925154 ABSTRACT This report summarize the analysis and cyclic testing of a laser welded steel sandwich panel end

  16. Workplace field testing of the pressure drop of particulate respirators using welding fumes.

    Science.gov (United States)

    Cho, Hyun-Woo; Yoon, Chung-Sik

    2012-10-01

    In a previous study, we concluded that respirator testing with a sodium chloride aerosol gave a conservative estimate of filter penetration for welding fume aerosols. A rapid increase in the pressure drop (PD) of some respirators was observed as fumes accumulated on the filters. The present study evaluated particulate respirator PD based on workplace field tests. A field PD tester was designed and validated using the TSI 8130 Automatic Filter Tester, designed in compliance with National Institute for Occupational and Safety and Health regulation 42 CFR part 84. Three models (two replaceable dual-type filters and one replaceable single-type filter) were evaluated against CO(2) gas arc welding on mild steel in confined booths in the workplace. Field tests were performed under four airborne concentrations (27.5, 15.4, 7.9, and 2.1 mg m(-3)). The mass concentration was measured by the gravimetric method, and number concentration was monitored using P-Trak (Model 8525, TSI, USA). Additionally, photos and scanning electron microscopy-energy dispersive X-ray spectroscopy were used to visualize and analyze the composition of welding fumes trapped in the filters. The field PD tester showed no significant difference compared with the TSI tester. There was no significant difference in the initial PD between laboratory and field results. The PD increased as a function of fume load on the respirator filters for all tested models. The increasing PD trend differed by models, and PD increased rapidly at high concentrations because greater amount of fumes accumulated on the filters in a given time. The increase in PD as a function of fume load on the filters showed a similar pattern as fume load varied for a particular model, but different patterns were observed for different models. Images and elemental analyses of fumes trapped on the respirator filters showed that most welding fumes were trapped within the first layer, outer web cover, and second layer, in order, while no fumes

  17. Assessment of mechanical properties of aluminium alloy welded joint using small punch test

    Institute of Scientific and Technical Information of China (English)

    Qiao Jisen; Tang Xueqin; Chen Jianhong; Zhu Liang

    2007-01-01

    The small punch test technique (SPT) was used to evaluate the mechanical properties of various materials and the basic method to test material tensile mechanics performance from an inverse finite element (FE) arithmetic with SPT was put forward. The research shows that specific tensile mechanical behavior and strain-stress distribution of each district of weld seam can be accurately determined by small punch test. Therefore, mechanical behavior of the inhomogeneous joint can be predicted by a numerical model. The simulation comes to good agreement with experimental data.

  18. Oblique Y-groove cracking test of the welding cold cracking susceptibility of domestic X-70 pipeline steel

    Institute of Scientific and Technical Information of China (English)

    陈丽萍; 杜则裕; 李云涛; 李九生

    2002-01-01

    "Gas Transmitting From West to East Project" is significant. It should ensure the welding quality and safety of pipeline. The task is very arduous to guarantee the quality of the project in the condition of long line, complex weather and geology features. In this paper, the welding cold cracking susceptibility of domestic X-70 pipeline steel adopted by the project, which is one of the most interesting questions of welding quality about petrol pipeline, was studied by means of oblique Y-groove cracking test. The crack ratio of surface and section was tested under the conditions of different welding materials and preheat temperature .The X-70 pipeline steel has good crack resistance. The research has important value for the construction of large-scale pipeline engineering and the application of domestic X-70 pipeline steel.

  19. Quantitative ultrasonic testing of acoustically anisotropic materials with verification on austenitic and dissimilar weld joints

    Science.gov (United States)

    Boller, C.; Pudovikov, S.; Bulavinov, A.

    2012-05-01

    Austenitic stainless steel materials are widely used in a variety of industry sectors. In particular, the material is qualified to meet the design criteria of high quality in safety related applications. For example, the primary loop of the most of the nuclear power plants in the world, due to high durability and corrosion resistance, is made of this material. Certain operating conditions may cause a range of changes in the integrity of the component, and therefore require nondestructive testing at reasonable intervals. These in-service inspections are often performed using ultrasonic techniques, in particular when cracking is of specific concern. However, the coarse, dendritic grain structure of the weld material, formed during the welding process, is extreme and unpredictably anisotropic. Such structure is no longer direction-independent to the ultrasonic wave propagation; therefore, the ultrasonic beam deflects and redirects and the wave front becomes distorted. Thus, the use of conventional ultrasonic testing techniques using fixed beam angles is very limited and the application of ultrasonic Phased Array techniques becomes desirable. The "Sampling Phased Array" technique, invented and developed by Fraunhofer IZFP, allows the acquisition of time signals (A-scans) for each individual transducer element of the array along with fast image reconstruction techniques based on synthetic focusing algorithms. The reconstruction considers the sound propagation from each image pixel to the individual sensor element. For anisotropic media, where the sound beam is deflected and the sound path is not known a-priori, a novel phase adjustment technique called "Reverse Phase Matching" is implemented. By taking into account the anisotropy and inhomogeneity of the weld structure, a ray tracing algorithm for modeling the acoustic wave propagation and calculating the sound propagation time is applied. This technique can be utilized for 2D and 3D real time image reconstruction. The

  20. Experimental Investigation of the Corrosion Behavior of Friction Stir Welded AZ61A Magnesium Alloy Welds under Salt Spray Corrosion Test and Galvanic Corrosion Test Using Response Surface Methodology

    Directory of Open Access Journals (Sweden)

    A. Dhanapal

    2013-01-01

    Full Text Available Extruded Mg alloy plates of 6 mm thick of AZ61A grade were butt welded using advanced welding process and friction stir welding (FSW processes. The specimens were exposed to salt spray conditions and immersion conditions to characterize their corrosion rates on the effect of pH value, chloride ion concentration, and corrosion time. In addition, an attempt was made to develop an empirical relationship to predict the corrosion rate of FSW welds in salt spray corrosion test and galvanic corrosion test using design of experiments. The corrosion morphology and the pit morphology were analyzed by optical microscopy, and the corrosion products were examined using scanning electron microscope and X-ray diffraction analysis. From this research work, it is found that, in both corrosion tests, the corrosion rate decreases with the increase in pH value, the decrease in chloride ion concentration, and a higher corrosion time. The results show the usage of the magnesium alloy for best environments and suitable applications from the aforementioned conditions. Also, it is found that AZ61A magnesium alloy welds possess low-corrosion rate and higher-corrosion resistance in the galvanic corrosion test than in the salt spray corrosion test.

  1. SAFT and TOFD evaluation for ultrasonic testing of longitudinal welds in large-diameter pipes; SAFT- und TOFD-Auswertung fuer die Ultraschall-Schweissnahtpruefung von laengsnahtgeschweissten Grossrohren

    Energy Technology Data Exchange (ETDEWEB)

    Rieder, Hans; Dillhoefer, Alexander; Spies, Martin [Fraunhofer-Institut fuer Techno- und Wirtschaftsmathematik ITWM, Kaiserslautern (Germany); Graff, Alfred; Orth, Thomas [Salzgitter Mannesmann Forschung GmbH, Duisburg (Germany); Kersting, Thomas [Europipe GmbH, Muelheim an der Ruhr (Germany). Werk Muelheim

    2010-07-01

    The authors present a mobile multichannel system for testing of longitudinal welds in large-diameter tubes. The prototype was designed for in situ inspection of longitudinal welds using transversal and longitudinal waves impacting at an angle from both sides in combined SE and IE operation. The reconstruction and imaging software enables SAFT calculations for all surface curves and superposition of the SAFT reconstructions from both sides into a general image of the weld. This includes superposition of the TOFD test data with a suitable evaluation and assessment concept. Details are presented, as are test results on test pieces for validation and on longitudinal welds in large-diameter tubes. (orig.)

  2. 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.

  3. Research on Welding Test of Grey Cast Iron and Low-Carbon Steel

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    Grey cast iron's welding itself is a complex proble m.So proper welding materials must be selected,complex welding techniques such as preheating before weldingslow cooling after welding etc,should be taken. However the carbon component in low-carbon steel is comparatively low,the carbo n of welded joint will diffuse to the low-carbon steel when it is welded with gr ey cast iron,which will cause the component of carbon greatly increased at the low-carbon steel side in HAZ,high carbon martensite and cracks ...

  4. Laboratory galling tests of several commercial cobalt-free weld hardfacing alloys

    Energy Technology Data Exchange (ETDEWEB)

    Cockeram, B.V.; Buck, R.F.; Wilson, W.L.

    1997-04-01

    Since the mechanical properties of most wear materials are generally insufficient for structural applications, hardfacing alloys have been traditionally weld deposited to provide a wear resistance surface for a base material. An important attribute of a hardfacing alloy that is subjected to high load sliding contact is the resistance to adhesive (galling) damage. Although Co-base hardfacing alloys generally possess excellent galling wear resistance, there is interest in developing cobalt-free replacement hardfacings to reduce radiation exposure costs. A laboratory galling test has been developed for weld hardfacing deposits that is a modification of the standardized ASTM G98-91 galling test procedure. The procedure for testing a weld hardfacing deposit on a softer base metal using a button-on-block configuration is described. The contact stresses for the initiation of adhesive galling damage were measured to rank the galling resistance of several commercial Fe-base, Ni-base and Co-base hardfacing alloys. Although the galling resistance of the Fe-base alloys was generally superior to the Ni-base alloys, neither system approached the excellent galling resistance of the Co-base alloys. Microstructure examinations were used to understand the micro-mechanisms for the initiation and propagation of galling damage. A physical model for the initiation and propagation of adhesive wear is used to explain the lower galling resistance for the Ni-base hardfacings and to understand the influence of composition on the galling resistance of Ni-base alloys. The composition of some Ni base hardfacings was modified in a controlled manner to quantify the influence of specific elements on the galling resistance.

  5. Estimated accuracy of classification of defects detected in welded joints by radiographic tests

    Energy Technology Data Exchange (ETDEWEB)

    Siqueira, M.H.S.; De Silva, R.R.; De Souza, M.P.V.; Rebello, J.M.A. [Federal Univ. of Rio de Janeiro, Dept., of Metallurgical and Materials Engineering, Rio de Janeiro (Brazil); Caloba, L.P. [Federal Univ. of Rio de Janeiro, Dept., of Electrical Engineering, Rio de Janeiro (Brazil); Mery, D. [Pontificia Unversidad Catolica de Chile, Escuela de Ingenieria - DCC, Dept. de Ciencia de la Computacion, Casilla, Santiago (Chile)

    2004-07-01

    This work is a study to estimate the accuracy of classification of the main classes of weld defects detected by radiography test, such as: undercut, lack of penetration, porosity, slag inclusion, crack or lack of fusion. To carry out this work non-linear pattern classifiers were developed, using neural networks, and the largest number of radiographic patterns as possible was used as well as statistical inference techniques of random selection of samples with and without repositioning (bootstrap) in order to estimate the accuracy of the classification. The results pointed to an estimated accuracy of around 80% for the classes of defects analyzed. (author)

  6. 高频焊钢管焊缝冲击试验问题探讨%Discussion on Weld Impact Test of High Frequency Welded Pipe

    Institute of Scientific and Technical Information of China (English)

    梁才萌; 张永

    2016-01-01

    In order to improve the HFW pipe product quality, ensure the measurement results accuracy of the welded pipe impact test is very important. In the process of the actual detection, due to the high frequency weld is a thin line with width less than 0.3 mm after heat treatment, so make sure the exact impact test result has certain difficulty. Some problems affecting impact test result were discussed, including the preparation of impact test sample, weld corrosion, small size test sample, testing machine and so on. And give the relevant solutions, thus the accuracy of impact test result can be ensured.%为提升高频焊钢管产品质量,保证焊管冲击试验测量结果的准确性非常重要.在实际检测过程中,因高频焊缝经热处理后是一条宽度不到0.3 mm的细线,因此要保证得到准确的冲击试验结果存在一定困难.通过对高频焊钢管焊缝冲击试验中试样的准备、 焊缝腐蚀、 小尺寸试样以及试验机等多方面影响冲击试验结果问题探讨,找到了相应的解决方案,从而保证了冲击试验结果准确性.

  7. Study of the corrosion behavior of magnesium alloy weldings in NaCl solutions by gravimetric tests

    Directory of Open Access Journals (Sweden)

    Segarra, José A.

    2015-09-01

    Full Text Available In this article, the corrosion behavior of commercial AZ31 welded plates in aqueous chloride media was investigated by means of gravimetric techniques and Neutral Salt Spray tests (NSS. The AZ31 samples tested were welded using Gas Tugsten Arc Welding (GTAW and different filler materials. Material microstructures were investigated by optical microscopy to stablish the influence of those microstructures in the corrosion behavior. Gravimetric and NSS tests indicate that the use of more noble filler alloys for the sample welding, preventing the reduction of aluminum content in weld beads, does not imply a better corrosion behavior.En este artículo se ha investigado el comportamiento frente a la corrosión en medios acuosos salinos de chapas soldadas de aleación AZ31 mediante técnicas gravimétricas y ensayo en cámara de niebla salina. Las muestras estudiadas han sido soldadas mediante soldadura TIG (Tungsten Inert Gas y con diferentes materiales de aporte. En el estudio se ha empleado microscopía óptica para analizar la microestructura. Los ensayos de gravimetría y los ensayos de niebla salina indican que el empleo de materiales de aporte más nobles para soldar las muestras evitando la disminución del contenido en aluminio en los cordones, no implica un mejor comportamiento frente a la corrosión.

  8. Liquid Metal Embrittlement in Resistance Spot Welding and Hot Tensile Tests of Surface-refined TWIP Steels

    Science.gov (United States)

    Barthelmie, J.; Schram, A.; Wesling, V.

    2016-03-01

    Automotive industry strives to reduce vehicle weight and therefore fuel consumption and carbon dioxide emissions. Especially in the auto body, material light weight construction is practiced, but the occupant safety must be ensured. These requirements demand high-strength steels with good forming and crash characteristics. Such an approach is the use of high- manganese-content TWIP steels, which achieve strengths of around 1,000 MPa and fracture strains of more than 60%. Welding surface-refined TWIP steels reduces their elongation at break and produces cracks due to the contact with liquid metal and the subsequent liquid metal embrittlement (LME). The results of resistance spot welds of mixed joints of high-manganese- content steel in combination with micro-alloyed ferritic steel and hot tensile tests are presented. The influence of different welding parameters on the sensitivity to liquid metal embrittlement is investigated by means of spot welding. In a high temperature tensile testing machine, the influence of different parameters is determined regardless of the welding process. Defined strains just below or above the yield point, and at 25% of elongation at break, show the correlation between the applied strain and liquid metal crack initiation. Due to the possibility to carry out tensile tests on a wide range of temperatures, dependencies of different temperatures of the zinc coating to the steel can be identified. Furthermore, the attack time of the zinc on the base material is investigated by defined heating periods.

  9. Ultrasonic Nondestructive Testing of Superplastic Solid-State Welding Joint for Different Steels

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    Based on quantitative microscopic examinations of welds and welding rate for different steels (40Cr and T10A) joint, which possess the ultra-fine microstructure after high frequency hardening (HFH) and salt-bath cyclic quenching (SCQ), the suitable defect grey scale threshold value was determined, and the welding rate of superplastic solid-state welding of different steels (40Cr and T10A steel) was systematically inspected and analyzed by means of self-made ultrasonic imaging inspection system. The experimental results showed that the superplastic solid-state weld of different steels can be inspected more accurately, reliably and quickly by this system, and the results were in good accordance with that of metallographic observation. The welding rate of superplastic welding is in linear relation with tensile strength of joint.

  10. 3D Modeling and Testing of Contact Problems in Resistance Welding

    DEFF Research Database (Denmark)

    Nielsen, Chris Valentin

    A generic, electro-thermo-mechanically coupled finite element program is developed for three-dimensional simulation of resistance welding. The developed computer program has reached a level of a complete standalone software that can be utilized as a tool in the analysis of resistance welding...... of resistance welding processes, which cover a wide range of spot welding and projection welding applications. Three-dimensional simulation of spot welding enables the analysis of critical effects like electrode misalignment and shunt effects between consecutive spots. A single-sided spot welding case involving...... experiment by a Japanese company that proposed the case. Another industrial case, by a German company, is joining of micro components. The joining is based on mechanical locking, and the deformation is accommodated by resistance heating, which at the same time is used to melt a polymer coating locally...

  11. Results of crack-arrest tests on two irradiated high-copper welds

    Energy Technology Data Exchange (ETDEWEB)

    Iskander, S.K.; Corwin, W.R.; Nanstead, R.K. (Oak Ridge National Lab., TN (USA))

    1990-12-01

    The objective of this study was to determine the effect of neutron irradiation on the shift and shape of the lower-bound curve to crack-arrest data. Two submerged-arc welds with copper contents of 0.23 and 0.31 wt % were commercially fabricated in 220-mm-thick plate. Crack-arrest specimens fabricated from these welds were irradiated at a nominal temperature of 288{degree}C to an average fluence of 1.9 {times} 10{sup 19} neutrons/cm{sup 2} (>1 MeV). Evaluation of the results shows that the neutron-irradiation-induced crack-arrest toughness temperature shift is about the same as the Charpy V-notch impact temperature shift at the 41-J energy level. The shape of the lower-bound curves (for the range of test temperatures covered) did not seem to have been altered by irradiation compared to those of the ASME K{sub Ia} curve. 9 refs., 21 figs., 10 tabs.

  12. 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 ...

  13. Isothermal Calorimetric Observations of the Effect of Welding on Compatibility of Stainless Steels with High-Test Hydrogen Peroxide Propellant

    Science.gov (United States)

    Gostowski, Rudy

    2003-01-01

    High-Test Hydrogen Peroxide (HTP) is receiving renewed interest as a monopropellant and as the oxidizer for bipropellant systems. HTP is hydrogen peroxide having concentrations ranging from 70 to 98%. In these applications the energy and oxygen released during decomposition of HTP is used for propulsion. In propulsion systems components must be fabricated and connected using available joining processes. Welding is a common joining method for metallic components. The goal of this study was to compare the HTP compatibility of welded vs. unwelded stainless steel.

  14. Assessment of Corona/Arcing Hazard for Electron Beam Welding in Space Shuttle Bay at LEO for ISWE: Test Results

    Science.gov (United States)

    Nunes, A. C., Jr.; Russell, C.; Vaughn, J.; Stocks, C.; ODell, D.; Bhat, B.

    1996-01-01

    Test welds were made in argon over a range of pressures from 10-5 to 10-3 torr (the latter pressure an order of magnitude above pressures anticipated in the space shuttle bay during welding) with and without plasma on 304 stainless steel, 6Al-4V titanium, and 5456 aluminum in search of any possible unwanted electrical discharges. Only a faint steady glow of beam-excited atoms around the electron beam and sometimes extending out into the vacuum chamber was observed. No signs of current spiking or of any potentially dangerous electrical discharge were found.

  15. X-ray tomographic in-service testing of girth welds - The European project TomoWELD; Roentgen-tomographische In-Service-Pruefung von Rundschweissnaehten. Das Europaeische Projekt TomoWELD

    Energy Technology Data Exchange (ETDEWEB)

    Ewert, Uwe; Redmer, Bernhard; Walter, David; Thiessenhusen, Kai-Uwe; Bellon, Carsten [BAM Bundesanstalt fuer Materialforschung und -pruefung, Berlin (Germany); Nicholson, P. Ian; Clarke, Alan [TWI Technology Centre, Port Talbot (United Kingdom); Finke-Haerkoenen, Klaus-Peter [Ajat Oy Ltd., Espoo (Finland); Scharfschwerdt, Joerg W.; Rohde, Karsten [AREVA GmbH, Erlangen (Germany)

    2015-07-01

    The new standard ISO 17636-2: 2013 'NDT of welded joints - Radiographic testing - Part 2: X- and gamma radiographic testing with digital detectors ''defines the testing practice for digital radiography of welds for the production and in-service inspection. Furthermore the DIN 25435-7:2014 ''In-service inspections of the components of the primary circuit of light water reactors - Part 7: Radiographic testing'' was published. The essential requirements are discussed. The new TomoWELD system can both perform measurements according to these standards as well as record tomographic cross-sectional images (equivalent to metallographic sections), to determine image sizes. Areas of application are chemical and nuclear facilities. It provides a fast testing of girth welds as compared to the use of film or imaging plates. In 2006 the mechanized planar tomography system, TomoCAR, was already introduced, with one could measure cross-sectional images. TomoWELD uses a new photon counting and energy resolving detector with CdTe-CMOS crystal hybrids. The new detector allows the choice of energy thresholds, and enables the reduction of the influence of scattered radiation on the radiographic images and the reconstructed cross-sectional images. An optimized irradiation geometry with a new manipulator design and a fast GPU-based reconstruction algorithm can be used to accelerate the reconstruction and to improve the reconstruction results. The size and the shape of planar and voluminous irregularities can be determined. The concept and the first pictures will be presented. (Contains mainly PowerPoint slides). [German] Der neue Standard ISO 17636-2:2013 ''ZfP von Schweissnaehten - Durchstrahlungspruefung - Teil 2: Roentgen- und Gammastrahlungstechniken mit digitalen Detektoren'' definiert die Pruefpraxis fuer die digitale Radiographie von Schweissnaehten fuer die Herstellung und In-Service- Pruefung. Ausserdem wurde die DIN 25435

  16. Development and Testing of an Experimental Polysensory Instructional System for Teaching Electric Arc Welding Processes. Report No. 24. Final Report.

    Science.gov (United States)

    Sergeant, Harold A.

    The population of the study consisted of 15 high school industrial arts students, 10 freshman and sophomore college students, and 10 adults. A polysensory, self-pacing instructional system was developed which included (1) pretests and post tests, (2) a general instruction book, (3) equipment to practice arc welding, (4) programed instruction…

  17. Analysis of solidification cracks in welds of Al-Mg-Si A6351 type alloy welded by high frequency pulsed TIG process. 1st report. Evaluation of solidification crack susceptibility by means of Houldcroft test

    Energy Technology Data Exchange (ETDEWEB)

    Pereira, M.; Machida, S. [The Univ. of Tokyo, Tokyo (Japan); Taniguchi, C.; Brandi, S. [Univ. of Sao Paulo, Sao Paulo, SP (Brazil)

    1994-08-05

    The main objective of this work is to study the susceptibility to solidification crack by means of Houldcroft test on Al-Mg-Si alloy A6351 welded by TIG process using a D.C. straight polarity and pulsed current with high frequency with varied parameters. The parameters are welding speed, current, arc pulse, frequency, and heat input per unit weld length. The effect of grain structures on the susceptibility of solidification crack is evaluated as well as the welding pool geometry in which these structures has developed. The `quasi-stationary` state is studied for the specimen geometry used, and the process efficiencies are estimated using welding pool width method. The trend of increase of crack length with the welding speed observed in no pulsed arc conditions is significantly changed with the introduction of the pulsed arc. Therefore, the pulsed frequency and the welding speed seem to be competing parameters in effect on the development of solidification crack. This work shows that the generalized tendency of solidification crack susceptibility with regard to the obtained grain structures as presented in previous works is not a general trend. 40 refs., 13 figs., 3 tabs.

  18. Testing of welded seams in the light of new requirements. Rules, new joining techniques, new test methods, automation, code cases; Schweissnahtpruefung im Licht neuer Anforderungen. Regelwerke, neue Fuegetechniken, neue Prueftechniken, Automatisierung, Code Cases

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    2005-07-01

    This proceedings CD contains 8 contributions on the following subjects: 1. Ultrasonic testing of welds using TOFD (A. Hecht); 2. Automated Ultrasonic Pipe Weld Inspection - Inspection of Welded Pipes in Accordance with New and Strict International Specifications (W.A.K. Deutsch); 3. Detection and analysis of longitudinal defects in welds of pipelines (K. Reber); 4. Ultrasonic inline inspection of pipelines for circumferential cracks (H. Willems); 6. Ultrasonic testing of welds at temperatures up to 200 C (A. Erhard); 7. Defect detection and defect size measurement in welds using ultrasonic phased arrays (W. Rathgeb); 8. Dry ultrasonic testing of laser-welded butt welds using guided SH waves illustrated by the example of tailored blanks (H.-J. Salzburger). Four papers are available as separate records in the ENERGY database. [German] Diese Berichtsband-CD enthaelt 8 Beitraege mit folgenden Themen: 1. Ultraschallpruefung an Schweissnaehten mittels TOFD (A. Hecht); 2. Automated Ultrasonic Pipe Weld Inspection - Inspection of Welded Pipes in Accordance with New and Strict International Specifications (W.A.K. Deutsch); 3. Detektion und Bewertung von Laengsfehlern an Schweissnaehten von Pipelines (K. Reber); 4. Inline-Pruefung von Pipelines auf Umfangrisse mittels Ultraschall (H. Willems); 6. Ultraschallschweissnahtpruefung bei Temperaturen bis 200 C (A. Erhard); 7. Fehlerauffindung und Fehlergroessenbestimmung mit der Gruppenstrahlertechnik bei der Schweissnahtpruefung (W. Rathgeb); 8. Trockene Ultraschallpruefung lasergeschweisster Stumpfschweissnaehte mittels gefuehrter SH-Wellen am Beispiel der Tailored Blanks (H.-J. Salzburger). Vier der Beitraege wurden separat fuer die ENERGY Datenbank aufgenommen.

  19. Technical Letter Report Assessment of Ultrasonic Phased Array Testing for Cast Austenitic Stainless Steel Pressurizer Surge Line Piping Welds and Thick Section Primary System Cast Piping Welds JCN N6398, Task 2A

    Energy Technology Data Exchange (ETDEWEB)

    Diaz, Aaron A.; Denslow, Kayte M.; Cinson, Anthony D.; Morra, Marino; Crawford, Susan L.; Prowant, Matthew S.; Cumblidge, Stephen E.; Anderson, Michael T.

    2008-07-21

    Research is being conducted for the NRC at PNNL to assess the effectiveness and reliability of advanced NDE methods for the inspection of LWR components. The scope of this research encompasses primary system pressure boundary materials including cast austenitic stainless steels (CASS), dissimilar metal welds (DMWs), piping with corrosion-resistant cladding, weld overlays, and far-side examinations of austenitic piping welds. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in coarse-grained steel components. This interim technical letter report (TLR) provides a synopsis of recent investigations at PNNL aimed at evaluating the capabilities of phased-array (PA) ultrasonic testing (UT) methods as applied to the inspection of CASS welds in nuclear reactor piping. A description of progress, recent developments and interim results are provided.

  20. Examination of the 1970 National Bureau of Standards Underground Corrosion Test Welded Stainless STeel Coupons from Site D

    Energy Technology Data Exchange (ETDEWEB)

    L. R. Zirker; M. K. Adler Flitton; T. S. Yoder; T. L. Trowbridge

    2008-01-01

    A 1970 study initiated by the National Bureau of Standards (NBS), now known as the National Institute of Standards and Technology (NIST), buried over 6000 corrosion coupons or specimens of stainless steel Types 201, 202, 301, 304, 316, 409, 410, 430, and 434. The coupons were configured as sheet metal plates, coated plates, cross-welded plates, U-bend samples, sandwiched materials, and welded tubes. All coupons were of various heat-treatments and cold worked conditions and were buried at six distinctive soil-type sites throughout the United States. The NBS scientists dug five sets of two trenches at each of the six sites. In each pair of trenches, they buried duplicate sets of stainless steel coupons. The NBS study was designed to retrieve coupons after one year, two years, four years, eight years, and x years in the soil. During the first eight years of the study, four of five planned removals were completed. After the fourth retrieval, the NBS study was abandoned, and the fifth and final set of specimens remained undisturbed for over 33 years. In 2003, an interdisciplinary research team of industrial, university, and national laboratory investigators were funded under the United States Department of Energy’s Environmental Management Science Program (EMSP; Project Number 86803) to extract part of the remaining set of coupons at one of the test sites, characterize the stainless steel underground corrosion rates, and examine the fate and transport of metal ions into the soil. Extraction of one trench at one of the test sites occurred in April 2004. This report details only the characterization of corrosion found on the 14 welded coupons–two cross welded plates, six U-bends, and six welded tubes–that were retrieved from Site D, located near Wildwood, NJ. The welded coupons included Type 301, 304, 316, and 409 stainless steels. After 33 years in the soil, corrosion on the coupons varied according to alloy. This report discusses the stress corrosion cracking and

  1. Charpy impact test of Ti-6Al-4V joints diffusion welded at low temperature

    Energy Technology Data Exchange (ETDEWEB)

    Salazar, J.M.G. de; Urena, A. [Complutense Univ. of Madrid (Spain); Carrion, J.G. [National Inst. of Aeroespatial Technologies, Madrid (Spain). Materials and Structures Div.

    1996-08-15

    The Diffusion Welding (DW) of two or more sheets of Ti-6Al-4V alloy is particularly interesting for aerospace parts manufacturing. In some cases, DW can be carried out together with Superplastic Forming (SPF), because they can share a single facility and the same processing parameters, such as temperature, pressure, time, surface condition and vacuum. The overall manufacturing process is known as SPF/DW, by which it is possible to obtain honeycomb structures in a range of designs. Temperature requirements for industrial SPF of Ti-6Al-4V are very restrictive and a temperature of 1,023 K is needed. However, temperature is not so critical for DW, and the bond can be produced at lower temperatures, when other DW parameters, mainly pressure and time, are changed in a suitable way. The DW parameters for this research were chosen in order to produce DW joints below 1,023 K. The differences between DW at SPF temperatures and other lower temperatures would thus be revealed. Mechanical tests were used as a tool to check DW joints obtained at the temperatures used in the research (1,123 K and 1,023 K), and were complemented with metallographic studies. The results obtained form shear and peel tests have been already discussed. In the present work the results of impact energy tests are also presented.

  2. Study of austenitic stainless steel welded with low alloy steel filler metal. [tensile and impact strength tests

    Science.gov (United States)

    Burns, F. A.; Dyke, R. A., Jr.

    1979-01-01

    The tensile and impact strength properties of 316L stainless steel plate welded with low alloy steel filler metal were determined. Tests were conducted at room temperature and -100 F on standard test specimens machined from as-welded panels of various chemical compositions. No significant differences were found as the result of variations in percentage chemical composition on the impact and tensile test results. The weldments containing lower chromium and nickel as the result of dilution of parent metal from the use of the low alloy steel filler metal corroded more severely in a marine environment. The use of a protective finish, i.e., a nitrile-based paint containing aluminum powder, prevented the corrosive attack.

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

    Science.gov (United States)

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

    2012-01-01

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

  4. Specimen Test of Large-Heat-Input Fusion Welding Method for Use of SM570TMCP

    Directory of Open Access Journals (Sweden)

    Dongkyu Lee

    2015-01-01

    Full Text Available In this research, the large-heat-input welding conditions optimized to use the rear plate and the high-performance steel of SM570TMCP, a new kind of steel suitable for the requirements of prospective customers, are proposed. The goal of this research is to contribute to securing the welding fabrication optimized to use the high-strength steel and rear steel plates in the field of construction industry in the future. This research is judged to contribute to securing the welding fabrication optimized to use the high-strength steel and rear steel plates in the field of construction industry in the future.

  5. FLUXES FOR MECHANIZED ELECTRIC WELDING,

    Science.gov (United States)

    WELDING FLUXES, WELDING ), (* WELDING , WELDING FLUXES), ARC WELDING , WELDS, STABILITY, POROSITY, WELDING RODS, STEEL, CERAMIC MATERIALS, FLUXES(FUSION), TITANIUM ALLOYS, ALUMINUM ALLOYS, COPPER ALLOYS, ELECTRODEPOSITION

  6. Studies of welded joints

    Directory of Open Access Journals (Sweden)

    J. M. Krupa

    2010-07-01

    Full Text Available Studies of a welded joint were described. The joint was made as a result of the reconstruction of a truss and one of the possible means to make a repair. The studies were of a simulation character and were targeted at the detection of welding defects and imperfections thatshould be eliminated in a real structure. A model was designed and on this model the tests and examinations were carried out. The modelwas made under the same conditions as the conditions adopted for repair. It corresponded to the real object in shape and dimensions, and in the proposed technique of welding and welding parameters. The model was composed of five plates joined together with twelve beads.The destructive and non-destructive tests were carried out; the whole structure and the respective welds were also examined visually. Thedefects and imperfections in welds were detected by surface methods of inspection, penetration tests and magnetic particle flaw detection.The model of the welded joint was prepared by destructive methods, a technique that would never be permitted in the case of a realstructure. For the investigations it was necessary to cut out the specimens from the welded joint in direction transverse to the weld run. The specimens were subjected to metallographic examinations and hardness measurements. Additionally, the joint cross-section was examined by destructive testing methods to enable precise determination of the internal defects and imperfections. The surface methods were applied again, this time to determine the severity of welding defects. The analysis has proved that, fabricated under proper conditions and with parameters of the welding process duly observed, the welded joint has good properties and repairs of this type are possible in practice.

  7. Experimental determination of the critical welding speed in high speed MAG welding

    Institute of Scientific and Technical Information of China (English)

    Hu Zhikun; Wu Chuansong

    2008-01-01

    In high speed MAG welding process, some weld formation defects may be encountered. To get good weld quality, the critical welding speed beyond which humping or undercutting weld bead can occur must be known for different conditions. In this research, high speed MAG welding tests were carried out to check out the effects of different factors on the critical welding speed. Through observing the weld bead profiles and the macrographs of the transverse sections of MAG welds, the occurrence tendency of humping weld was analyzed, and the values of critical welding speed were determined under different levels of welding current or voltage, and the effect of shielding gas compositions on the critical welding speed was also investigated.

  8. Characterization of mechanical properties by indentation tests and FE analysis – validation by application to a weld zone of DP590 steel

    National Research Council Canada - National Science Library

    Chung, Kwansoo; Chung, Kyung-Hwan; Lee, Wonoh; Kim, Ji Hoon; Kim, Chongmin; Park, Sung Ho; Kwon, Dongil

    2009-01-01

    .... As for the failure criterion of the base material and weld zones particularly for the failure evaluation in the uni-axial tension test, Hill's bifurcation theory and the M-K theory were applied...

  9. Study on H2S stress corrosion test of welded joint for X65 pipeline steel and numerical analysis

    Institute of Scientific and Technical Information of China (English)

    金晓军; 霍立兴; 张玉凤; 白秉仁; 李晓巍; 曹军

    2004-01-01

    The susceptibility of welded joint for the X65 pipeline steel to H2S stress corrosion cracking (SCC) is investigated. SCC tests on the steel are carried out in the environment based on NACE TM-01-77 solution with saturated gaseous H2S. The threshold stress intensity factor and crack propagation velocity are calculated according to wedge-opening loading (WOL) specimens. The three-dimensional elastic-plastic finite element analysis of WOL specimens is performed by using the FEM programming package ANSYS. Stress field and concentration of hydrogen distribution property ahead of the crack tip are obtained. This paper surveyed the microstructure of welded joint and studied on the mechanical properties of X65 pipeline steel. It provides experimental basis for studying stress corrosion. The results of numerical analysis are consistent with conclusions of stress corrosion test.

  10. Corrosion Properties of Laser Welded Stainless Steel

    DEFF Research Database (Denmark)

    Weldingh, Jakob; Olsen, Flemmming Ove

    1997-01-01

    In this paper the corrosion properties of laser welded AISI 316L stainless steel are examined. A number of different welds has been performed to test the influence of the weld parameters of the resulting corrosion properties. It has been chosen to use the potential independent critical pitting...... temperature (CPT) test as corrosion test. The following welding parameters are varied: Welding speed, lsser power, focus point position and laser operation mode (CW or pulsed)....

  11. Development of a pseudo phased array technique using EMATs for DM weld testing

    Energy Technology Data Exchange (ETDEWEB)

    Cobb, Adam C., E-mail: adam.cobb@swri.org; Fisher, Jay L., E-mail: adam.cobb@swri.org [Southwest Research Institute, Sensor Systems and Nondestructive Technology Department, 6220 Culebra Road, San Antonio, TX 78238-5166 (United States); Shiokawa, Nobuyuki; Hamano, Toshiaki; Horikoshi, Ryoichi; Ido, Nobukazu [IHI Corporation, Nuclear Power Operations, Yokohama Engineering Center, 1, Shin-Nakahara-cho, Isogo-ku, Yokohama 235-8501 (Japan)

    2015-03-31

    Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS material in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.

  12. Development of a pseudo phased array technique using EMATs for DM weld testing

    Science.gov (United States)

    Cobb, Adam C.; Fisher, Jay L.; Shiokawa, Nobuyuki; Hamano, Toshiaki; Horikoshi, Ryoichi; Ido, Nobukazu

    2015-03-01

    Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS material in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.

  13. Design, Fabrication and Testing of Fixture for Implementation of a New Approach to Incorporate Tool tilting in Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Awang Mokhtar

    2014-07-01

    Full Text Available Friction Stir Welding (FSW is solid-state process for joining materials by using frictional heat generated due to rotating tool along the weld line. Since its invention about two decades ago, wide spread use of FSW is still restricted due to very expensive purpose built FSW machines available in the market. As an alternative, a milling machine can be used to carry out the FSW depending on the capabilities of the machine. In cases where milling machines have a fixed head, limitation of zero degree tool tilt angle results in substantial defects (e.g. tunnel defect in weldments. The objective of this study is to design and fabricate an adjustable-angle fixture to incorporate tool tilting in a CNC milling machine with fixed spindle head. The testing of the fabricated fixture is then carried out by running the FSW experiments at different tilt angles.

  14. Modelling the attenuation in the ATHENA finite elements code for the ultrasonic testing of austenitic stainless steel welds.

    Science.gov (United States)

    Chassignole, B; Duwig, V; Ploix, M-A; Guy, P; El Guerjouma, R

    2009-12-01

    Multipass welds made in austenitic stainless steel, in the primary circuit of nuclear power plants with pressurized water reactors, are characterized by an anisotropic and heterogeneous structure that disturbs the ultrasonic propagation and makes ultrasonic non-destructive testing difficult. The ATHENA 2D finite element simulation code was developed to help understand the various physical phenomena at play. In this paper, we shall describe the attenuation model implemented in this code to give an account of wave scattering phenomenon through polycrystalline materials. This model is in particular based on the optimization of two tensors that characterize this material on the basis of experimental values of ultrasonic velocities attenuation coefficients. Three experimental configurations, two of which are representative of the industrial welds assessment case, are studied in view of validating the model through comparison with the simulation results. We shall thus provide a quantitative proof that taking into account the attenuation in the ATHENA code dramatically improves the results in terms of the amplitude of the echoes. The association of the code and detailed characterization of a weld's structure constitutes a remarkable breakthrough in the interpretation of the ultrasonic testing on this type of component.

  15. Welding Curriculum.

    Science.gov (United States)

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

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

  16. Materials and welding engineering in advanced coal utilization plants

    Energy Technology Data Exchange (ETDEWEB)

    Schuhmacher, D.; Schulze-Frielinghaus, W.; Puetz, J.; Eichhorn, F.; Gaever, E. van

    1983-08-01

    The authors present the findings of studies on welding methods for high-temperature alloys used in advanced coal gasification plants. They discuss weld preparation, automatic TIG welding, MIG welding (also with pulsed arc) and plasma arc welding. The mechanical properties of welded joints before and after age hardening are investigated, and the results of fatigue and corrosion tests are presented. The welding methods are compared with a view to their suitability for high-temperature materials.

  17. A study of weld quality in ultrasonic spot welding of similar and dissimilar metals

    Science.gov (United States)

    Al-Sarraf, Z.; Lucas, M.

    2012-08-01

    Several difficulties are faced in joining thinner sheets of similar and dissimilar materials from fusion welding processes such as resistance welding and laser welding. Ultrasonic metal welding overcomes many of these difficulties by using high frequency vibration and applied pressure to create a solid-state weld. Ultrasonic metal welding is an effective technique in joining small components, such as in wire bonding, but is also capable of joining thicker sheet, depending on the control of welding conditions. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal welding device. The ultrasonic welding horn is modelled using finite element analysis and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. Control of the vibration amplitude profile through the weld cycle is used to enhance weld strength and quality, providing an opportunity to reduce part marking. Optical microscopic examination and scanning electron microscopy (SEM) were employed to investigate the weld quality. The results show how the weld quality is particularly sensitive to the combination of clamping force and vibration amplitude of the welding tip.

  18. The Application of Stress-Relaxation Test to Life Assessment of T911/T22 Weld Metal

    Science.gov (United States)

    Cao, Tieshan; Zhao, Jie; Cheng, Congqian; Li, Huifang

    2016-03-01

    A dissimilar weld metal was obtained through submerged arc welding of a T911 steel to a T22 steel, and its creep property was explored by stress-relaxation test assisted by some conventional creep tests. The creep rate information of the stress-relaxation test was compared to the minimum and the average creep rates of the conventional creep test. Log-log graph showed that the creep rate of the stress-relaxation test was in a linear relationship with the minimum creep rate of the conventional creep test. Thus, the creep rate of stress-relaxation test could be used in the Monkman-Grant relation to calculate the rupture life. The creep rate of the stress-relaxation test was similar to the average creep rate, and thereby the rupture life could be evaluated by a method of "time to rupture strain." The results also showed that rupture life which was assessed by the Monkman-Grant relation was more accurate than that obtained through the method of "time to rupture strain."

  19. Spot Welding Parameter Optimization to Improve Weld Characteristics for Dissimilar Metals

    Directory of Open Access Journals (Sweden)

    Aravinthan Arumugam

    2015-01-01

    Full Text Available 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 dissimilar thickness and type using Grey Based Taguchi Method. The experimentation in this work used a L9 orthogonal array with three factors with each factor having three levels. The three factors used are welding current weld time and electrode force. The three weld characteristics that were optimized are weld strength weld nugget diameter and weld indentation. The analysis of variance ANOVA that was carried out showed that welding current gave the most significant contribution in the optimum welding schedule. The comparison test that was carried out to compare the current welding schedule and the optimum welding schedule showed distinct improvement in the increase of weld diameter and weld strengthas well as decrease in electrode indentation.

  20. Weld examination on tube test specimen using TOFD; Untersuchungen mit TOFD an geschweissten Laengsnahtproben

    Energy Technology Data Exchange (ETDEWEB)

    Brekow, G.; Erhard, A. [Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin (Germany). Labor fuer Ultraschallverfahren

    2000-07-01

    In contrast to the pulse echo technique, which is based on the sound field reflection at the flaw surface, the Time of Flight Diffraction (TOFD) technique uses the diffraction of the sound field at the flaw tips. For this purpose two angle beam probes for longitudinal waves are used in a pitch and catch arrangement. The transducers are positioned at both sides of the welding seam and are moved parallel to it during the measurement. The diffraction at the flaw tips causes different time of flight values with respect to the upper and lower flaw tip. Time dependent signals are stored in a series of A-scan pictures, which can finally be represented in a B-picture, which has to be interpreted. As investigations show there are additional useful information concerning defect size which can be given by TOFD, but pulse echo techniques with additional radiographic testing cannot be substituted by TOFD. (orig.) [German] Im Gegensatz zur Impuls-Echo-Technik, die im Wesentlichen auf der Reflexion am Fehler basiert, wird bei der Time-Of-Flight Diffraction Technique (TOFD-Technik) die Beugung der Schallwellen am Fehler zum Nachweis genutzt. Zwei Winkelpruefkoepfe fuer Longitudinalwellen sind in V-Durchschallung angeordnet. Die Pruefkoepfe befinden sich jeweils auf einer Seite der Schweissnaht und werden bei der Messung parallel zur Schweissnaht verschoben. Das ausgesandte Schallbuendel trifft auf Fehlerraender, an denen gebeugte Wellenanteile entstehen, die je nach Entstehungsort mit unterschiedlichen Schallaufzeiten empfangen, in hochfrequenten A-Bildern abgespeichert und fuer die Auswertung in B-Bildern dargestellt werden. Die Untersuchungen zeigen, dass die TOFD-Technik Beitraege zur Fehlergroessenabschaetzung liefert, aber keinesfalls die Impuls-Echo-Technik mit nachgeschalteter Roentgenpruefung ersetzen kann. (orig.)

  1. Laser welding and post weld treatment of modified 9Cr-1MoVNb steel.

    Energy Technology Data Exchange (ETDEWEB)

    Xu, Z. (Nuclear Engineering Division)

    2012-04-03

    Laser welding and post weld laser treatment of modified 9Cr-1MoVNb steels (Grade P91) were performed in this preliminary study to investigate the feasibility of using laser welding process as a potential alternative to arc welding methods for solving the Type IV cracking problem in P91 steel welds. The mechanical and metallurgical testing of the pulsed Nd:YAG laser-welded samples shows the following conclusions: (1) both bead-on-plate and circumferential butt welds made by a pulsed Nd:YAG laser show good welds that are free of microcracks and porosity. The narrow heat affected zone has a homogeneous grain structure without conventional soft hardness zone where the Type IV cracking occurs in conventional arc welds. (2) The laser weld tests also show that the same laser welder has the potential to be used as a multi-function tool for weld surface remelting, glazing or post weld tempering to reduce the weld surface defects and to increase the cracking resistance and toughness of the welds. (3) The Vicker hardness of laser welds in the weld and heat affected zone was 420-500 HV with peak hardness in the HAZ compared to 240 HV of base metal. Post weld laser treatment was able to slightly reduce the peak hardness and smooth the hardness profile, but failed to bring the hardness down to below 300 HV due to insufficient time at temperature and too fast cooling rate after the time. Though optimal hardness of weld made by laser is to be determined for best weld strength, methods to achieve the post weld laser treatment temperature, time at the temperature and slow cooling rate need to be developed. (4) Mechanical testing of the laser weld and post weld laser treated samples need to be performed to evaluate the effects of laser post treatments such as surface remelting, glazing, re-hardening, or tempering on the strength of the welds.

  2. PINCH WELD TESTING TO SUPPORT CHANGE IN MANUFACTURING OIL AT THE KCP

    Energy Technology Data Exchange (ETDEWEB)

    Korinko, P; David Maxwell, D

    2008-02-28

    This task supports the change from an oil mixture termed 50:50 oil (an equal parts mixture of Milpro 634 and Pennex N47) to a new oil mixture (Castrol Illocut 334). This change was necessitated by a KCP vendor no longer supplying the Pennex N47 component of the 50-50. In order to continue production of machined parts, a detailed process was followed to ensure that high quality parts could be manufactured and that the cutting oil selected would provide acceptable human performance characteristics, e.g., skin irritability, smell, etc. A prime consideration in changing the oil was that no apparent change in the pinch weldability of the fill stems fabricated using the new oil and process parameters, if any, be observed. A two part approach, as detailed in the plan shown in Appendix B, was used to qualify the effect of the process on pinch weld characteristics. In the first phase, ref. 1., the weld parameter window was defined using fill stems made from 304L, 21-6-9, and 316 stainless steel. These weld conditions were then subsequently used for the Castrol Illocut 334 machined fill stems. The results of this activity are reported in this document. A follow-on task of welding in the facility was requested by one of the design agencies and this will be completed and reported separately.

  3. Experimental and simulated strength of spot welds

    DEFF Research Database (Denmark)

    Nielsen, Chris Valentin; Bennedbæk, Rune A.K.; Larsen, Morten B.

    2014-01-01

    Weld strength testing of single spots in DP600 steel is presented for the three typical testing procedures, i.e. tensile-shear, cross-tension and peel testing. Spot welds are performed at two sets of welding parameters and strength testing under these conditions is presented by load-elongation cu......Weld strength testing of single spots in DP600 steel is presented for the three typical testing procedures, i.e. tensile-shear, cross-tension and peel testing. Spot welds are performed at two sets of welding parameters and strength testing under these conditions is presented by load......-elongation curves revealing the maximum load and the elongation at break. Welding and strength testing is simulated by SORPAS® 3D, which allows the two processes to be prepared in a combined simulation, such that the simulated welding properties are naturally applied to the simulation of strength testing. Besides...

  4. Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion - an Overview

    Science.gov (United States)

    Thomä, M.; Wagner, G.; Straß, B.; Conrad, C.; Wolter, B.; Benfer, S.; Fürbeth, W.

    2016-03-01

    Due to the steadily increasing demand on innovative manufacturing processes, modern lightweight construction concepts become more and more important. Especially joints of dissimilar metals offer a variety of advantages due to their high potential for lightweight construction. The focus of the investigations was Al/Mg-joints. Friction Stir Welding (FSW) is an efficient process to realize high strength joints between these materials in ductile condition. Furthermore, for a simultaneous transmission of power ultrasound during the FSW-process (US-FSW) a positive effect on the achievable tensile strength of the Al/Mg-joints was proven. In the present work the industrial used die cast alloys EN AC-48000 (AlSi12CuNiMg) and AZ80 (MgAl8Zn) were joined by a machining center modified especially for Ultrasound Supported Friction Stir Welding. The appearing welding zone and the formation of intermetallic phases under the influence of power ultrasound were examined in particular. In order to identify optimal process parameters extensive preliminary process analyzes have been carried out. Following this, an ultrasound-induced more intensive stirring of the joining zone and as a result of this a considerably modified intermetallic zone was detected. At the same time an increase of the tensile strength of about 25% for US-FSW-joints and for fatigue an up to three times higher number of cycles to failure in comparison to a conventional welding process was observed. Moreover, detailed corrosion analyzes have shown that especially the welding zone was influenced by the corrosive attack. To expand and deepen the knowledge of the US-FSW-process further material combinations such as Ti/Steel and Al/Steel will be considered in future.

  5. PVRC/MPC Round Robin Tests for the Low Toughness High-Copper 72W Weld Using Master Curve Methodology of PCVN Specimens

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Bong-Sang; Hong, Jun Hwa; Yang, Won Jon

    2000-06-01

    This report summarizes the results obtained from the Korean contribution the PVRC/MPC cooperative program on {sup R}ound Robin Tests for Low Toughness High-Copper 72W Weld Using Master Curve Methodology of PCVN Specimens. The mandatory part of this program is to perform fracture toughness (K{sub jc}) tests on the low toughness 72W weld at three different temperatures using pre-cracked Charpy specimens. The purpose of the tests is to verify the specimen size requirements in the ASTM E 1921, 'Standard test method for determination of reference temperature, T{sub o}, for ferritic steels in the transition range'.

  6. Advanced Welding Concepts

    Science.gov (United States)

    Ding, Robert J.

    2010-01-01

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

  7. 薄壁高频电阻焊管焊缝的爬波检测%Creeping Wave Testing for Weld of Thin-walled High-frequency Electric Resistance Welded Pipe

    Institute of Scientific and Technical Information of China (English)

    甘正红; 方晓东; 余国民; 余洋; 苏继权

    2014-01-01

    电阻焊管焊缝中易出现的缺陷有未熔合(冷焊)、裂纹、夹杂等,该类缺陷主要为沿焊缝延伸的面积型缺陷,采用超声检测。根据薄壁高频电阻焊管焊缝的缺陷特征,选用了超声爬波检测。阐述了超声爬波检测的原理、特点和工艺方法,设计了爬波检测专用探头和对比试块。实际检测结果表明,爬波检测是一种新型高效的检测方法,证明了爬波检测技术在薄壁电阻焊管焊缝检测中的可行性。%Some defects easily appear in weld of HFW pipe, such as incomplete fusion (cold welding), crack, inclusion etc. The above defects are mainly area type defects along weld extension. These defects can be detected by creeping wave testing according to defects characteristics of thin-walled high-frequency electric resistance welded pipe. In this article, it expatiated the detection principle, features and process method of the creeping wave testing method, designed the creeping wave testing special probe and the reference blocks. The practical detection results showed that the creeping wave testing is a new type of high efficient detection method, and the creeping wave detection technology feasibility in thin-walled high-frequency electric resistance welded pipe was proved.

  8. Quality and innovation in education and certification of the personnel with the responsibility for welding coordination and non-destructive testing

    Directory of Open Access Journals (Sweden)

    J. Słania

    2010-07-01

    Full Text Available The article presents the activities of Instytut Spawalnictwa (Institute of Weldingwhich include essential supervision of training of welding and non-destructive testing personnel conducted at Instytut Spawalnictwa and outside the Institute. The activity comprise approval and attestation of centres for welding and NDT training as well as verification of lecturers and examiners for the welders training centres located outside the Institute, supervision of run courses in all levels of training, participation in examination and verification of welders’ and specialists’ qualifications. On the basis of acquired accreditations, authorisations and current regulations InstytutSpawalnictwa initiates drafting of guidelines for training and examining in all levels of training in the field of welding technology and allied technologies as well as NDT. Training is conducted in accordance with Instytut’s own programmes as well as programmes of International Welding Institute (IIW and European Federation for Welding, Joining and Cutting (EWF. Training is the base for welding and NDT personnel to obtain European and International diplomas and certificates.

  9. Friction stir welding of copper alloys

    Institute of Scientific and Technical Information of China (English)

    Liu Shuhua; Liu Meng; Wang Deqing; Xu Zhenyue

    2007-01-01

    Copper plates,brass plates and copper/brass plates were friction stir welded with various parameters. Experimental results show that the microstructure of the weld is characterized by its much finer grains as contrasted with the coarse grains of parent materials and the heat-affected zones are very narrow. The microhardness of the copper weld is a little higher than that of parent plate. The microhardness of brass weld is about 25% higher than that of parent material. The tensile strength of copper joints increases with increasing welding speed in the test range. The range of parameters to obtain good welds for copper is much wider than that for brass. When different materials were welded, the position of copper plate before welding affected the quality of FSW joints. If the copper plate was put on the advancing side of weld, the good quality of weld could be got under proper parameters.

  10. Technique for the residual life assessment of high temperature components based on creep-rupture testing on welded miniature specimens

    Energy Technology Data Exchange (ETDEWEB)

    Garzillo, A.; Guardamagna, C.; Moscotti, L.; Ranzani, L. [Ente Nazionale per l`Energia Elettrica, Milan (Italy)

    1995-06-01

    Following the present trend in the development of advanced methodologies for residual life assessment of high temperature components operating in power plants, particularly in non destructive methods, a testing technique has been set up at ENEL-CRAM based on creep-rupture testa in an argon on welded miniature specimens. Five experimental systems for creep-rupture tests in an argon atmosphere have been set up which include high accuracy systems, vacuum chambers and exrwnsometer devices. With the aim of establishing and validating the suitability of the experimental methodology, creep-rupture and interrupted creep testing programmes have been performed on miniature specimens (2 mm diameter and 10 mm gauge lenght). On the basis of experience gathered by various European research laboratories, a miniature specimen construction procedure has been developed using a laser welding technique for joining threaded heads to sample material. Low alloy ferritic steels, such as virgin 2.25CrlMo, 0.5Cr 0.5Mo 0.25V, and IN 738 superalloy miniature specimens have been investigated and the results, compared with those from standard specimens, show a regular trend in deformation vs time. Additional efforts to provide guidelines for material sampling from each plant component will be required in order to reduce uncertainties in residual life prediction.

  11. Low activation steels welding with PWHT and coating for ITER test blanket modules and DEMO

    Science.gov (United States)

    Aubert, P.; Tavassoli, F.; Rieth, M.; Diegele, E.; Poitevin, Y.

    2011-02-01

    EUROFER weldability is investigated in support of the European material properties database and TBM manufacturing. Electron Beam, Hybrid, laser and narrow gap TIG processes have been carried out on the EUROFER-97 steel (thickness up to 40 mm), a reduced activation ferritic-martensitic steel developed in Europe. These welding processes produce similar welding results with high joint coefficients and are well adapted for minimizing residual distortions. The fusion zones are typically composed of martensite laths, with small grain sizes. In the heat-affected zones, martensite grains contain carbide precipitates. High hardness values are measured in all these zones that if not tempered would degrade toughness and creep resistance. PWHT developments have driven to a one-step PWHT (750 °C/3 h), successfully applied to joints restoring good material performances. It will produce less distortion levels than a full austenitization PWHT process, not really applicable to a complex welded structure such as the TBM. Different tungsten coatings have been successfully processed on EUROFER material. It has shown no really effect on the EUROFER base material microstructure.

  12. Microstructure characterization and corrosion testing of MAG pulsed duplex stainless steel welds

    Energy Technology Data Exchange (ETDEWEB)

    Mitelea, Ion; Utu, Ion Dragos; Urlan, Sorin Dumitru; Karancsi, Olimpiu [Politehnica Univ. Timisoara (Romania). Faculty of Mechanical Engineering

    2017-08-01

    Duplex stainless steels are extremely attractive construction materials for their usage in intense aggressive environments. They offer numerous advantages compared to the austenitic stainless steels having an excellent behavior to pitting and cavernous corrosion, and a high resistance to stress cracking corrosion in chlorides media. However, their corrosion properties are largely dependent on the microstructural factors such as: the quantitative ratio of the two phases ferrite/austenite (F/A), the presence of intermetallic compounds and the distribution of the alloying elements between the ferrite and austenite. As a result of the thermal cycles experienced by the base metal without a post-weld heat treatment, the mechanical properties are significantly different in the heat affected zone and the deposited metal compared with the properties of the base metal. The present paper highlights the effect of the post-weld solution treatment in order to restore the balance between austenite and ferrite in the welded joint areas and also to limit undesirable precipitation of secondary phases with implications for increasing the corrosion resistance.

  13. Welding Technician

    Science.gov (United States)

    Smith, Ken

    2009-01-01

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

  14. Characteristics of Welding Crack Defects and Failure Mode in Resistance Spot Welding of DP780 Steel

    Institute of Scientific and Technical Information of China (English)

    Xiao-pei WANG; Yong-qiang ZHANG; Jian-bin JU; Jian-qiang ZHANG; Jian-wei YANG

    2016-01-01

    The mechanical properties of welded joints in resistance spot welding of DP780 steel were tested,and three dif-ferent types of welding cracks in welded joints were investigated by optical microscopy,scanning electron microscopy and electron back-scattered diffraction.Finally,the failure mode of the welded joints in shear tensile test was dis-cussed.It is found the shear tensile strength of welded joints can be greatly improved by adding preheating current or tempering current.The surface crack in welded joint is intergranular fracture,while the inner crack in welded joint is transgranular fracture,and the surface crack on the edge of the electrode imprint can be improved by adding prehea-ting current or tempering current.The traditional failure mode criterion advised by American Welding Society is no longer suitable for DP780 spot welds and the critical nugget size suggested by Pouranvari is overestimated.

  15. X120管线钢焊接试验及分析%Welding Test and Analysis of X120 Pipeline Steel

    Institute of Scientific and Technical Information of China (English)

    杜伟; 娄琦; 王长安; 杨专钊

    2011-01-01

    The influence of linear energy on HAZ toughness was studied by means of welding thermal simulation. The best matching scheme for welding materials was determined through matching tests of 3 kinds of different welding wire and welding flux. Using determinate parameter to carry out welding for X120 pipeline steel formed by JCO process, and analyzed steel pipe properties after welding. The results showed when the linear energy is 35 kJ ·cm- 1, HAZ has the highest toughness value;But the present welding materials hardly achieve over-matching welding. In future special X120 welding materials should be developed. The common pipeline steel has good bend deformation ability,while the crack occurred in X120 steel pipe under bend axis diameter with 8 times thickness. The reason was that CGHAZ gains in weld obviously growed big and existed large quantity M/A in structure which was distributed in long strip,it led to CGHAZ brittleness of X120 steel pipe.%采用焊接热模拟方法研究了线能量对X120管线钢HAZ韧性的影响,并通过3种不同成分焊丝与焊剂的匹配试验,确定了X120管线钢的最佳焊材匹配方案.以确定的工艺参数对JCO成型的X120管线钢进行了焊接实践,并对焊后钢管的性能进行了分析.研究表明,当线能量为35 kJ·cm-1时,X120管线钢HAZ具有最高的韧性值;目前现有的焊接材料较难实现X120管线钢的过匹配焊接,应重点开发X120管线钢专用焊材;与普通管线钢具有较佳的弯曲变形能力不同,X120钢管在8倍壁厚的弯轴直径下弯曲出现裂纹,这主要是因为X120钢管焊缝CGHAZ晶粒长大明显,组织中M/A数量多,呈长条状分布,导致了X120钢管焊缝CGHAZ的脆化.

  16. Demands on and testing of resistance welding for HDPE pipes. Status and prospects of codes, frequent errors; Anforderungen und Pruefung von Heizwendelschweissverbindungen fuer Rohre aus PE-HD. Stand und Aussicht der Richtlinien, haeufige Fehler

    Energy Technology Data Exchange (ETDEWEB)

    Langlouis, Winfried; Baudrit, Benjamin; Behr, Heinz; Bastian, Martin [SKZ, Wuerzburg (Germany)

    2009-01-15

    Resistance welding (RW) of pipes and pipeline elements has been an established process, permitting construction of reliable and durable piping systems, for many decades. Up to now, however, there have been no standardized requirements for performance in shear and peeling tests. This gap has now been closed, and a comprehensive DVS code covering resistance welding from the training stage, via welding parameters, up to and including inspection, is now available. (orig.)

  17. TECHNOLOGICAL ISSUES IN MECHANISED FEED WIG/TIG WELDING SURFACING OF WELDING

    Directory of Open Access Journals (Sweden)

    BURCA Mircea

    2016-09-01

    manual welding tests in the light of using the process for welding surfacing being known that in such applications mechanised operations are recommended whenever possible given the latter strengths i.e. increased productivity and quality deposits. The research also aims at achieving a comparative a study between wire mechanised feed based WIG manual welding and the manual rod entry based manual welding in terms of geometry deposits, deposits aesthetics, operating technique, productivity, etc . In this regard deposits were made by means of two welding procedures, and subsequently welding surfacing was made with the optimum values of the welding parameters in this case.

  18. Creep-fatigue evaluation method for weld joint of Mod.9Cr-1Mo steel Part II: Plate bending test and proposal of a simplified evaluation method

    Energy Technology Data Exchange (ETDEWEB)

    Ando, Masanori, E-mail: ando.masanori@jaea.go.jp; Takaya, Shigeru, E-mail: takaya.shigeru@jaea.go.jp

    2016-12-15

    Highlights: • Creep-fatigue evaluation method for weld joint of Mod.9Cr-1Mo steel is proposed. • A simplified evaluation method is also proposed for the codification. • Both proposed evaluation method was validated by the plate bending test. • For codification, the local stress and strain behavior was analyzed. - Abstract: In the present study, to develop an evaluation procedure and design rules for Mod.9Cr-1Mo steel weld joints, a method for evaluating the creep-fatigue life of Mod.9Cr-1Mo steel weld joints was proposed based on finite element analysis (FEA) and a series of cyclic plate bending tests of longitudinal and horizontal seamed plates. The strain concentration and redistribution behaviors were evaluated and the failure cycles were estimated using FEA by considering the test conditions and metallurgical discontinuities in the weld joints. Inelastic FEA models consisting of the base metal, heat-affected zone and weld metal were employed to estimate the elastic follow-up behavior caused by the metallurgical discontinuities. The elastic follow-up factors determined by comparing the elastic and inelastic FEA results were determined to be less than 1.5. Based on the estimated elastic follow-up factors obtained via inelastic FEA, a simplified technique using elastic FEA was proposed for evaluating the creep-fatigue life in Mod.9Cr-1Mo steel weld joints. The creep-fatigue life obtained using the plate bending test was compared to those estimated from the results of inelastic FEA and by a simplified evaluation method.

  19. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Semiautomatic gas metal arc welding of 6XXX aluminum. [6061 and 6063

    Energy Technology Data Exchange (ETDEWEB)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-1015 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for semiautomatic gas metal arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.187 to 2.0 inch; filler metal is ER4043 (F-23); shielding gas is argon.

  20. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Manual gas tungsten arc (DC) and semiautomatic gas metal arc welding of 6XXX aluminum. [6061 and 6063

    Energy Technology Data Exchange (ETDEWEB)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-1009 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for manual gas tungsten arc (DC) and semiautomatic gas metal arc (DC) welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.187 to 2,0 inch; filler metal is ER4043 (F-23); shielding gases are helium (GTAW) and argon (GMAW).

  1. Gas tungsten arc welding of aluminum alloys 6XXX. Welding procedure specification. Supplement 1. Records of procedure qualification tests. [6061 and 6063

    Energy Technology Data Exchange (ETDEWEB)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-1003 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.035 to 0.516 inch; filler metal is ER4043 (F-23) or ER5356 (F-22); shielding gas is argon.

  2. Welding procedure specification: gas tungsten arc dc welding of aluminum alloys 6XXX. Supplement 1. Records of procedure qualification tests. [6061 and 6063

    Energy Technology Data Exchange (ETDEWEB)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-1007 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.125 to 2.0 inch; filler metal is ER4043 (F-23); current is direct, shielding gas is helium.

  3. 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...

  4. 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...

  5. Effect of Multi-repair Welding on Fatigue Performance of Aluminum Alloy Profile Welded Joint

    Science.gov (United States)

    Diao, You-De; Shi, Chun-Yuan; Tian, Hong-Lei

    2016-05-01

    Aluminum alloy profile has been widely used in the manufacture of the rail vehicles. But it's necessary for the repair welding of the welded joints to be conducted because some defects exist in the weld such as porosity, inclusions and incomplete penetrations in the welding processes. In this paper, the influence of the multi-repair welding of 6005A aluminum alloy profile butt welded joints on the fatigue performance are investigated based on the results of fatigue tests. The parameters of curves and the fatigue strength of the welded joints are calculated, and Goodman fatigue limit diagram is also obtained. The results show that fatigue strength of aluminum alloy profile butt welded joints, in condition of 107 cycle life, meet the standard requirement for the as-welded, repair welded state one time or two times respectively.

  6. Effects of welding parameters on the mechanical properties of inert gas welded 6063 Aluminium alloys

    Energy Technology Data Exchange (ETDEWEB)

    Ertan, Taner [MAKO Corporation (Turkey); Uguz, Agah [Uludag Univ. (Turkey). Mechnical Engineering Dept.; Ertan, Rukiye

    2012-07-01

    The influence of welding parameters, namely welding current and gas flow rate, on the mechanical properties of Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) welded 6063 Aluminum alloy (AA 6063) has been investigated. In order to study the effect of the welding current and gas flow rate, microstructural examination, hardness measurements and room temperature tensile tests have been carried out. The experimental results show that the mechanical properties of GTAW welded joints have better mechanical properties than those of SMAW welded joints. Increasing the welding current appeared to have a beneficial effect on the mechanical properties. However, either increasing or decreasing the gas flow rate resulted in a decrease of hardness and tensile strength. It was also found that, the highest strength was obtained in GTAW welded samples at 220 A and 15 l/min gas flow rate.

  7. Influence of weld structure on cross-weld creep behavior in P23 steel

    Energy Technology Data Exchange (ETDEWEB)

    Allen, D.J.; Degnan, C.C. [E.ON Engineering (United Kingdom); Brett, S.J. [RWE npower (United Kingdom); Buchanan, L.W. [Doosan Babcock (United Kingdom)

    2010-07-01

    A thick section pipe weld in low alloy steel P23 has been characterised by cross-weld creep rupture testing at a range of stresses, together with all-weld-metal and parent material testing, under the auspices of the UK High Temperature Power Plant Forum. The results generally show that the weld metal can be weak when tested in the transverse (cross-weld) orientation, and can fail with limited overall ductility by cracking in the zone of refined weld metal beneath the fusion boundary of the superposed weld bead. However, one specimen showed a much superior performance, which could be understood in terms of its locally more creep resistant weld macrostructure. The implications for P23 performance and weld manufacture are discussed. (orig.)

  8. Technical specifications on the welding in fuel reprocessing plants

    Energy Technology Data Exchange (ETDEWEB)

    Karino, Motonobu; Uryu, Mitsuru; Matsui, N.; Nakazawa, Fumio; Imanishi, Makoto; Koizumi; Kazuhiko; Sugawara, Junichi; Tanaka, Hideo

    1999-04-01

    The past specifications SGN of the welding in JNC was reexamined for the reprocessing plants in order to further promote the quality control. The specification first concerns the quality of raw materials, items of the quality tests, material management, and qualification standards of the welders. It extends over details of the welding techniques, welding design, welding testings, inspection and the judgment standards. (H. Baba)

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

    Science.gov (United States)

    Hohhertz, Durwin

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

  10. WELDING TORCH

    Science.gov (United States)

    Correy, T.B.

    1961-10-01

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

  11. Advantages of new micro-jet welding technology on weld microstructure control

    Directory of Open Access Journals (Sweden)

    Jan PIWNIK

    2013-01-01

    Full Text Available An innovative apparatus to welding process with micro-jet cooling of the weld made it possible to carry out technological tests, which have proved theoretical considerations about this problem. This project gives real opportunities for professional development in the field of welding with controlling the parameters of weld structure. These tests have proved that the new micro-jet technology has the potential for growth. It may be great achievement of welding technology in order to increase weld metal strength. The new technology with micro-jet cooling may have many practical applications in many fields, for example such as in the transport industry or to repair damaged metal elements. The advantages of the new device over the traditional system are the ability to control the structure of the weld, the weld mechanical performance increases and improve the quality of welded joints.

  12. Genotoxic Evaluation of Mexican Welders Occupationally Exposed to Welding-Fumes Using the Micronucleus Test on Exfoliated Oral Mucosa Cells: A Cross-Sectional, Case-Control Study.

    Directory of Open Access Journals (Sweden)

    Ana Cecilia Jara-Ettinger

    Full Text Available An estimated 800,000 people worldwide are occupationally exposed to welding-fumes. Previous studies show that the exposure to such fumes is associated with damage to genetic material and increased cancer risk. In this study, we evaluate the genotoxic effect of welding-fumes using the Micronucleus Test on oral mucosa cells of Mexican welders.We conducted a cross-sectional, matched case-control study of n = 66 (33 exposed welders, and 33 healthy controls. Buccal mucosa smears were collected and stained with acridine orange, observed under 100x optical amplification with a fluorescence lamp, and a single-blinded observer counted the number of micronuclei and other nuclear abnormalities per 2,000 observed cells. We compared the frequencies of micronuclei and other nuclear abnormalities, and fitted generalised linear models to investigate the interactions between nuclear abnormalities and the exposure to welding-fumes, while controlling for smoking and age.Binucleated cells and condensed-chromatin cells showed statistically significant differences between cases and controls. The frequency of micronuclei and the rest of nuclear abnormalities (lobed-nuclei, pyknosis, karyolysis, and karyorrhexis did not differ significantly between the groups. After adjusting for smoking, the regression results showed that the occurrence of binucleated cells could be predicted by the exposure to welding-fumes plus the presence of tobacco consumption; for the condensed-chromatin cells, our model showed that the exposure to welding-fumes is the only reliable predictor.Our findings suggest that Mexican welders who are occupationally exposed to welding-fumes have increased counts of binucleated and condensed-chromatin cells. Nevertheless, the frequencies of micronuclei and the rest of nuclear abnormalities did not differ between cases and controls. Further studies should shed more light on this subject.

  13. 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.

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

    Science.gov (United States)

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

    2016-01-01

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

  15. Gas Metal Arc Welding. Welding Module 5. Instructor's Guide.

    Science.gov (United States)

    Missouri Univ., Columbia. Instructional Materials Lab.

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

  16. Experimental tests of irradiation-anneal-reirradiation effects on mechanical properties of RPV plate and weld materials

    Energy Technology Data Exchange (ETDEWEB)

    Hawthorne, J.R. [Materials Engineering Associates, Inc., Lanham, MD (United States)

    1996-01-01

    The Charpy-V (C{sub V}) notch ductility and tension test properties of three reactor pressure vessel (RPV) steel materials were determined for the 288{degree}C (550{degree}F) irradiated (I), 288{degree}C (550{degree}F) irradiated + 454{degree}C (850{degree}F)-168 h postirradiation annealed (IA), and 288{degree}C (550{degree}F) reirradiated (IAR) conditions. Total fluences of the I condition and the IAR condition were, respectively, 3.33 {times} 10{sup 19} n/cm{sup 2} and 4.18 {times} 10{sup 19} n/cm{sup 2}, E > 1 MeV. The irradiation portion of the IAR condition represents an incremental fluence increase of 1. 05 {times} 10{sup 19} n/cm{sup 2}, E > 1 MeV, over the I-condition fluence. The materials (specimens) were supplied by the Yankee Atomic Electric Company and represented high and low nickel content plates and a high nickel, high copper content weld deposit prototypical of the Yankee-Rowe reactor vessel. The promise of the IAR method for extending the fluence tolerance of radiation-sensitive steels and welds is clearly shown by the results. The annealing treatment produced full C{sub V} upper shelf recovery and full or nearly full recovery in the C{sub V} 41 J (30 ft-lb) transition temperature. The C{sub V} transition temperature increases produced by the reirradiation exposure were 22% to 43% of the increase produced by the first cycle irradiation exposure. A somewhat greater radiation embrittlement sensitivity and a somewhat greater reirradiation embrittlement sensitivity was exhibited by the low nickel content plate than the high nickel content plate. Its high phosphorus content is believed to be responsible. The IAR-condition properties of the surface vs. interior regions of the low nickel content plate are also compared.

  17. Nitrogen segregation and blister formation of 316LN austenitic steel during electron beam welding tests for ITER gravity supports

    Science.gov (United States)

    Lee, P. Y.; Hou, B. L.; Wu, J. H.; Yang, D.; Zhang, G. R.; Zhang, C. P.

    2009-04-01

    316LN has been widely applied in the design of ITER components, such as shield blanket and gravity supports, due to its excellent corrosion resistance and high strength. The behavior of nitrogen in this steel during welding is important for the mechanical properties of the components. In this study, a focused 150 kv high voltage electron beam with 300 mA beam current has been used to weld 316LN steel under vacuum condition. The microstructure and composition of the welding area were observed and analyzed. The influence of welding on the shock resistance and tensile strength at both room temperature and low temperature were examined. It was found that the mechanical properties are strongly related to the defects formed in the welding process.

  18. Effect of weld schedule variation on the weldability and durability of AHSS spot weld joints

    Science.gov (United States)

    Weishaupt, Eric Raymond

    Tensile strength testing and high cycle fatigue testing of advanced high strength steel spot welded shear lap joints were performed for the various weld conditions. The materials used in this study were DP 980, DP 780 and TRIP 780. The microstructure and microhardness of the shear lap joints were examined in an effort to identify the effect of microstructural changes on the strength and fatigue durability of the spot weld specimens. The occurrence of interfacial failure was recorded for the differing weld processes. Several weld schedules were examined and used to produce shear lap spot weld joints, specifically varying the squeeze force and the average current. The weld force used to produce a spot weld does not have a significant effect on the fracture mode of the specimen given the average current is constant. The average current used to produce a spot weld has a significant effect on the fracture mode of the spot weld for several squeeze forces. Interfacial failure of spot welded TRIP 780 can be mitigated using a certain range of currents when welding. This appears to come as a tradeoff for sacrificing the strength of the joint. Higher values of weld strength were obtainable; however, welds that failed with higher strengths also experienced interfacial failure. A fracture mechanics approach to estimating the high cycle fatigue life of the shear lap specimen is also proposed and represents a conservative estimate of the shear lap specimen durability.

  19. Weldability of AISI 304 to copper by friction welding

    Energy Technology Data Exchange (ETDEWEB)

    Kirik, Ihsan [Batman Univ. (Turkey); Balalan, Zulkuf [Firat Univ., Elazig (Turkey)

    2013-06-01

    Friction welding is a solid-state welding method, which can join different materials smoothly and is excessively used in manufacturing industry. Friction welding method is commonly used in welding applications of especially cylindrical components, pipes and materials with different properties, for which other welding methods remain incapable. AISI 304 stainless steel and a copper alloy of 99.6 % purity were used in this study. This couple was welded in the friction welding machine. After the welding process, samples were analyzed macroscopically and microscopically, and their microhardness was measured. Tensile test was used to determine the bond strength of materials that were joined using the friction welding method. At the end of the study, it was observed that AISI 304 stainless steel and copper could be welded smoothly using the friction welding method and the bond strength is close to the tensile strength of copper. (orig.)

  20. Damage Tolerance Assessment of Friction Pull Plug Welds

    Science.gov (United States)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

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

  1. 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.

  2. Physical Simulation of a Duplex Stainless Steel Friction Stir Welding by the Numerical and Experimental Analysis of Hot Torsion Tests

    Science.gov (United States)

    da Fonseca, Eduardo Bertoni; Santos, Tiago Felipe Abreu; Button, Sergio Tonini; Ramirez, Antonio Jose

    2016-09-01

    Physical simulation of friction stir welding (FSW) by means of hot torsion tests was performed on UNS S32205 duplex stainless steel. A thermomechanical simulator Gleeble 3800® with a custom-built liquid nitrogen cooling system was employed to reproduce the thermal cycle measured during FSW and carry out the torsion tests. Microstructures were compared by means of light optical microscopy and electron backscatter diffraction. True strain and strain rate were calculated by numerical simulation of the torsion tests. Thermomechanically affected zone (TMAZ) was reproduced at peak temperature of 1303 K (1030 °C), rotational speeds of 52.4 rad s-1 (500 rpm) and 74.5 rad s-1 (750 rpm), and 0.5 to 0.75 revolutions, which represent strain rate between 10 and 16 s-1 and true strain between 0.5 and 0.8. Strong grain refinement, similar to the one observed in the stir zone (SZ), was attained at peak temperature of 1403 K (1130 °C), rotational speed of 74.5 rad s-1 (750 rpm), and 1.2 revolution, which represent strain rate of 19 s-1 and true strain of 1.3. Continuous dynamic recrystallization in ferrite and dynamic recrystallization in austenite were observed in the TMAZ simulation. At higher temperature, dynamic recovery of austenite was also observed.

  3. Comparative evaluation of tungsten inert gas and laser beam welding of AA5083-H321

    Indian Academy of Sciences (India)

    K Subbaiah; M Geetha; B Shanmugarajan; S R Koteswara Rao

    2012-10-01

    In this study, the bead-on-plate welds were made on AA5083-H321 alloy plates using both tungsten inert gas (TIG) welding and laser beam (LB) welding processes to study the enhancement of mechanical properties such as weld yield strength and hardness. The low heat input of laser beam welding effectively reduced the size of the fusion zone and heat affected zone compared to tungsten inert gas welding process. High speed LB welding and fast heating and cooling of LB welding process hinders grain growth compared to TIG welding process. The effect of vapourization of volatile alloying elements is also considered. It seems that magnesium evaporation is relatively less in LB welding compared to TIG welding. Tensile testing of the welded joints revealed that LB welding results in superior mechanical properties. It is concluded that LB welding process is more suitable to join AA5083-H321.

  4. Laser Welding of Ultra-Fine Grained Steel SS400

    Institute of Scientific and Technical Information of China (English)

    PENG Yun; TIAN Zhi-ling; CHEN Wu-zhu; WANG Cheng; BAO Gang

    2003-01-01

    The effects of laser welding on microstructure and mechanical properties of ultra-fine grained steel SS400 were studied. The plasma arc welding and MAG welding were conducted to make a comparison between these weldings and laser welding. The coarse grain heat-affected zone (HAZ) of laser welding was simulated using thermomechanical simulation machine, and the impact toughness was tested. The deep penetration laser welding produces weld of large depth and narrow width. The weld metal and HAZ of laser welding was heated and then cooled rapidly. The prior austenite grain size of coarse grain HAZ is 1/10 of that for arc welding. For laser welding, the toughness of weld metal is higher than that of base metal, and the toughness of the coarse grain HAZ of laser welding is on a level with that of base metal. Matching lower laser power with lower welding speed, the hardening tendency of the weld metal and the coarse grain HAZ can be decreased. There is no softened zone. The tensile strength of welded joint formed by laser is higher than that of base metal. The joint has good bending ductility.

  5. 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.

  6. Comparing the reinforcement capacity of welded steel mesh and a thin spray-on liner using large scale laboratory tests

    Institute of Scientific and Technical Information of China (English)

    Zhenjun Shan; Porter Ian; Nemcik Jan; Baafi Ernest

    2014-01-01

    Steel mesh is used as a passive skin confinement medium to supplement the active support provided by rock bolts for roof and rib control in underground coal mines. Thin spray-on liners (TSL) are believed to have the potential to take the place of steel mesh as the skin confinement medium in underground mines. To confirm this belief, large scale laboratory experiments were conducted to compare the behaviour of welded steel mesh and a TSL, when used in conjunction with rock bolts, in reinforcing strata with weak bedding planes and strata prone to guttering, two common rock conditions which exist in coal mines. It was found that while the peak load taken by the simulated rock mass with weak bedding planes acting as the control sample (no skin confinement) was 2494 kN, the corresponding value of the sample with 5 mm thick TSL reinforcement reached 2856 kN. The peak load of the steel mesh reinforced sample was only 2321 kN, but this was attributed to the fact that one of the rock bolts broke during the test. The TSL rein-forced sample had a similar post-yield behaviour as the steel mesh reinforced one. The results of the large scale guttering test indicated that a TSL is better than steel mesh in restricting rock movement and thus inhibiting the formation of gutters in the roof.

  7. New trends for the NDT of aeronautic welds

    Science.gov (United States)

    Ithurralde, G.; Simonet, D.; Choffy, J.-P.; Bernard, L.

    2001-04-01

    Recent advances in laser beam welding, electron beam welding and friction stir welding enable to join aeronautic and space alloys (mainly aluminum based) and think about new welded design for structural parts at a lower cost. This paper deals with both the non destructive testing approach implemented for welding process optimization, and the NDT multi-sensors tools selected because of their ability for on-line defect tracking automation.

  8. ELECTRIC WELDING EQUIPMENT AND AUTOMATION OF WELDING IN CONSTRUCTION,

    Science.gov (United States)

    WELDING , *ARC WELDING , AUTOMATION, CONSTRUCTION, INDUSTRIES, POWER EQUIPMENT, GENERATORS, POWER TRANSFORMERS, RESISTANCE WELDING , SPOT WELDING , MACHINES, AUTOMATIC, STRUCTURES, WIRING DIAGRAMS, USSR.

  9. 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…

  10. Prediction of numerical distortion after welding with various welding sequences and clampings

    Directory of Open Access Journals (Sweden)

    S. Kastelic

    2010-10-01

    Full Text Available Welding simulation of a test cover for hydropower plant was made due to very large dimensions of the cover. The main aim was to predict distortion after welding in order to avoid machining the cover. Welding process was simulated with the Sysweld program to keep distortion in desired limits. Various welding sequences and clamping conditions were calculated to reduce the distortion. Calculation of microstructure constituents in virtual complex geometry of joints was also analyzed.

  11. Test research on cold bend of {phi}1219 mm x 22 mm X80 longitudinally submerged-arc welded line pipes

    Energy Technology Data Exchange (ETDEWEB)

    Qiang, Chi; Lingkang, Ji; Yinglai, Liu; Peng, Wang [China National Petroleum Corporation (CNPC), Xi' an (China). Tubular Goods Research Center

    2009-07-01

    The tests of cold bend of {phi}1219 mm x 22 mm X80 longitudinally submerged-arc welded line pipes were done to research the effects of cold bend processes on the configuration and property of X80 steel pipe in this paper. In the filed bend tests, the six kinds radius of curvature consist of 18D, 20D, 24D, 28D, 35D and 47D (D is the diameter of steel pipe) were adopted. The results of welding seam non-destructive and macrograph examination show that the effect of bending process on the quality of welding seam is not obvious. The appearance inspections show that the serious distortions occur on the bend pipes of 18D and 20D radius of curvature. The mechanical property tests results indicate that the change of the transverse tensile property, toughness and hardness of cold bend pipes manufactured by various radius of curvature compare with the mother pipe are smaller. The change of longitudinal tensile property is bigger. Compared with the mother pipe, the yield strength and yield ratio in inner arc of bend pipe decrease, but those in outer arc of bend pipe increase. The longitudinal tensile curves in different sampling locations of bend pipe exhibit a rather large difference. (author)

  12. 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

  13. effect of post-weld heat treatment on the microstructure and ...

    African Journals Online (AJOL)

    user

    results of the optical microscopic test show that fine grains of pearlite in ferrite were obtained in normalized samples and ... submerge arc welding, gas metal arc welding, plasma arc welding .... were then etched with 2% Nital solution using the.

  14. Fine tuning of dwelling time in friction stir welding for preventing material overheating, weld tensile strength increase and weld nugget size decrease

    Directory of Open Access Journals (Sweden)

    Mijajlović Miroslav M.

    2016-01-01

    Full Text Available After successful welding, destructive testing into test samples from Al 2024-T351 friction stir butt welds showed that tensile strength of the weld improve along the joint line, while dimensions of the weld nugget decrease. For those welds, both the base material and the welding tool constantly cool down during the welding phase. Obviously, the base material became overheated during the long dwelling phase what made conditions for creation of joints with the reduced mechanical properties. Preserving all process parameters but varying the dwelling time from 5-27 seconds a new set of welding is done to reach maximal achievable tensile strength. An analytical-numerical-experimental model is used for optimising the duration of the dwelling time while searching for the maximal tensile strength of the welds

  15. Performance Improvement of Friction Stir Welds by Better Surface Finish

    Science.gov (United States)

    Russell, Sam; Nettles, Mindy

    2015-01-01

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

  16. Comparison of fatigue property between friction stir and TIG welds

    Institute of Scientific and Technical Information of China (English)

    Xunhong Wang; Kuaishe Wang; Yang Shen; Kai Hu

    2008-01-01

    The alloy 5052 was welded by friction stir welding (FSW) and tungsten inert gas (TIG) welding. The effect of welding processes (FSW and TIG) on the fatigue properties of 5052 aluminum-welded joints was analyzed based on fatigue testing, and the S-N curve of the joints were established. The results show that the fatigue properties of FSW welded joints are better than those of TIG welded joints. The fatigue strength is determined as 65 Mpa under 106 cycling of fatigue life. The microstructure of joints is fine grains and narrow HAZ zone in FSW welds, which inhibit the growth of cracks and produce high fatigue life compared with that of TIG welds. Fracture morphologies also show that the fatigue fracture results from weld defects.

  17. Study on full automatic arc welding machine for spherical tank

    Institute of Scientific and Technical Information of China (English)

    蒋力培; 张甲英; 俞建荣

    2002-01-01

    A full automatic welding machine for spherical tanks' all position multi-layer welds has been developed. This machine is mainly composed of a two-dimension seam tracking system based on microcomputer's memory and a welding tractor as well as rail. The main features of the machine are: while welding the first layer of a seam, its microcomputer system can analyze and store the tracing information from a two-dimension sensor, and control the welding head device to realize two-dimension real time tracing; while welding the second layer up to the top layer of the seam, it can realize two-dimension tracing based on the memorial data, automatically determine the layer number and continually sway the welding head. The welding test shows that the machine has good tracing and welding behavior, and is suitable for spherical tank's all position multi-layer welds.

  18. Effect of welding parameters on the mechanical properties of GMA-welded HY-80 steels

    Energy Technology Data Exchange (ETDEWEB)

    Durmusoglu, Senol [Gazi Univ., Ankara (Turkey); Tuerker, Mehmet [RWTH Aachen Univ. (Germany). ISF - Welding and Joining Inst.; Tosun, Murat [Gedik Univ., Istanbul (Turkey)

    2015-07-01

    In this publication, investigations of HY-80 steels joined by gas metal arc welding by using different welding parameters are described. Different samples obtained from the welded joints were subjected to mechanical testing by means of tensile, hardness and impact toughness tests. The tensile test results showed that the strength of weld metal and heat affected zone were higher than of base metal. Similar Charpy impact toughness test results were obtained for weld metal and heat affected zone. Weld metal hardness was almost similar to the base metal hardness, nevertheless, the heat affected zone indicated higher values. The base metal has ferritic-perlitic structure with fine grains. Martensite needles and bainite are seen in the heat affected zone. Weld metal has martensite needles, partial bainite and residual austenite.

  19. H2S Stress Corrosion Tests of Welded Joint for X65 Pipeline Steel and Finite Element Numerical Analysis of Crack Tip

    Institute of Scientific and Technical Information of China (English)

    金晓军; 霍立兴; 张玉凤; 白秉仁; 李小巍; 曹军

    2003-01-01

    The microstructure of welded joint is surveyed and the mechanical properties of X65 pipeline steel are studied in this paper, which provides experimental basis of performance effect on stress corrosion. H2S stress corrosion cracking (SCC) tests on the steel are carried out in the environment based on NACE TM-01-77 solution. The threshold stress intensity factor and crack propagation velocity for base metal and HAZ are obtained. The susceptibility of welded joint for X65 pipeline steel to H2S stress corrosion cracking is investigated. The programming package ANSYS of finite element model (FEM) is used to perform the three-dimensional elastic-plastic finite element analysis of WOL specimens. Stress field and concentration of hydrogen distribution property of the crack tip are obtained.

  20. The impact of welding wire on the mechanical properties of welded joints

    Directory of Open Access Journals (Sweden)

    Magdalena Mazur

    2014-06-01

    Full Text Available This paper presents results of the mechanical properties of Hardox 450 steel welded joints. These welded joints were made in accordance with welding procedure specifications (WPS, which was prepared and  applied in the Wielton company. Fillers were provided by welding wires with two different diameters. The welding wire was G4Sil with diameter of 1.0 mm and 1.2 mm. The aim of this study was to examine whether the thickness of the welding wire has a direct effect on the properties of welded joints. Test specimens were made in similar parameters of the welding process. Then they were subjected to macroscopic research, tensile strength, impact strength and hardness

  1. A NEURAL NETWORK FOR WELD PENETRATION CONTROL IN GAS TUNGSTEN ARC WELDING

    Institute of Scientific and Technical Information of China (English)

    C.S. Wu; J.Q. Gao; Y.H. Zhao

    2006-01-01

    Realizing of weld penetration control in gas tungsten arc welding requires establishment of a model describing the relationship between the front-side geometrical parameters of weld pool and the back-side weld width with sufficient accuracy. A neural network model is developed to attain this aim. Welding experiments are conducted to obtain the training data set (including 973 groups of geometrical parameters of the weld pool and back-side weld width) and the verifying data set (108 groups). Two data sets are used for training and verifying the neural network, respectively.The testing results show that the model has sufficient accuracy and can meet the requirements of weld penetration control.

  2. Improvement and qualification of ultrasonic testing of dissimilar welds in the primary circuit of NPPs; Verbesserung und Qualifizierung der Ultraschallpruefung von Mischnaehten im Primaerkreis von KKW

    Energy Technology Data Exchange (ETDEWEB)

    Mitzscherling, Steffen; Barth, Enrico; Homann, Tobias; Prager, Jens [Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin (Germany); Goetschel, Sebastian; Weiser, Martin [Konrad-Zuse-Zentrum fuer Informationstechnik Berlin (ZIB) (Germany)

    2017-08-01

    The austenitic and dissimilar welds found in the primary circuit of nuclear power plants are not only extremely relevant to safety but also place very high demands on material testing. In addition to limited accessibility, the macroscopic structure of the weld seam is of paramount importance for ultrasound testing. In order to reliably determine material errors in position and size, the grain orientations and the elastic constants of the anisotropic weld bead structure must be known. The following work steps are used for the imaging representation of possible material defects: First, the weld seam is sounded in order to be able to determine important weld seam parameters, such as, for example, the grain orientation, using an inverse method. On the basis of these parameters, the sound paths are simulated in the next step by means of raytracing (RT). Finally, this RT simulation is assigned the measurement data (A-scans) from different transmitter and receiver positions and superimposed according to the Synthetic Aperature Focusing Technique (SAFT) method. The combination of inverse process, RT and SAFT also ensures a correct visualization of the faults in anisotropic materials. We explain these three methods and present the test arrangement of test specimens with artificial test errors. Measurement data as well as their evaluation are compared with the results of a CIVA simulation. [German] Die im Primaerkreislauf von Kernkraftwerken anzutreffenden austenitischen Schweiss- und Mischnaehte sind nicht nur extrem sicherheitsrelevant, sondern stellen auch sehr hohe Anforderungen an die Materialpruefung. Neben der eingeschraenkten Zugaenglichkeit ist das makroskopische Gefuege der Schweissnaht fuer die Pruefung mit Ultraschall von hoechster Bedeutung. Um Materialfehler zuverlaessig in Position und Groesse bestimmen zu koennen, muessen die Kornorientierungen und die elastischen Konstanten des anisotropen Schweissnahtgefueges bekannt sein. Fuer die bildgebende Darstellung

  3. Monitoring of solidification crack propagation mechanism in pulsed laser welding of 6082 aluminum

    Science.gov (United States)

    von Witzendorff, P.; Kaierle, S.; Suttmann, O.; Overmeyer, L.

    2016-03-01

    Pulsed laser sources with pulse durations in the millisecond regime can be used for spot welding and seam welding of aluminum. Seam welds are generally produced with several overlapping spot welds. Hot cracking has its origin in the solidification process of individual spot welds which determines the cracking morphology along the seam welding. This study used a monitoring unit to capture the crack geometry within individual spot welds during seam welding to investigate the conditions for initiation, propagation and healing (re-melting) of solidification cracking within overlapping pulsed laser welds. The results suggest that small crack radii and high crack angles with respect to welding direction are favorable conditions for crack healing which leads to crack-free seam welds. Optimized pulse shapes were used to produce butt welds of 0.5 mm thick 6082 aluminum alloys. Tensile tests were performed to investigate the mechanical strength in the as-welded condition.

  4. Ultrasonic Phased Array Testing of Austenitic Stainless Steel Welds%奥氏体不锈钢焊缝的相控阵超声检测

    Institute of Scientific and Technical Information of China (English)

    胡栋; 王强; 肖琨; 刘富君

    2013-01-01

    The ultrasonic testing(UT) of austenitic stainless steel welds defects is always difficult because its coarse-grained material and anisotropic structure which lead to aberration and scattering of the ultrasonic waves. In this paper, ultrasonic testing properties of austenitic welds were analyzed. Ultrasonic test and ultrasonic phased array test were performed in an austenitic stainless steel welds test block. The results reveal that 14 dB signal-to-noise ratio (SNR) is obtained by ultrasonic phased array test while by ultrasonic test only 6 dB SNR is obtained to the defects in 10 mm depth. But both of these two tests cannot detect the defects in 30 mm depth.%由于奥氏体不锈钢焊缝晶粒组织粗大以及结构的各向异性导致超声声束的散射和畸变,其超声检测比较困难.本文分析了奥氏体不锈钢焊缝超声检测特性,在奥氏体不锈钢焊缝试块上进行了常规超声和相控阵超声检测试验.研究结果表明:对于10 mm深焊缝缺陷,相控阵超声检测信噪比可达14 dB,而常规超声技术仅获得6 dB的信噪比,对于30 mm深内部缺陷,均未取得较好的效果.

  5. 转轮焊缝相控阵超声检测工艺研究%Study on Ultrasonic Testing Technology for Runner Weld Phased Array

    Institute of Scientific and Technical Information of China (English)

    肖凯; 李晓红; 马庆增

    2014-01-01

    针对常规超声检测方法在进行三维多变断面转轮焊缝检测时存在的局限性,介绍了相控阵超声检测技术的特点。根据转轮焊缝容易出现的缺陷类型制作了模拟试块,设计超声相控阵检测工艺并进行检测,对检出缺陷进行常规超声检测验证。结果表明,超声相控阵技术可明显提高检测效率及检出能力,但对位向不好的层间未熔合,仍需配合直探头在焊缝弧面进行补充检测。%Aiming at existing boundedness of conventional ultrasonic testing method in testing 3D changeable cross-section runner weld,this paper introduces features of phased array ultrasonic testing technology.According to defect types easy to appear of runner weld,it makes simulation samples and designs ultrasonic phased array testing technology to test detected de-fects and proceed conventional ultrasonic testing verification.The result indicates that ultrasonic phased array technology is obviously able to improve testing effectiveness and detecting ability but it is not able to finish fuse of interlamination of bad exposure.Thus,it is necessary to carry out supplementary testing on the weld cambered surface by coordinating with normal probe.

  6. Mechanized US test method for welded rotors in power plant engineering - new approaches, experience, outlook; Mechanisierte US-Prueftechnik an geschweissten Rotoren im Kraftwerksbau - Neue Wege, Erfahrungen, Ausblick

    Energy Technology Data Exchange (ETDEWEB)

    Lohmann, H.P.; Boewe, M. [Siemens AG PG, Muelheim a. d. Ruhr (Germany)

    2002-07-01

    The new US technology has the following advantages: 1. Testing of welds on shafts which cannot be tested by direct vertical acoustic testing. 2. Testing of narrow gap welds in narrow and cramped space; 3. Variable test probe distances and acoustic testing angles. 4. Good sensivity for faults vertical to the surface. Implementation of the phased array technology is possible, which shortens the testing time. Modern multichannel ultrasonic test equipment enables classification into 3D and 2D signals. The new technology is an important tool for quality assurance in the production and repair of welded turbine shafts. [German] Die Vorteile der vorgestellten US-Prueftechnik lassen sich wie folgt zusammenfassen: 1. Wellenschweissnaehte, die konstruktiv keine Moeglichkeit der direkten Senkrechteinschallung bieten, koennen auf diese Weise auf Flankenbindefehler ueberprueft werden. 2. Durch die Anordnung der Pruefkoepfe ist es moeglich, Engspaltschweissungen unter eingeschraenkten Platzverhaeltnissen zu pruefen. 3. Durch die Variation der Pruefkopfabstaende und Einschallwinkel koennen die Tiefenlagen frei gewaehlt werden. 4. Eine sehr gute Nachweisempfindlichkeit fuer Flankenbindefehler (senkrecht zur Oberflaeche orientiert) ist gewaehrleistet. Eine klare Bewertung der detektierten Anzeigen ueber die AVG - oder Vergleichskoerpermethode ist moeglich. Weiteres Potential liegt in der Implementierung der Phased Array Prueftechnik, was zu einer erheblichen Zeitersparnis fuehrt. Die Verwendung moderner, mehrkanaliger Ultraschallgeraete laesst darueber hinaus bei gleichzeitigem Einsatz der Pruefkoepfe im Impuls-Echo-Betrieb und im Sender-Empfaenger-Betrieb eine Klassifizierung von Anzeigen in ''voluminoes'' und ''flaechig'' zu. Mit der entwickelten Prueftechnik wurde ein wichtiges Instrument zur Qualitaetssicherung bei der Herstellung und Reparatur geschweisster Turbinenwellen geschaffen.

  7. 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

  8. Estimation of Fracture Porosity in an Unsaturated Fractured Welded Tuff Using Gas Tracer Testing

    Energy Technology Data Exchange (ETDEWEB)

    B.M. Freifeild

    2001-10-18

    Kinematic fracture porosity is an important hydrologic transport parameter for predicting the potential of rapid contaminant migration through fractured rock. The transport velocity of a solute moving within a fracture network is inversely related to the fracture porosity. Since fracture porosity is often one or two orders of magnitude smaller than matrix porosity, and fracture permeability is often orders of magnitude greater than matrix permeability, solutes may travel significantly faster in the fracture network than in the surrounding matrix. This dissertation introduces a new methodology for conducting gas tracer tests using a field portable mass spectrometer along with analytical tools for estimating fracture porosity using the measured tracer concentration breakthrough curves. Field experiments were conducted at Yucca Mountain, Nevada, consisting of air-permeability transient testing and gas-tracer-transport tests. The experiments were conducted from boreholes drilled within an underground tunnel as part of an investigation of rock mass hydrological behavior. Air-permeability pressure transients, recorded during constant mass flux injections, have been analyzed using a numerical inversion procedure to identify fracture permeability and porosity. Dipole gas tracer tests have also been conducted from the same boreholes used for air-permeability testing. Mass breakthrough data has been analyzed using a random walk particle-tracking model, with a dispersivity that is a function of the advective velocity. The estimated fracture porosity using the tracer test and air-injection test data ranges from .001 to .015. These values are an order of magnitude greater than the values estimated by others using hydraulically estimated fracture apertures. The estimates of porosity made using air-permeability test data are shown to be highly sensitive to formation heterogeneity. Uncertainty analyses performed on the gas tracer test results show high confidence in the parameter

  9. Nondestructive testing of PE welds; Zerstoerungsfreie Pruefung von PE-Schweissverbindungen

    Energy Technology Data Exchange (ETDEWEB)

    Sievering, F. [E.ON Ruhrgas AG, Essen (Germany)

    2008-05-15

    Polyethylene pipes are increasingly coming into use for gas and water transmission purposes. Rising operating pressures mean that the need for rational nondestructive testing procedures is also rising correspondingly. E.ON-Ruhrgas has now started testing of the potentials of ultrasonic methods, in particular, and adapting existing nondestructive procedures, such as TOFD and Phased Array. The results achieved up to the present time are examined in this article. (orig.)

  10. 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.

  11. Recent progress on gas tungsten arc welding of vanadium alloys

    Energy Technology Data Exchange (ETDEWEB)

    Grossbeck, M.L.; King, J.F.; Alexander, D.J. [Oak Ridge National Lab., TN (United States)] [and others

    1997-08-01

    Emphasis has been placed on welding 6.4 mm plate, primarily by gas tungsten arc (GTA) welding. The weld properties were tested using blunt notch Charpy testing to determine the ductile to brittle transition temperature (DBTT). Erratic results were attributed to hydrogen and oxygen contamination of the welds. An improved gas clean-up system was installed on the welding glove box and the resulting high purity welds had Charpy impact properties similar to those of electron beam welds with similar grain size. A post-weld heat treatment (PWHT) of 950{degrees}C for two hours did not improve the properties of the weld in cases where low concentrations of impurities were attained. Further improvements in the gas clean-up system are needed to control hydrogen contamination.

  12. Pulsed Magnetic Welding for Advanced Core and Cladding Steel

    Energy Technology Data Exchange (ETDEWEB)

    Cao, Guoping [Univ. of Wisconsin, Madison, WI (United States); Yang, Yong [Univ. of Florida, Gainesville, FL (United States)

    2013-12-19

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

  13. Hybrid Al/steel-joints manufactured by ultrasound enhanced friction stir welding (USE-FSW): Process comparison, nondestructive testing and microscopic analysis

    Science.gov (United States)

    Thomä, M.; Wagner, G.; Straß, B.; Wolter, B.; Benfer, S.; Fürbeth, W.

    2017-03-01

    The process of friction stir welding (FSW) is an innovative joining technique, which proved its potential in joining dissimilar metals that are poorly fusion weldable. This ability opens a wide range for applications in industrial fields, where weight reduction by partial substitution of conventional materials through lightweight materials is a current central aim. As a consequence of this, the realization of aluminum / steel-joints is of great interest. For this material compound, several friction stir welds were carried out by different researchers for varying Al/steel-joints, whereas the definition of optimal process parameters as well as the increase of mechanical properties was in the focus of the studies. To achieve further improved properties for this dissimilar joint a newly developed hybrid process named “ultrasound enhanced friction stir welding (USE-FSW)” was applied. In this paper the resulting properties of Al/steel-joints using FSW and USE-FSW will be presented and compared. Furthermore, first results by using the nondestructive testing method “computer laminography” to analyze the developed joining area will be shown supplemented by detailed light-microscopic investigations, scanning electron microscopic analysis, and EDX.

  14. The reliability of untempered end plug welds on HT9-clad IFR fuel elements

    Energy Technology Data Exchange (ETDEWEB)

    Crawford, D C; Porter, D L

    1987-02-01

    Welding generally leaves residual stresses in transformed weld zones, which can initiate cracks from flaws already present in the weld zones. When HT9 cools from welding temperatures, a martensite phase forms in the weld fusion zone and heat-affected zone. Because this martensite phase is hard and brittle, it is particularly susceptible to cracking aggravated by residual stresses. This causes concern over the use of untempered welds on HT9-clad fuel elements. To determine if residual stresses present in end-plug weld zones would affect fuel pin performance, HT9 capsules with prototypic TIG- and CD-welded end plugs (in the tempered and as-welded conditions) were pressurized to failure at room temperature, 550{sup 0}C, and 600{sup 0}C. None of the capsules failed in a weld zone. To determine the effects of reactor operating temperatures on untempered welds, prototypic TIG welds were tempered at reactor bulk sodium temperature and an expected sodium outlet temperature for various lengths of time. Subsequent tensile and burst tests of these specimens proved that any embrittling effects that may have been induced in these welds were of no consequence. Hardness tests on longitudinal sections of welds indicated the amount of tempering a weld will receive inreactor after relatively short lengths of time. The pressure burst tests proved that untemperted welds on HT9-clad fuel elements are as reliable as tempered welds; any residual stresses in untempered weld zones were of no consequence. The tempering test showed that welds used in the as-welded condition will sufficiently temper in 7 days at 550{sup 0}C, but will not, sufficiently temper in 7 days at bulk sodium temperature. A comparison of the structure of laser welds to those of CD and TIG welds indicated that untempered laser welds will perform and temper in a manner similar to the TIG welds tested in this effort.

  15. Braze welding of cobalt with a silver–copper filler

    Directory of Open Access Journals (Sweden)

    Everett M. Criss

    2015-01-01

    Full Text Available A new method of joining cobalt by braze-welding it with a silver–copper filler was developed in order to better understand the residual stresses in beryllium–aluminum/silicon weldments which are problematic to investigate because of the high toxicity of Be. The base and filler metals of this new welding system were selected to replicate the physical properties, crystal structures, and chemical behavior of the Be–AlSi welds. Welding parameters of this surrogate Co–AgCu system were determined by experimentation combining 4-point bending tests and microscopy. Final welds are 5 pass manual TIG (tungsten inert gas, with He top gas and Ar back gas. Control of the welding process produces welds with full penetration melting of the cobalt base. Microscopy indicates that cracking is minimal, and not through thickness, whereas 4-point bending shows failure is not by base-filler delamination. These welds improve upon the original Be–AlSi welds, which do not possess full penetration, and have considerable porosity. We propose that utilization of our welding methods will increase the strength of the Be–AlSi weldments. The specialized welding techniques developed for this study may be applicable not only for the parent Be–AlSi welds, but to braze welds and welds utilizing brittle materials in general. This concept of surrogacy may prove useful in the study of many different types of exotic welds.

  16. Laser based spot weld characterization

    Science.gov (United States)

    Jonietz, Florian; Myrach, Philipp; Rethmeier, Michael; Suwala, Hubert; Ziegler, Mathias

    2016-02-01

    Spot welding is one of the most important joining technologies, especially in the automotive industry. Hitherto, the quality of spot welded joints is tested mainly by random destructive tests. A nondestructive testing technique offers the benefit of cost reduction of the testing procedure and optimization of the fabrication process, because every joint could be examined. This would lead to a reduced number of spot welded joints, as redundancies could be avoided. In the procedure described here, the spot welded joint between two zinc-coated steel sheets (HX340LAD+Z100MB or HC340LA+ZE 50/50) is heated optically on one side. Laser radiation and flash light are used as heat sources. The melted zone, the so called "weld nugget" provides the mechanical stability of the connection, but also constitutes a thermal bridge between the sheets. Due to the better thermal contact, the spot welded joint reveals a thermal behavior different from the surrounding material, where the heat transfer between the two sheets is much lower. The difference in the transient thermal behavior is measured with time resolved thermography. Hence, the size of the thermal contact between the two sheets is determined, which is directly correlated to the size of the weld nugget, indicating the quality of the spot weld. The method performs well in transmission with laser radiation and flash light. With laser radiation, it works even in reflection geometry, thus offering the possibility of testing with just one-sided accessibility. By using heating with collimated laser radiation, not only contact-free, but also remote testing is feasible. A further convenience compared to similar thermographic approaches is the applicability on bare steel sheets without any optical coating for emissivity correction. For this purpose, a proper way of emissivity correction was established.

  17. The Classification of Weld Seam Defects for Quantitative Analysis by means of Ultrasonic Testing

    Science.gov (United States)

    Salchak, Y.; Tverdokhlebova, T.; Sharavina, S.; Lider, A.

    2016-06-01

    The paper describes effective quality assessment of spent nuclear fuel storage cask. The ultrasonic testing method is considered. The classification of possible defects with corresponding dimensions limits is proposed. The database of defects of the spent nuclear fuel storage cask was created in compliance with the nuclear energy industry regulatory documents.

  18. Dependence of the mechanical properties of joints welded according to the parameters of the metal active gas (MAG welding regime

    Directory of Open Access Journals (Sweden)

    D. Dobrotă

    2015-10-01

    Full Text Available The main objective followed in the realization of welded structures is to obtain superior mechanical characteristics for these structures. The research aimed at setting ranges of values for the welding voltage (Uw, respectively for the welding current (Iw so as to obtain superior mechanical features for welded constructions. The research was carried out using E 36-4 steel as base material and SG2 wire as filler material, whereas the applied welding process was MAG. The optimization was done with the help of a number of 31 test bars considering various welding procedures for each test bar, and the experimental data were processed using the STATISTCA program.

  19. Welding Curtains

    Science.gov (United States)

    1984-01-01

    Concept of transparent welding curtains made of heavy duty vinyl originated with David F. Wilson, President of Wilson Sales Company. In 1968, Wilson's curtains reduced glare of welding arc and blocked ultraviolet radiation. When later research uncovered blue light hazards, Wilson sought improvement of his products. He contracted Dr. Charles G. Miller and James B. Stephens, both of Jet Propulsion Laboratory (JPL), and they agreed to undertake development of a curtain capable of filtering out harmful irradiance, including ultraviolet and blue light and provide protection over a broad range of welding operation. Working on their own time, the JPL pair spent 3 years developing a patented formula that includes light filtering dyes and small particles of zinc oxide. The result was the Wilson Spectra Curtain.

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

    Science.gov (United States)

    Hovanski, Yuri

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

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

    Science.gov (United States)

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

    2012-06-01

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

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

    Science.gov (United States)

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

    2016-02-01

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

  3. Implementation and testing of WELD and automatic spectral rule-based classifications for Landsat ETM+ in South Africa

    CSIR Research Space (South Africa)

    Wessels, Konrad J

    2013-04-01

    Full Text Available The Web-enabled Landsat Data (WELD) system was successfully installed in South Africa (SA) and used for pre-processing large amounts of Landsat ETM+ data to composited seasonal mosaics. In pursuit of automated land cover mapping, the overall...

  4. 一种建筑用高性能耐火耐候钢的焊接试验%Welding Test for High Performance Fire and Weathering Resistant Steel Used for Building

    Institute of Scientific and Technical Information of China (English)

    李世红; 田璐; 牛全峰

    2011-01-01

    针对具有优异强韧性及耐火耐候性能的建筑用WGJ510C2钢,进行了气体保护焊焊接评定试验研究,内容包括熔敷金属试验、接头常规力学性能试验、高温拉伸性能试验及微观组织分析.结果表明,焊接接头常温和高温拉伸强度均满足WGJ510C2钢技术条件要求,焊接接头低温冲击功有较大的富余量.因此,采用气体保护焊焊接方法及NHG-1焊丝匹配WGJ510C2钢,焊接接头综合性能指标完全满足高层建筑用钢焊接技术要求.%The welding assessment test research of gas shielded was conducted, for WGJ510C2 steel with high toughness, fire and weathering resistant used for building. The tests included deposited metal test, routine mechanical properties test of welded joint, tensile performance test at high temperature and microstructure analysis. The results showed that the tensile property at room temperature and high temperature both can meet the welding requirements of WGJ510C2 steel, and the impact energy value of welded joint is surplus at low temperature . Therefore, adopting gas shielded welding method and NHG-1 wire to match with WGJ510C2 steel, the comprehensive properties of welded joint can completely satisfy the welding requirements of the steel used for high-rise building.

  5. DEFORMATION INFLUENCE ON A LIFETIME OF WELDING ELECTRODE TIPS

    Directory of Open Access Journals (Sweden)

    Ján Viňáš

    2009-02-01

    Full Text Available The contribution deals with the influence of welding electrode tips deformation on their lifetime. The influence of material properties, production technology and the intensity of welding electrodes load on their lifetime are presented. The electrode tips of the most used type of CuCr1Zr alloy of three basic standard shapes before and after the process of welding are evaluated. The process of welding is realized with low, middle and maximum welding parameters on programmable pneumatic spot welding machine VTS BPK 20. The influence of welding parameters on chosen material characteristics of welding tips is observed. Through the use of upsetting test, dependency of forming strength and deformation of material on used technology of welding tip production is observed.

  6. Development of Automatic Extraction Weld for Industrial Radiographic Negative Inspection

    Institute of Scientific and Technical Information of China (English)

    张晓光; 林家骏; 李浴; 卢印举

    2003-01-01

    In industrial X-ray inspection, in order to identify weld defects automatically, raise the identification ratio, and avoid processing of complex background, it is an important step for sequent processing to extract weld from the image. According to the characteristics of weld radiograph image, median filter is adopted to reduce the noise with high frequency, then relative gray-scale of image is chosen as fuzzy characteristic, and image gray-scale fuzzy matrix is constructed and suitable membership function is selected to describe edge characteristic. A fuzzy algorithm is adopted for enhancing radiograph image processing. Based on the intensity distribution characteristic in weld, methodology of weld extraction is then designed. This paper describes the methodology of all the weld extraction, including reducing noise, fuzzy enhancement and weld extraction process. To prove its effectiveness, this methodology was tested with 64 weld negative images available for this study. The experimental results show that this methodology is very effective for extracting linear weld.

  7. Laser welding of AZ61 magnesium-based alloys

    Institute of Scientific and Technical Information of China (English)

    Wang Hongying; Li Zhijun; Zhang Yihui

    2006-01-01

    Laser welding of AZ61 magnesium alloys was carried out asing a CO2 laser weldingexperimental system.The welding properties of AZ61 sheets with different thickness were investigated.The effect of processing parameters including laser power, welding speed and protection gas flow was researched.The results show that laser power and welding speed have large effect on the weld width and joint dimensions.Protection gas flow has relatively slight effect on the weld width.The property test of three typical joints indicates that microhardness and tensile strength in weld zone are higher than that of AZ61 base metal.Joints with good appearance and excellent mechanical properties can be produced using CO2 laser welding method.The microstructure with small grains in weld zone is believed to be responsible for the excellent mechanical properties of AZ61 joints.

  8. Differences between Laser and Arc Welding of HSS Steels

    Science.gov (United States)

    Němeček, Stanislav; Mužík, Tomáš; Míšek, Michal

    Conventional welding processes often fail to provide adequate joints in high strength steels with multiphase microstructures. One of the promising techniques is laser beam welding: working without filler metal and with sufficient capacity for automotive and transportation industry (where the amount of AHSS steels increases each year, as well as the length of laser welds). The paper compares microstructures and properties of HSS (high strength steel) joints made by MAG (Metal Active Gas) and laser welding. The effects of main welding parameters (heat input, welding speed and others) are studied on multiphase TRIP 900 steel tubes and martensitic sheets DOCOL 1200, advanced materials for seat frames and other automotive components. Whereas the strength of conventional welds is significantly impaired, laser welding leaves strength of the base material nearly unaffected. As the nature of fracture changes during loading and depending on the welding method, failure mechanisms upon cross tension tests have been studied as well.

  9. 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

  10. ITER lip seal welding and cutting developments

    Energy Technology Data Exchange (ETDEWEB)

    Levesy, B.; Cordier, J.J.; Jokinen, T. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France); Kujanpää, V.; Karhu, M. [VTT Technical Research Centre of Finland (Finland); Le Barbier, R. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France); Määttä, T. [VTT Technical Research Centre of Finland (Finland); Martins, J.P.; Utin, Y. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France)

    2015-10-15

    Highlights: • Different TIG and Laser welding techniques are tested. • Twin spot laser welding techniques is the best. • Limited heat input gives a stable weld pool in all positions. • Penetrations is achieved. • Lip seal welding and cutting with a robotic arm is successfully performed on a representative mock-up. - Abstract: The welded lip seals form part of the torus primary vacuum boundary in between the port plugs and the vacuum vessel, and are classified as Protection Important Component. In order to refurbish the port plugs or the in-vessel components, port plugs have to be removed from the machine. The lip seal design must enable up to ten opening of the vacuum vessel during the life time operation of the ITER machine. Therefore proven, remote reliable cutting and re-welding are essential, as these operations need to be performed in the port cells in a nuclear environment, where human presence will be restricted. Moreover, the combination of size of the components to be welded (∼10 m long vacuum compatible thin welds) and the congested environment close to the core of the machine constraint the type and size of tools to be used. This paper describes the lip seal cutting and welding development programme performed at the VTT Technical Research Centre, Finland. Potential cutting and welding techniques are analyzed and compared. The development of the cutting, TIG and laser welding techniques on samples are presented. Effects of lip seal misalignments and optimization of the 2 welding processes are discussed. Finally, the manufacturing and test of the two 1.2 m × 1 m representative mock-ups are presented. The set-up and use of a robotic arm for the mock-up cutting and welding operations are also described.

  11. 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.

  12. 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)

  13. The arc characteristic of ultrasonic assisted TIG welding

    Institute of Scientific and Technical Information of China (English)

    2008-01-01

    Many applications of ultrasonic-assisted methods were used during metal solidification, but they could not be introduced into weld pool. In this paper, a way of ultrasonic assisted TIG welding is introduced. By directly imposed ultrasonic vibration on welding arc, the vibration interacts with arc plasma and passes to the weld pool. Measurement results show that arc pressure is significantly increased with the ultrasonic vibration and the arc pressure distribution models are changed. Bead-on-plate welding tests on SUS304 confirm that this technology can influence the style of metal melting and increase weld penetration depth.

  14. Characterization of electrical properties of resistance welding machines

    Institute of Scientific and Technical Information of China (English)

    Wu Pei; Shao Yingli; Wenqi Zhang; Niels Bay

    2008-01-01

    Due to the individual electrical and mechanical characteristics of resistance welding machines, choice of the right machine and welding parameters for an optimized production is often difficult. This is especially the case in projection welding of complex joints. In this paper, a new approach of characterizing the electrical properties of AC resistance welding machines is presented, involving testing and mathematical modelling of the weld current, the firing angle and the conduction angle of silicon controlled rectifiers with the aid of a series of proof resistances. The model predicts the weld current and the conduction angle (or heat setting) at each set current, when the workpiece resistance is given.

  15. Nondestructive Ultrasonic Inspection of Friction Stir Welds

    Science.gov (United States)

    Tabatabaeipour, M.; Hettler, J.; Delrue, S.; Van Den Abeele, K.

    Friction Stir Welding (FSW) is a relatively new solid-state welding procedure developed at The Welding Institute (TWI-UK) and the technique is widely employed for welding aluminum alloys in various applications. In order to examine the quality of the welds and to detect a variety of welding flaws such as wormholes and root-flaws, it is required to develop a methodical inspection technique that can be used for the identification and localization of such defects. The most prevalent and risky defect in this type of welding is the barely visible root flaw with a length varying from 100-700 μm. Due to the extreme characteristics of the flaw, off-the-shelf ultrasonic weld inspection methods are not always able to readily detect this type of minute defect feature. Here, we propose a novel approach to characterize root flaws using an oblique incident ultrasonic C-scan backscattering analysis. The implementation consists of an immersion ultrasonic testing method in pulse echo (i.e. backscatter) mode with a 3.5 MHz transducer, and makes use of an empirical procedure to engender of a shear wave dominated excitation at the root surface, and to properly gate the received signal for root flaw examination. By scanning the surface above the welded component, a C-scan image displaying the backscatter response from the root surface of the nugget zone can be obtained which allows a simple interpretation of the root flaw status of the weld.

  16. EFFECT OF CARBON MIGRATION ON CREEP PROPERTIES OF Cr5Mo DISSIMILAR WELDED JOINTS WITH Ni-BASED AND AUSTENITIC WELD METAL

    Institute of Scientific and Technical Information of China (English)

    J.M. Gong; Y. Jiang; S.T. Tu

    2004-01-01

    In this paper, the effect of carbon migration on creep properties of Cr5Mo dissimilar welded joints with Ni-based (Inconel 182) and Cr23Ni13 (A302) austenitic weld metal was investigated. Carbon migration near the weld metal/ferritic steel interface of Cr5Mo dissimilar welded joints was analyzed by aging method. Local creep deformations of the dissimilar welded joints were measured by a long-term local creep deformation measuring technique. The creep rupture testing was performed for Cr5Mo dissimilar welded joints with Inconel 182 and A302 weld metal. The research results show that the maximum creep strain rate occurs in the decarburized zone located on heat affect zone (HAZ) of Cr5Mo ferritic steel. The creep rupture life of Cr5Mo dissimilar welded joints with A302 weld metal decreases due to carbon migration and is about 50% of that welded with Inconel 182 weld metal.

  17. Mechanical Properties of Welded Deformed Reinforcing Steel Bars

    Directory of Open Access Journals (Sweden)

    Ghafur H. Ahmed

    2015-05-01

    Full Text Available Reinforcement strength, ductility and bendability properties are important components in design of reinforced concrete members, as the strength of any member comes mainly from reinforcement. Strain compatibility and plastic behaviors are mainly depending on reinforcement ductility. In construction practice, often welding of the bars is required. Welding of reinforcement is an instant solution in many cases, whereas welding is not a routine connection process. Welding will cause deficiencies in reinforcement bars, metallurgical changes and re-crystallization of microstructure of particles. Weld metal toughness is extremely sensitive to the welding heat input that decreases both of its strength and ductility. For determining the effects of welding in reinforcement properties, 48 specimens were tested with 5 different bar diameters, divided into six groups. Investigated parameters were: properties of un-welded bars; strength, ductility and density of weld metal; strength and ductility reduction due to heat input for bundled bars and transverse bars; welding effect on bars’ bending properties; behavior of different joint types; properties of three weld groove shapes also the locations and types of failures sections. Results show that, strength and elongation of the welded bars decreased by (10-40% and (30-60% respectively. Cold bending of welded bars and groove welds shall be prevented.

  18. BASIC THEORY AND APPLICATIONS OF WELDING ARC SPECTRAL INFORMATION

    Institute of Scientific and Technical Information of China (English)

    LI Junyue; XUE Haitao; LI Huan; SONG Yonglun

    2007-01-01

    Welding arc spectral information is a rising welding Information source. In some occasion, it can reflect many physical phenomena of welding process and solve many problems that cannot be done with arc electric information, acoustic information and other arc information. It is of important significance in developing automatic control technique of welding process and other similar process. Many years study work on welding arc spectral information of the anthor are discussed from three aspects of theory, method and application. Basic theory, view and testing methods of welding arc spectral information has been put forward. In application aspects, many applied examples, for example, monitoring of harmful gases in arc (such as hydrogen and nitrogen) with the method of welding arc spectral information; welding arc spectral imaging of thc welding pool which is used in automatic seam tracking; controlling of welding droplet transfer with welding arc spectral information and so on, are introduced. Especially, the successful application in real time controlling of welding droplet transfer in pulsed GMAW is introduced too. These application examples show that the welding arc spectral information has great applied significance and development potentialities. These content will play an important role in applying and spreading welding arc spectral information technology.

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

    Science.gov (United States)

    2015-12-01

    FOR THE RECOMMENDATION OF IMPROVED GAS METAL ARC WELDING PROCEDURES FOR HY-80 STEEL PLATE BUTT JOINTS AT NORFOLK NAVAL SHIPYARD by Veronika J...FOR THE RECOMMENDATION OF IMPROVED GAS METAL ARC WELDING PROCEDURES FOR HY-80 STEEL PLATE BUTT JOINTS AT NORFOLK NAVAL SHIPYARD 5. FUNDING NUMBERS 6...gas metal arc welding, submarine, hull cut, butt joint, weld, shielding gas, HY-80 steel , plate 15. NUMBER OF PAGES 53 16. PRICE CODE 17

  20. 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...

  1. 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...

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

    Energy Technology Data Exchange (ETDEWEB)

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

    2015-05-01

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

  3. Research on CMT welding of nickel-based alloy with stainless steel

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Cold Metal Transfer (CMT) welding technique is a new welding technique introduced by Fronius company. CMT welding of nickel-based alloy with stainless steel was carried out using CuSi3 filler wire in this paper. Effects of welding parameters, including welding current, welding speed, etc, on weld surface appearance were tested. Microstructure and mechanical properties of CMT weld were studied. The results show that the thickness of interface reaction layer of the nickel-based alloy is 14.3μm, which is only 4.33% of base material. The weld is made up of two phases,α-copper and iron-based solid solution. Rupture occurs initially at the welded seam near the edge of stainless steel in shear test. The maximum shear strength of the CuSi3 welded joint is 184.9MPa.

  4. Phased Array Ultrasonic Testing Procedure for Cracks in Fillets Weld%角焊缝裂纹类缺陷相控阵超声检测工艺

    Institute of Scientific and Technical Information of China (English)

    左延田; 方雨; 刘晴岩; 薛利杰

    2016-01-01

    角焊缝是工程中较为常见的焊缝形式,与对接焊缝相比,其特殊的结构和焊缝形式增加了超声检测的难度和工艺的复杂性。在分析角焊缝常规检测工艺的基础上,提出了应用超声相控阵检测工艺的方案,并以Y型焊缝为例制定了相控阵超声检测方案并进行了检测试验。检测结果验证了方案的可行性,为相控阵超声技术在角焊缝检测中的推广应用提供了经验。%Fillet weld is a common form of welding in engineering.However,comparison to butt weld,its special structure and welding type increase the difficulty and complexity of its testing.Based on the analysis of traditional ultrasonic testing,this paper comes up with phased array ultrasonic testing for fillets,and takes T and Y weld joint as example to throw light on the procedure to make testing plan for fillet.The results of the phased array ultrasonic testing of cracks in T and Y weld joints are also displayed to verify the testing plan.This research would provide experience to the application of phased array ultrasonic testing for fillet.

  5. High frequency welded (ERW) casing

    Energy Technology Data Exchange (ETDEWEB)

    Duisberg, J. (Hoesch Roehrenwerke A.G., Hamm (Germany, F.R.))

    1980-09-01

    Due to the up-to-date standard in welding and testing techniques, the significance of ERW-casing is growing rapidly. The basic items of ERW-pipe are explained in detail. The forming mechanism, the high frequency welding by induction and contact welding processes is explained in detail as well as destructive and non-destructive testing methods. Finishing the ends as threading, thread control (gauging), power tight connection, pressure test and final quality control are rounding up the picture of the production of ERW-casing. Last but not least the test results from the joint strength- and collapse tests which are of outstanding interest for casings, are compared with API requirements in order to demonstrate compliance with API requirements.

  6. Microstructure analysis in friction welding of copper and aluminum

    Science.gov (United States)

    Wibowo, A. G. Wahyu; Ismail, Rifky; Jamari, J.

    2016-04-01

    The Friction welding is a welding method with utilizing heat generated due to friction. Surfaces of two materials to be joined, one rotates the other being idle, is contacted by a pressure force. Friction on the second contact surface is done continuously so that the heat generated by the continuous friction will continue to rise. With the heat and the pressure force on the second surface to the second meeting of the material reaches its melting temperature then there is the process of welding. This paper examines the influence of the pressure force, rotational speed and contact time on friction welding of Aluminum (Al) and Copper (Cu) to the quality of welded joints. Friction welding process is performed on a friction welding machine that is equipped with the loading mechanism. The parameters used are the pressure force, rotational speed and friction time. Determination of the quality of welding is done by testing the tensile strength, hardness, and micro structure on the weld joint areas. The results showed that the friction welding quality is very good, this is evidenced by the results of a tensile strength test where the fault occurs outside the weld joint and increased violence in the weld joint. On the results visually cuts the welding area did not reveal any porosity so that it can be concluded that each metal contacts have melted perfectly and produce a connection with good quality.

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

    Science.gov (United States)

    Mazar Atabaki, Mehdi

    . The heat and mass transfer and the issues in joining of dissimilar alloys by the hybrid laser/arc welding process (HLAW) were explicitly explained in details. A finite element model was developed to simulate the heat transfer in HLAW of the aluminum alloys. Two double-ellipsoidal heat source models were considered to describe the heat input of the gas metal arc welding and laser welding processes. An experimental procedure was also developed for joining thick advanced high strength steel plates by using the HLAW, by taking into consideration different butt joint configurations. The geometry of the weld groove was optimized according to the requirements of ballistic test, where the length of the softened heat affected zone should be less than 15.9 mm measured from the weld centerline. Since the main issue in HLAW of the AHSS was the formation of the pores, the possible mechanisms of the pores formation and their mitigation methods during the welding process were investigated. Mitigation methods were proposed to reduce the pores inside in the weld area and the influence of each method on the process stability was investigated by an on-line monitoring system of the HLAW process. The groove angle was optimized for the welding process based on the allowed amount of heat input along the TRICLADRTM interface generated by an explosive welding. The weld was fractured in the heat affected zone of the aluminum side in the tensile test. The microharness was shown that the temperature variation caused minor softening in the heat affected zone satisfying the requirement that the width of the softened heat affected zone in the steel side falls within 15.9 mm far away from the weld centerline. The microstructure analysis showed the presence of tempered martensite at the vicinity of the weld area, which it was a cause of softening in the heat affected zone.

  8. 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...

  9. Technical Letter Report, An Evaluation of Ultrasonic Phased Array Testing for Reactor Piping System Components Containing Dissimilar Metal Welds, JCN N6398, Task 2A

    Energy Technology Data Exchange (ETDEWEB)

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

    2009-11-30

    Research is being conducted for the U.S. Nuclear Regulatory Commission at the Pacific Northwest National Laboratory to assess the effectiveness and reliability of advanced nondestructive examination (NDE) methods for the inspection of light-water reactor components. The scope of this research encom¬passes primary system pressure boundary materials including dissimilar metal welds (DMWs), cast austenitic stainless steels (CASS), piping with corrosion-resistant cladding, weld overlays, inlays and onlays, and far-side examinations of austenitic piping welds. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in steel components that challenge standard and/or conventional inspection methodologies. This interim technical letter report provides a summary of a technical evaluation aimed at assessing the capabilities of phased-array (PA) ultrasonic testing (UT) methods as applied to the inspection of small-bore DMW components that exist in the reactor coolant systems (RCS) of pressurized water reactors (PWRs). Operating experience and events such as the circumferential cracking in the reactor vessel nozzle-to-RCS hot leg pipe at V.C. Summer nuclear power station, identified in 2000, show that in PWRs where primary coolant water (or steam) are present under normal operation, Alloy 82/182 materials are susceptible to pressurized water stress corrosion cracking. The extent and number of occurrences of DMW cracking in nuclear power plants (domestically and internationally) indicate the necessity for reliable and effective inspection techniques. The work described herein was performed to provide insights for evaluating the utility of advanced NDE approaches for the inspection of DMW components such as a pressurizer surge nozzle DMW, a shutdown cooling pipe DMW, and a ferritic (low-alloy carbon steel)-to-CASS pipe DMW configuration.

  10. Reduction of Deformations during Welding Metal Wire Mesh with Frames

    Directory of Open Access Journals (Sweden)

    Krawczyk R.

    2016-06-01

    Full Text Available The article presents an issue referring to a reduction of deformation during welding metal wire mesh into the frames. A problem of a possible reduction of deformations was described taking into account characteristics of a construction of a welded element. Technological tests and their results are provided. Technological recommendations relating to the reduction of deformations of the welded element are given.

  11. 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.

  12. Sensor based robot laser welding - based on feed forward and gain sceduling algorithms

    DEFF Research Database (Denmark)

    Andersen, Henrik John

    2001-01-01

    A real-time control system forlaser welding of thick steel plates are developed and tested in a industrial environment. The robotic execution of the laser welding process is based on measure weld joint geometry and impirically established welding procedures. The influence of industrial production...

  13. B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

    Science.gov (United States)

    Bjorkman, Gerry; Russell, Carolyn

    2000-01-01

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

  14. Distortion Control during Welding

    NARCIS (Netherlands)

    Akbari Pazooki, A.M.

    2014-01-01

    The local material expansion and contraction involved in welding result in permanent deformations or instability i.e., welding distortion. Considerable efforts have been made in controlling welding distortion prior to, during or after welding. Thermal Tensioning (TT) describes a group of in-situ met

  15. Introduction to Welding.

    Science.gov (United States)

    Fortney, Clarence; Gregory, Mike

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

  16. Development of thick wall welding and cutting tools for ITER

    Energy Technology Data Exchange (ETDEWEB)

    Nakahira, Masataka; Takahashi, Hiroyuki; Akou, Kentaro; Koizumi, Koichi [Japan Atomic Energy Research Inst., Tokai, Ibaraki (Japan). Tokai Research Establishment

    1998-04-01

    The Vacuum Vessel, which is a core component of International Thermonuclear Experimental Reactor (ITER), is required to be exchanged remotely in a case of accident such as superconducting coil failure. The in-vessel components such as blanket and divertor are planned to be exchanged or fixed. In these exchange or maintenance operations, the thick wall welding and cutting are inevitable and remote handling tools are necessary. The thick wall welding and cutting tools for blanket are under developing in the ITER R and D program. The design requirement is to weld or cut the stainless steel of 70 mm thickness in the narrow space. Tungsten inert gas (TIG) arc welding, plasma cutting and iodine laser welding/cutting are selected as primary option. Element welding and cutting tests, design of small tools to satisfy space requirement, test fabrication and performance tests were performed. This paper reports the tool design and overview of welding and cutting tests. (author)

  17. Laser welding in space

    Science.gov (United States)

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

    1991-01-01

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

  18. Weld Decay Recovery by Laser Beam Surfacing of Austenitic Stainless Steel Welded Joints

    OpenAIRE

    Isao, MASUMOTO; Takeshi, SHINODA; Toshimasa, HIRATE; Nagoya University, currently at Gifu Vocational Training College; Faculty of Engineering, Nagoya University; Nagoya University, currently at Toshiba Co. Ltd.

    1990-01-01

    This study is an attempt to improve corrosion resistance by laser beam surface treatment. AISI 304 type stainless steel welds were surface treated by laser and the effectivenesses of various treatment conditions were evaluated by acidic corrosion tests and metallurgical observation. It was found that laser treatment changed the morphology of carbide precipitates in the heat affected zone of AISI 304 austenitic steel MIG welded joints, and that it is possible to effect revovery from weld decay...

  19. Effect of Post-Weld Heat Treatment on Creep Rupture Properties of Grade 91 Steel Heavy Section Welds

    Energy Technology Data Exchange (ETDEWEB)

    Li, Leijun

    2012-11-02

    This project will conduct a systematic metallurgical study on the effect of post-weld heat treatment (PWHT) on the creep rupture properties of P91 heavy section welds. The objective is to develop a technical guide for selecting PWHT parameters, and to predict expected creep-rupture life based on the selection of heat treatment parameters. The project consists of four interdependent tasks: Experimentally and numerically characterize the temperature fields of typical post-weld heat treatment procedures for various weld and joint configurations to be used in Gen IV systems. Characterize the microstructure of various regions, including the weld fusion zone, coarse-grain heat-affected zone, and fine-grain heat affected zone, in the welds that underwent the various welding and PWHT thermal histories. Conduct creep and creep-rupture testing of coupons extracted from actual and physically simulated welds. Establish the relationship among PWHT parameters, thermal histories, microstructure, creep, and creep-rupture properties.

  20. Effect of Shoulder Size on Weld Properties of Dissimilar Metal Friction Stir Welds

    Science.gov (United States)

    Akinlabi, E. T.

    2012-07-01

    This article reports a research study that shows the effect of shoulder diameter size on the resulting weld properties of dissimilar friction stir welds between 5754 aluminum alloy (AA) and C11000 copper (Cu). Welds were produced using three different shoulder diameter tools: 15, 18, and 25 mm by varying the rotational speed between 600 and 1200 rpm and the traverse speed between 50 and 300 mm/min to achieve the best result. Each parameter combination was chosen to represent different heat input conditions (low, intermediates and high). The welds were characterized through microstructural evaluation, tensile testing, microhardness measurements, x-ray diffraction analysis, and electrical resistivity. Microstructural evaluation of the welds revealed that the welds produced consisted of all the friction stir welding (FSW) microstructure zones with organized flow lines comprising mixture layers of aluminum (Al) and copper (Cu) at the Stir Zones. The average Ultimate Tensile Strength (UTS) of the welds considered ranged from 178 to 208 MPa. Higher Vickers microhardness values were measured at the joint interfaces of all the welds because of the presence of intermetallic compounds in these regions. The x-ray diffraction analysis revealed the presence of Al4Cu9 and Al2Cu intermetallics at the interfacial regions, and low electrical resistivities were obtained at the joint interfaces. An optimized parameter setting for FSW of Al and Cu was obtained at the weld produced at 950 rpm and 50 mm/min with the 18-mm shoulder diameter tool.

  1. 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.

  2. Laser transmission welding of Clearweld-coated polyethylene glycol terephthalate by incremental scanning technique

    Science.gov (United States)

    Wang, Y. Y.; Wang, A. H.; Weng, Z. K.; Xia, H. B.

    2016-06-01

    Transmission laser welding using Incremental Scanning Technique(TWIST) mode and conventional contour welding mode were adopted to investigate laser transmission welding of 0.5 mm thick PET plate. A 1064 nm fiber laser was used to weld PET at the (TWIST) mode, and an 808 nm diode laser was applied to conduct the conventional contour welding. The Clearweld coating was used as laser absorbing material. The influences of laser parameters (i.e. defocusing distance, distance between two circles) on the quality of weld seams were analyzed by optical microscopy. Moreover, geometry and shear strength of the weld zone were tested to optimize laser parameters. Additionally, the water vapor permeability (WVP) of weld seams was measured to test hermetical capacity. Results show that the shear strength and hermetic capacity of weld seam by TWIST mode are at the same level in comparison with that of the conventional contour welding.

  3. Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

    Science.gov (United States)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

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

  4. Particulate and gaseous emissions when welding aluminum alloys.

    Science.gov (United States)

    Cole, Homer; Epstein, Seymour; Peace, Jon

    2007-09-01

    Fabrication and repair of aluminum components and structures commonly involves the use of electric arc welding. The interaction of the arc and the metal being welded generates ultraviolet radiation, metallic oxides, fumes, and gases. Aluminum is seldom used as the pure metal but is often alloyed with other metals to improve strength and other physical properties. Therefore, the exact composition of any emissions will depend on the welding process and the particular aluminum alloy being welded. To quantify such emissions, The Aluminum Association sponsored several studies to characterize arc welding emissions by the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes for various combinations of base and filler alloys. In all cases, the tests were conducted under conditions that could be found in a production weld shop without forced ventilation. The concentrations of each analyte that a welder could be exposed to were greatly affected by the welding process, the composition of the base and filler alloys, the position of the welder, and the welding helmet. The results obtained can be used by employers to identify and control potential hazards associated with the welding of aluminum alloys and can provide the basis for hazard communication to employees involved in the welding of these alloys.

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

    Science.gov (United States)

    Shen, Changbin; Zhang, Jiayan; Ge, Jiping

    2011-06-01

    By using optical microscope, the microstructures of 5083/6082 friction stir welding (FSW) weld and parent materials were analyzed. Meanwhile, at ambient temperature and in 0.2 mol/L NaHS03 and 0.6 mol/L NaCl solutionby gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation, the electrochemical behavior of 5083/6082 friction stir welding weld and parent materials were comparatively investigated by gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation. The results indicated that at given processing parameters, the anti-corrosion property of the dissimilar weld was superior to those of the 5083 and 6082 parent materials.

  6. 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.

  7. Friction stir welding (FSW of aluminium foam sandwich panels

    Directory of Open Access Journals (Sweden)

    M. Bušić

    2016-07-01

    Full Text Available The article focuses on the influence of welding speed and tool tilt angle upon the mechanical properties at the friction stir welding of aluminium foam sandwich panels. Double side welding was used for producing butt welds of aluminium sandwich panels applying insertion of extruded aluminium profile. Such insertion provided lower pressure of the tool upon the aluminium panels, providing also sufficient volume of the material required for the weldment formation. Ultimate tensile strength and flexural strength for three-point bending test have been determined for samples taken from the welded joints. Results have confirmed anticipated effects of independent variables.

  8. 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.

  9. Development of ultrasonic test specifications for heavy welded rotor parts during the past few decades; Entwicklung der Ultraschallpruefanforderungen an schweren Rotor-Schmiedeteilen ueber die letzten Jahrzehnte

    Energy Technology Data Exchange (ETDEWEB)

    Vrana, Johannes; Heinrich, Werner [Siemens Energy, Berlin (Germany); Zimmer, Alexander [Saarschmiede, Voelklingen (Germany); Bailey, Kevin; Zombo, Paul; Shannon, Robert E. [Siemens Energy, Orlando, FL (United States); Lohmann, Hans-Peter [Siemens Energy, Muelheim an der Ruhr (Germany)

    2011-07-01

    Heavy welded rotor parts, e.g. in land-based turbines and generators for power generation, are tested before they are put in operation, e.g. by ultrasonic methods. The tests were introduced several decades ago in an attempt to ensure component integrity. In the early years, the tests were carried out manually in contact using longitudinal wave test probes in pulse-echo operation, at first without fixed registration or decision limits. The development of inspection techniques, the change in construction requirements, the further development of fracture-mechanical calculations, new findings in rotor operation, experience with the inspection method, and theoretical reflections on detection probabilities all contributed to the changes that led to the current inspection requirements. The development of size measuring techniques led to the establishment of registration and decision limits. Angles and transmitter-receiver test probes were introduced, and automatic equipment came next. All this resulted in more sensitive techniques based on theoretical specifications, and modern ultrasonic methods were introduced at the same time. This publication describes the development of ultrasonic test specifications during the past few decades and also gives an outlook to the future.

  10. 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....

  11. 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.

  12. Intraoral metal laser welding: a case report.

    Science.gov (United States)

    Fornaini, Carlo; Vescovi, Paolo; Merigo, Elisabetta; Rocca, Jean-Paul; Mahler, Patrick; Bertrand, Caroline; Nammour, Samir

    2010-03-01

    The possibility of laser welding of dental prostheses offers great advantages: first, the operator has the possibility of welding on the master model, which decreases the number of passages and thus the possibility of errors and damage, and secondly, the patient attends only a few sessions, and, due to the possibility of fixing the damaged prostheses, there is no need to resort to the technician's laboratory. In a previous study we described the experimental phases of intraoral welding, from the in vitro model on animal jaws with evaluations of the temperature variations during welding through thermal chamber and type K thermocouples. In this study we describe the intraoral welding in vivo on human subjects by using, as in the previous study, a fibre-delivered neodymium:yttrium-aluminum-garnet (Nd:YAG) laser. The in vivo phase allowed a restored prosthesis to be positioned and intraorally welded in the upper central sector with optimal results both in patient's comfort and in aesthetic effects. This first in vivo test confirmed that the use of a laser technique for the intraoral welding of metal prostheses is possible, with no particular problems and risks for the biological structures close to the welding zone.

  13. The study on the properties of AISI 4140 and AISI 1040 steel rods welded by friction welding

    OpenAIRE

    Thanee Toomprasen; Chawalit Thinvongpituk; Sukangkana Talangkun

    2014-01-01

    This paper is aimed to investigate the properties of joint between AISI 4140 and AISI 1040 welded by friction welding. The specimens were prepared in round shape of 13 mm diameter and 100 mm long. They were welded by friction welding method under the following conditions; friction pressure of 183 MPa, friction time of 12 sec, upset pressure of 428 MPa, upset time of 7 sec. and rotational speed of 1400 rpm. The strength and hardness were tested on the welded area. The result showed finer grain...

  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. Parametric optimization of seam welding of stainless steel (SS 304) sheets

    Energy Technology Data Exchange (ETDEWEB)

    Krishnan, Muthuraman Pandi; Sait, Abdullah Naveen; Ravichandran, Manickam [Chendhuran College of Engineering and Technology, Pudukkottai, Tamilnadu (India)

    2015-06-01

    In the present study, seam welding process parameters were optimized for joining 306 stainless steel plates. Welding pressure, welding speed and welding temperature combinations were carefully selected with the objective of producing a weld joint with maximum impact strength and hardness. Taguchi technique was applied for optimizing the selected welding parameters. The factors used in this study consisted of pressure, welding speed and welding temperature, each of which had three levels in the study. L{sub 27} orthogonal array and corresponding levels were selected according to the aforementioned factors and experimental tests were performed. Signal-to-noise (S/N) ratio was used to evaluate the experimental results. The results indicate that the welding speed has the greatest influence on impact strength, followed by welding pressure and temperature. Experiments have also been conducted to validate the optimized parameters.

  16. CHARACTERISATION OF SPOT WELD GROWTH ON DISSIMILAR JOINTS WITH DIFFERENT THICKNESSES

    Directory of Open Access Journals (Sweden)

    Nachimani Charde

    2012-06-01

    Full Text Available A sound weld from spot welding is what most manufacturers desire and prefer for mechanical assemblies in their systems. The robustness is mainly attributed to the joining mechanism of mechanical parts. This paper focuses on the effect of parametric changes for dissimilar joints using 304 austenitic stainless steel and carbon steel of two different thicknesses. A pneumatic-based spot welder was used to accomplish the entire welding process. The parameters varied during the experiments are the welding current and welding time, while the electrode pressing force and electrode tip size are kept constant. The welding process began from a poor weld and moved on to a better weld by increasing the process parameters. However, this study is limited to the basic parametric variation to find the optimum parametric setup for 1 and 2 mm base metals. The welded specimens are subjected to tensile, hardness and metallurgical tests to characterise the spot weld growth for both thicknesses.

  17. Numerical Modeling of Weld Joint Corrosion

    Science.gov (United States)

    Lu, Yongxin; Jing, Hongyang; Han, Yongdian; Xu, Lianyong

    2016-03-01

    A numerical model is presented in this work that predicts the corrosion rate of weld joint. The model is able to track moving boundary of the corroding constituent of weld joint. The corrosion rates obtained from the model are compared with those estimated from mixed potential theory and two experimental techniques, namely immersion test and constant potential polarization test. The corrosion rate predicted using the model is within 10% of the estimate from the mixed potential theory, within 20% of that got from the immersion experiment and within 10% of that got from the constant potential polarization experiment for weld joint.

  18. Assessment of Hot Crack Properties of Laser Welded Stainless Steel

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove

    2003-01-01

    Crack testing concerning small and fast solidifying laser welds in austenitic stainless steel has been studied. A set of methods has been applied to investigate alloy properties, including (1) Application of known information to predict solidification phases, (2) Weld metal solidification rate...... are given. Results from the solidification rate measurements had high variations. They do not show an expected correlation between the crack resistance and the solidification rate. The employment of pulsed seam welds is assessed not to be usable in the present measurement method. From evaluation of several...... crack tests, the Weeter spot weld test has been chosen to form a basis for the development of a practicable method to select specific alloys for welding applications. A new test, the Groove weld test was developed, which has reduced the time consumption and lightened the analysis effort considerably...

  19. Weld repair of helium degraded reactor vessel material

    Energy Technology Data Exchange (ETDEWEB)

    Kanne, W.R. Jr.; Lohmeier, D.A.; Louthan, M.R. Jr.; Rankin, D.T.; Franco-Ferreira, E.A. (Westinghouse Savannah River Co., Aiken, SC (United States)); Bruck, G.J.; Madeyski, A.; Shogan, R.P.; Lessmann, G.G. (Westinghouse Electric Corp., Pittsburgh, PA (United States). Science and Technology Center)

    1990-01-01

    Welding methods for modification or repair of irradiated nuclear reactor vessels are being evaluated at the Savannah River Site. A low-penetration weld overlay technique has been developed to minimize the adverse effects of irradiation induced helium on the weldability of metals and alloys. This technique was successfully applied to Type 304 stainless steel test plates that contained 3 to 220 appm helium from tritium decay. Conventional welding practices caused significant cracking and degradation in the test plates. Optical microscopy of weld surfaces and cross sections showed that large surface toe cracks formed around conventional welds in the test plates but did not form around overlay welds. Scattered incipient underbead cracks (grain boundary separations) were associated with both conventional and overlay test welds. Tensile and bend tests were used to assess the effect of base metal helium content on the mechanical integrity of the low-penetration overlay welds. The axis of tensile specimens was perpendicular to the weld-base metal interface. Tensile specimens were machined after studs were resistance welded to overlay surfaces.

  20. Weld repair of helium degraded reactor vessel material

    Energy Technology Data Exchange (ETDEWEB)

    Kanne, W.R. Jr.; Lohmeier, D.A.; Louthan, M.R. Jr.; Rankin, D.T.; Franco-Ferreira, E.A. [Westinghouse Savannah River Co., Aiken, SC (United States); Bruck, G.J.; Madeyski, A.; Shogan, R.P.; Lessmann, G.G. [Westinghouse Electric Corp., Pittsburgh, PA (United States). Science and Technology Center

    1990-12-31

    Welding methods for modification or repair of irradiated nuclear reactor vessels are being evaluated at the Savannah River Site. A low-penetration weld overlay technique has been developed to minimize the adverse effects of irradiation induced helium on the weldability of metals and alloys. This technique was successfully applied to Type 304 stainless steel test plates that contained 3 to 220 appm helium from tritium decay. Conventional welding practices caused significant cracking and degradation in the test plates. Optical microscopy of weld surfaces and cross sections showed that large surface toe cracks formed around conventional welds in the test plates but did not form around overlay welds. Scattered incipient underbead cracks (grain boundary separations) were associated with both conventional and overlay test welds. Tensile and bend tests were used to assess the effect of base metal helium content on the mechanical integrity of the low-penetration overlay welds. The axis of tensile specimens was perpendicular to the weld-base metal interface. Tensile specimens were machined after studs were resistance welded to overlay surfaces.

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

    Science.gov (United States)

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

    2013-12-18

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

  2. Galvanic Corrosion Behavior of Microwave Welded and Post-weld Heat-Treated Inconel-718 Joints

    Science.gov (United States)

    Bansal, Amit; Sharma, Apurbba Kumar; Kumar, Pradeep

    2017-05-01

    In the present study, corrosion behavior of microwave welded Inconel-718 at various conditions was investigated. Welding of Inconel-718 in 980 °C solution-treated condition was performed using microwave hybrid heating technique. The microwave welds were subjected to post-heat treatment for improving its microstructure and mechanical properties by solubilizing the Nb-enriched Laves phase. The microstructural features of the fabricated welds at various conditions were investigated through scanning electron microscopy. The electrochemical testing results revealed that Inconel-718 welds were galvanic corroded when they were anodically polarized in 3.5 wt.% NaCl solution at 28 °C. The difference in the corrosion potentials between the base metal (BM) and fusion zone (FZ) in an Inconel-718 weld was the main factor for galvanic corrosion. The highest corrosion was occurred in the as-welded/aged weldments, followed by 980 °C solution-treated and aged weldments, as-welded specimen, and 1080 °C solution-treated and aged (1080STA) weldments. The least galvanic corrosion was occurred in the 1080STA specimens due to almost uniform microstructure developed in the weldment after the treatment. Thus, it was possible to minimize the galvanic corrosion in the microwave welded Inconel-718 by 1080STA treatment which resulted in reducing the difference in corrosion potentials between the BM and the FZ.

  3. New Developed Welding Electrode for Improving the Fatigue Strength of Welded Joints

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    A new welding electrode, low transformation temperatur e electrode (LTTE), was introduced in this paper. It was described in design principle, mechanics, chemical compositions of their deposited metal and manufacturing methods.It was proved that the best transformation starting temperature from austenite to martensite of the deposited metal of LTTE was at about 191℃ and it was obtained by adding alloying elements such as Cr, Ni, Mn and Mo. The microstructure of the weld metal of the LTTE was low carbon martensite and residual austenite. The compressive residual stress was induced around the weld of the LTTE and the -145 MPa in compression could be obtained in middle of weld metal. The fatigue tests showed that the fatigue strength of the longitudinal welded joints welded with the LTTE at 2×106 cycles was improved by 59% compared with that of the same type of welded joints welded with conventional E5015 and the fatigue life was increased by 47 times at 162 MPa. It is a very valuable method to improve the fatigue performance of welded joints.

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

    Directory of Open Access Journals (Sweden)

    Sabina Luisa Campanelli

    2013-12-01

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

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

    Science.gov (United States)

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

    2015-05-01

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

  6. AH32钢T型焊接接头疲劳强度的试验与数值模拟%Research of test and simulation on fatigue strength of T welded joint for AH32 steel

    Institute of Scientific and Technical Information of China (English)

    张晓飞; 李良碧; 李永正

    2013-01-01

    对AH32钢T型试件进行疲劳试验,并利用有限元软件对T型焊接接头的应力分布及疲劳寿命进行数值模拟,最终将疲劳试验结果与数值模拟结果对比分析.研究发现,T型焊接接头在焊趾附近处应力值最大,寿命最短.本文研究结果为今后船海结构物的疲劳寿命预测提供了有益参考.%The fatigue tests of the T-shape welded specimen for AH32 steel were performed in this paper,the stress distribution and the fatigue life of T welded joint were numerically simulated by finite element software,the fatigue test results and numerical simulation results were compared and analysed finally.The study found that the maximum stress and the minimum life of T welded joint would be appeared on the location of weld toes.This paper provided a beneficial reference for fatigue life predictions of maritime structures.

  7. Research of the Resistance of Contact Welding Joint of R65 Type Rail

    Directory of Open Access Journals (Sweden)

    Kęstutis Dauskurdis

    2015-03-01

    Full Text Available In the article the R65 type rail joints that were welded by resistance welding are analysed. Survey methodology of the research consists of the following parts: visual inspection of welded joint, ultrasonic rail inspection, hardness test of upper part of the rail, fusion area research, the measurement hardness test of heat-softened area, the measurement microhardness test, microstructure research of the welded joint, impact strength experiments, chemical analysis of welded joint, wheel-rail interaction research using the finite element method (FEM. The results of the research are analysed and the quality of weld is evaluated. The conclusion is based on the results of this research.

  8. Application of Taguchi approach to optimize friction stir welding parameters of polyethylene

    Directory of Open Access Journals (Sweden)

    Bejaoui S.

    2010-06-01

    Full Text Available This paper presents experimental and numerical results of butt friction stir welding of high density polyethylene. The FSW designed tool insulates the welded samples and preserves the heat gained from friction thus avoiding the appearance of blisters and splits after welding. The experimental tests, conducted according to combinations of process factors such as rotation speed, welding speed, pin diameter and hold time at beginning welding, were carried out according the Taguchi orthogonal table L27 in randomized way. Temperatures in the joint during the welding operation and flow stresses from the tensile tests of welded samples were measured and variances were analyzed. Identified models were used to simulate, by finite elements, the tensile tests performed on specimens having a weld cordon in their active area. The results show coherence between the numerical predictions and experimental observations in different cases of weld cordon mechanical behaviour.

  9. Application of Taguchi approach to optimize friction stir welding parameters of polyethylene

    Science.gov (United States)

    Rezgui, M. A.; Ayadi, M.; Cherouat, A.; Hamrouni, K.; Zghal, A.; Bejaoui, S.

    2010-06-01

    This paper presents experimental and numerical results of butt friction stir welding of high density polyethylene. The FSW designed tool insulates the welded samples and preserves the heat gained from friction thus avoiding the appearance of blisters and splits after welding. The experimental tests, conducted according to combinations of process factors such as rotation speed, welding speed, pin diameter and hold time at beginning welding, were carried out according the Taguchi orthogonal table L27 in randomized way. Temperatures in the joint during the welding operation and flow stresses from the tensile tests of welded samples were measured and variances were analyzed. Identified models were used to simulate, by finite elements, the tensile tests performed on specimens having a weld cordon in their active area. The results show coherence between the numerical predictions and experimental observations in different cases of weld cordon mechanical behaviour.

  10. 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.

  11. A finite element model for residual stress in repair welds

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Z. [Edison Welding Inst., Columbus, OH (United States); Wang, X.L.; Spooner, S.; Goodwin, G.M.; Maziasz, P.J.; Hubbard, C.R.; Zacharia, T. [Oak Ridge National Lab., TN (United States)

    1996-03-28

    This paper describes a three-dimensional finite element model for calculation of the residual stress distribution caused by repair welding. Special user subroutines were developed to simulate the continuous deposition of filler metal during welding. The model was then tested by simulating the residual stress/strain field of a FeAl weld overlay clad on a 2{1/4}Cr-1 Mo steel plate, for which neutron diffraction measurement data of the residual strain field were available. It is shown that the calculated residual stress distribution was consistent with that determined with neutron diffraction. High tensile residual stresses in both the longitudinal and transverse directions were observed around the weld toe at the end of the weld. The strong spatial dependency of the residual stresses in the region around the weld demonstrates that the common two-dimensional cross-section finite element models should not be used for repair welding analysis.

  12. The mechanical measuring method of welding heat source efficiency

    Institute of Scientific and Technical Information of China (English)

    Zhang Jianqiang; Zhang Guodong; He Jie; Wang Chengquan; Chen Bingquan

    2007-01-01

    Based on the principle of residual deformation induced by superposition of the welding residual stress and working stress, the welding heat source efficiency has been determined by measuring displacement changes of specimens under loading and unloading in tensile tests, and combining with calculating welding parameters. Meanwhile, the welding heat source efficiencies obtained are compared with those of the measuring-calculating method. The research results show that the welding heat source efficiencies are almost the same as those obtained by the measuring-calculating method. Therefore, the welding heat source efficiency can be determined accurately by this method, and a new determining method of the heat source efficiency for the welding heat process calculating has been provided.

  13. Low temperature friction stir welding of P91 steel

    Directory of Open Access Journals (Sweden)

    Prasad Rao Kalvala

    2016-08-01

    Full Text Available Bead-on-plate friction stir welds were made on P91 alloy with low and high rotational speeds (100 and 1000 RPM to study their effects on weld microstructural changes and impression creep behavior. Temperatures experienced by the stir zone were recorded at the weld tool tip. Different zones of welds were characterized for their microstructural changes, hardness and creep behavior (by impression creep tests. The results were compared with submerged arc fusion weld. Studies revealed that the stir zone temperature with 100 RPM was well below Ac1 temperature of P91 steel while it was above Ac3 with 1000 RPM. The results suggest that the microstructural degradation in P91 welds can be controlled by low temperature friction stir welding technique.

  14. Modelling of damage development and ductile failure in welded joints

    DEFF Research Database (Denmark)

    Nielsen, Kim Lau

    This thesis focuses on numerical analysis of damage development and ductile failure in welded joints. Two types of welds are investigated here. First, a study of the localization of plastic flow and failure in aluminum sheets, welded by the relatively new Friction Stir (FS) Welding method, has been...... conducted ([P1], [P2], [P7]-[P9]). The focus in the thesis is on FS-welded 2xxx and 6xxx series of aluminum alloys, which are attractive, for example, to the aerospace industry, since the 2024 aluminum in particular, is typically classified as un-weldable by conventional fusion welding techniques. Secondly......, a study of the damage development in Resistance SpotWelded joints, when subject to the commonly used static shear-lab or cross-tension testing techniques, has been carried out ([P3]-[P6]). The focus in thesis is on the Advanced High Strength Steels, Dual-Phase 600, which is used in for example...

  15. Friction stir welding of AZ31 magnesium alloy

    Institute of Scientific and Technical Information of China (English)

    林三宝; 张华; 吴林; 冯吉才; 戴鸿滨

    2003-01-01

    Friction stir welding (FSW) is an new solid-phase joining technology which has more advantages over fusion welding methods in welding of aluminum and other non-ferrous metals. The effects of welding parameters on mechanical properties and microstructure during friction stir welding of AZ31 magnesium alloy were studied in this paper. Microstructures and mechanical properties of the joints were investigated by means of optical microscopy, scanning electric microscopy (SEM), micro-hardness analysis, and tensile test. Experimental results show that the magnesium alloy can be successfully welded by FSW method, and the ultimate tensile strength (UTS) of FSW joint reaches up to 90 percent of base metal. The microstructures of welded joints exhibit the variation from dynamically recrystallized fine grains to greatly deformed grains. Hardness in nugget zone was found lower than the base metal but not too obvious.

  16. Twinning in weld HAZ of ZK21 commercial magnesium alloy

    Institute of Scientific and Technical Information of China (English)

    2008-01-01

    The microstructure and properties of Mg ZK21 laser beam weld without filler were researched using optical microscopy (OM), electron microscopy and mechanical test. The results show that the fracture strain of the joints after laser beam welding reduces by about 10.7% at room temperature. By means of laser beam welding, the fusion zones contain tensile RS, while the base material far away from the fusion line is under balancing compressive RS. The microstructm-es of the weld were characterized by a narrow heat affected zone and twins. Significant { 10-12 } tension twins occur in the weld HAZ during laser welding processing. Due to the influence of temperature field and stress on morphologies, most of twins form twinning bands, which are nearly parallel to the welding direction.

  17. Weld geometry strength effect in 2219-T87 aluminum

    Science.gov (United States)

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

    1981-01-01

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

  18. Kinetics of Acicular Ferrite Transformation in Weld Metal

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Acicular Ferrite (AF) is beneficial in welds because it providesa tough and strong microstructure. Therefore, much works have been done in the study of the effect of alloying elements and welding conditions aimed at obtaining more AF in the weld metal. However, the knowledge about the nature of AF is limited due to the lack of kinetics researches. In this paper, the kinetic curves of AF transformation in an X65 weld metal were established by means of welding thermal simulation test. The results showed that AF transformation is a typical diffusion process of nucleation and growth with incubation period. AF transformation in weld metal obeys the relationship described by JMA Equation. The effect of welding heat input was also studied.

  19. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc (DC) welding to aluminum alloys 1XXX and 3003 to 6XXX. [1060, 1100, and 3003 to 6061 and 6063

    Energy Technology Data Exchange (ETDEWEB)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-2207 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 1060, 1100, and 3003 (P-21) to 6061 and 6063 (P-23), in thickness range 0.125 to 0.516; filler metal is ER4043 (F-23); current is direct; shielding gas is helium.

  20. Assessment of the integrity of welded pipes

    OpenAIRE

    Šarkoćević, Živče; Arsić, Miodrag; Sedmak, Aleksandar; MEĐO, Bojan; Mišić, Milan; id_orcid 0000-0003-0550-1851

    2014-01-01

    The subject of the paper is analysis of the integrity of welded pipes made of API J55 steel by high frequency contact welding (HF). Experimental research on the mechanical properties of the base material was conducted on pipes withdrawn from exploatation after 70 000 hours at service. Defect influence of the surface crack on the integrity of pipes was tested using hydrostatic pressure of pipes with axial surface crack in the base material. Fracture behaviour was tested using modified compact ...

  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. Vision-based detection of weld pool width in TIG welding of copper-clad aluminum cable

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    In order to realize automatic control of the width of weld pool, a visual sensor system for the width of weld pool detection is developed. By initiative arc light, the image of copper plate weld pool is taken back of the torch through the process of weakening and filtering arc light. In order to decrease the time of processing video signals, analog circuit is applied in the processing where video signals is magnified, trimmed and processed into binary on the datum of dynamic average value, therefore the waveform of video signals of weld pool is obtained. The method that is used for detecting the width of weld pool is established. Results show that the vision sensing method for real-time detecting weld pool width to copper-clad aluminum wire TIG welding is feasible. The response cycle of this system is no more than 50ms, and the testing precision is less than0.1mm.

  3. Coil Welding Aid

    Science.gov (United States)

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

    1983-01-01

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

  4. 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.

  5. Welding Course Curriculum.

    Science.gov (United States)

    Genits, Joseph C.

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

  6. Instructional Guidelines. Welding.

    Science.gov (United States)

    Fordyce, H. L.; Doshier, Dale

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

  7. Inspection of thick welded joints using laser-ultrasonic SAFT.

    Science.gov (United States)

    Lévesque, D; Asaumi, Y; Lord, M; Bescond, C; Hatanaka, H; Tagami, M; Monchalin, J-P

    2016-07-01

    The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing.

  8. MODELLING AND CHARACTERIZATION OF LASER WELDED INCOLOY 800 HT JOINTS

    Directory of Open Access Journals (Sweden)

    Sathiya Paulraj

    2016-06-01

    Full Text Available This study aims at finding the effect of laser welding speed on incoloy 800 HT. This alloy is one of the potential materials for Generation IV nuclear plants. Laser welding has several advantages over arc welding such as low fusion zone, low heat input and concentrated heat intensity. Three different welding speeds were chosen and CO2 laser welding was performed. 2D modeling and simulation were done using ANSYS 15 to find out the temperature distribution at different welding speeds and it was found that an increase in the welding speed decreased the temperature. Mechanical properties such as tensile strength, toughness and hardness were evaluated. The effect of welding speed on metallurgical characteristics was studied using optical microscopy (OM, Scanning Electron Microscopy (SEM with EDS, X-Ray Diffraction (XRD technique and fractographic analysis. From the results it was found that high welding speed (1400 mm/min decreased the joint strength. The M23C6 and Ni3Ti carbides were formed in a discrete chain and in a globular form along the grain boundaries of the weld region which increased the strength of the grain boundaries. Fractographic evaluations of the tested specimens for welding speed (1000 and 1200 mm/min showed deep and wide dimples indicating ductile failures.

  9. Assessment of Ductile-to-Brittle Transition Behavior of Localized Microstructural Regions in a Friction-Stir Welded X80 Pipeline Steel with Miniaturized Charpy V-Notch Testing

    Science.gov (United States)

    Avila, Julian A.; Lucon, Enrico; Sowards, Jeffrey; Mei, Paulo Roberto; Ramirez, Antonio J.

    2016-06-01

    Friction-stir welding (FSW) is an alternative welding process for pipelines. This technology offers sound welds, good repeatability, and excellent mechanical properties. However, it is of paramount importance to determine the toughness of the welds at low temperatures in order to establish the limits of this technology. Ductile-to-brittle transition curves were generated in the present study by using a small-scale instrumented Charpy machine and miniaturized V-notch specimens (Kleinstprobe, KLST); notches were located in base metal, heat-affected, stirred, and hard zones within a FSW joint of API-5L X80 Pipeline Steel. Specimens were tested at temperatures between 77 K (-196 °C) and 298 K (25 °C). Based on the results obtained, the transition temperatures for the base material and heat-affected zone were below 173 K (-100 °C); conversely, for the stirred and hard zones, it was located around 213 K (-60 °C). Fracture surfaces were characterized and showed a ductile fracture mechanism at high impact energies and a mixture of ductile and brittle mechanisms at low impact energies.

  10. PDC IC WELD FAILURE EVALUATION AND RESOLUTION

    Energy Technology Data Exchange (ETDEWEB)

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

    2012-04-16

    During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process could be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process

  11. Expulsion characterization in resistance spot welding by means of a hardness mapping technique

    Institute of Scientific and Technical Information of China (English)

    H.Ghazanfari; M.Naderi

    2014-01-01

    Expulsion is an undesired event during resistance spot welding because the weld quality deteriorates. It is the ejection of molten metal from the weld nugget which usually occurs due to applying a high current for a short welding time. Expulsion has a significant impact on the final yield strength of the weld, thus the detection and characterization of expulsion events is significant for the quality assurance of resistance spot welds. In this study, hardness mapping, using a scanning hardness machine, was used as a quality assurance technique for re-sistance spot welding. Hardness tests were conducted on a resistance spot welded sample to prepare a hardness map. The test results showed good correlation between the hardness map and metallographic cross sections. The technique also provided further fundamental understand-ing of the resistance spot welding process, especially regarding the occurrence of expulsion in the nugget.

  12. Active flux tungsten inert gas welding of austenitic stainless steel AISI 304

    Directory of Open Access Journals (Sweden)

    D. Klobčar

    2016-10-01

    Full Text Available The paper presents the effects of flux assisted tungsten inert gas (A-TIG welding of 4 (10 mm thick austenitic stainless steel EN X5CrNi1810 (AISI 304 in the butt joint. The sample dimensions were 300 ´ 50 mm, and commercially available active flux QuickTIG was used for testing. In the planned study the influence of welding position and weld groove shape was analysed based on the penetration depth. A comparison of microstructure formation, grain size and ferrit number between TIG welding and A-TIG welding was done. The A-TIG welds were subjected to bending test. A comparative study of TIG and A-TIG welding shows that A-TIG welding increases the weld penetration depth.

  13. Ultrasonic C-scanning imaging inspection of superplastic solid-state welded joint quality

    Institute of Scientific and Technical Information of China (English)

    张柯柯; 陈怀东; 杨蕴林; 薛锦

    2002-01-01

    Based on a large amount of dissection at welded interface and quantitative microscopic examination of welded rate, the suitable limit grey scale value was determined, and the welded rate of superplastic solid-state welding interface of heterogeneous steel was systematically studied by means of self-made ultrasonic C-scanning imaging inspection system. The experimental results show: the welded state of superplastic solid-state welding interface of heterogeneous steel can be conducted to be more accurately, reliably and quickly inspected by means of this system, and the ultrasonic testing results are good consistent with actual examination results of the interface defective distribution. Within the extent of the suitble welded rate,the welded rate in 40Cr/T10A superplastic welding process tested by this system is linear with its tensile strength of joint.

  14. Solid state impact welding of BMG and copper by vaporizing foil actuator welding

    Energy Technology Data Exchange (ETDEWEB)

    Vivek, Anupam, E-mail: vivek.4@osu.edu [Department of Materials Science and Engineering, The Ohio State University, 2041 College Road, Columbus, OH 43210 (United States); Presley, Michael [Department of Materials Science and Engineering, The Ohio State University, 2041 College Road, Columbus, OH 43210 (United States); Flores, Katharine M. [Department of Materials Science and Engineering, The Ohio State University, 2041 College Road, Columbus, OH 43210 (United States); Department of Mechanical Engineering and Materials Science, Institute of Materials Science and Engineering, Washington University, One Brookings Drive, St. Louis, MO 63130 (United States); Hutchinson, Nicholas H.; Daehn, Glenn S. [Department of Materials Science and Engineering, The Ohio State University, 2041 College Road, Columbus, OH 43210 (United States)

    2015-05-14

    The objective of this study was to create impact welds between a Zr-based Bulk Metallic Glass (BMG) and copper at a laboratory scale and subsequently investigate the relationship between interfacial structure and mechanical properties. Vaporizing Foil Actuator (VFA) has recently been demonstrated as a versatile tool for metalworking applications: impact welding of dissimilar materials being one of them. Its implementation for welding is termed as VFA Welding or VFAW. With 8 kJ input energy into an aluminum foil actuator, a 0.5 mm thick Cu110 alloy sheet was launched toward a BMG target resulting in an impact at a velocity of nearly 600 m/s. For this experiment, the welded interface was straight with a few BMG fragments embedded in the copper sheet in some regions. Hardness tests across the interface showed increase in strength on the copper side. Instrumented peel test resulted in failure in the parent copper sheet. A slower impact velocity during a separate experiment resulted in a weld, which had wavy regions along the interface and in peel failure again happened in the parent copper sheet. Some through-thickness cracks were observed in the BMG plate and there was some spall damage in the copper flyers. TEM electron diffraction on a sample, cut out from the wavy weld interface region using a focused ion beam, showed that devitrification of the BMG was completely avoided in this welding process.

  15. Study on self-optimizing function for intelligent control of CO2 welding

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    Based on the analysis data from a great deal welding tests, a quantitative synthetic evaluation function has been built to describe and evaluate the short-circuit transfer processes of CO2 arc welding. Then a self-optimizing objective function has been presented for developing the intelligent control system of CO2 arc welding machine by choosing 4 main measurable parameters in the evaluation function and regulating the range of the arc welding voltage and the current waveform controllable parameters. The simulation tests show that this function can be used for the microcomputer control system of CO2 arc welding machine to improve its performance and reduce the welding spatter greatly.

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

    Science.gov (United States)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

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

  17. Mechanical and Microstructural Evaluation of DMAG Welding of Structural Steel

    Directory of Open Access Journals (Sweden)

    Tolga Mert

    2015-01-01

    Full Text Available Double channel torch, which allows concentric flow of two different shielding gases, was designed and manufactured in order to pursue double channel torch gas metal arc welding of unalloyed structural steel S235JR (EN 10025-2 with fourteen passes. Tensile and Charpy V-notch tests were realized and the results were compared with those of conventional gas metal arc welding. In order to evaluate mechanical testing results, microstructural analyses were conducted. It was found that the increase with double channel gas metal arc welding process in yield and tensile strengths as well as in toughness tests, especially in subzero temperatures, compared with conventional gas metal arc welding was due to longer columnar grains and finer tempered zone grain structure between passes and due to solidification and less dendritic structure formation in all-weld metal in double channel gas metal arc welding.

  18. Fatigue Analysis of Load-Carrying Fillet Welds

    DEFF Research Database (Denmark)

    Sørensen, John Dalsgaard; Tychsen, Jesper; Andersen, Jens Ulfkjær

    2006-01-01

    is a doubler plate connection, which is often applied in connection with modifications of offshore structures. As a part of the present work, fatigue tests have been performed with test specimens fabricated by the current industry standard for welded offshore steel structures. The fatigue tests show......The fatigue strength of load-carrying fillet welds is, in most codes of practice, performed neglecting the influence of bending in the weld throat section. However, some commonly applied structural details give rise to significant bending in the weld throat section. An example of such a detail...... that the degree of bending (DOB) has an influence on the fatigue lifetime. The fatigue lifetime decreases significantly when increasing the bending stress. In order to take into account the effect of the bending, a new fatigue stress definition applicable for fillet welds failing through the weld is presented...

  19. Design of inspection and acceptance test methodology for TIG welded aluminum-alloy bracket for camera housings for IRS-1A space craft and executing it

    Science.gov (United States)

    Manglik, V. K.; Vaghmare, Rajeev; Shah, A. K.

    1992-10-01

    The Indian Remote Sensing Satellite (IRS) 1A was the first indigenously developed operational remote sensing satellite. The most critical element in the satellite was the remote sensing camera. The camera was mounted on aluminum alloy bracket which was fabricated by TIG welding. The methodology of acceptance and inspection of the TIG welded bracket is presented and discussed. These efforts not only provided the confidence in reliable welded joint but also provided trouble free operation of the camera on board the satellite for its whole life.

  20. Effect of welding parameters of Gas Metal Arc welding on weld bead geometry: A Review

    Directory of Open Access Journals (Sweden)

    Pushp Kumar Baghel

    2012-07-01

    Full Text Available Weld quality comprises bead geometry and its microstructure, which influence the mechanical properties of the weld. This brief review illustrates the effect of pulse parameters on weld quality. The responsefactors, namely bead penetration, weld width, reinforcement height, weld penetration shape factor and weld reinforcement form factor as affected by arc voltage, wire feed rate, welding speed, gas flow rate and nozzle-toplate distance has also been analysed

  1. Mechanical property variation within Inconel 82/182 dissimilar metal weld between low alloy steel and 316 stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Jang, Changheui [Department of Nuclear and Quantum Engineering, Korea Advanced Institute of Science and Technology, 373-1, Guseong-dong, Yuseong-gu, Daejeon 305-701 (Korea, Republic of)], E-mail: chjang@kaist.ac.kr; Lee, Jounghoon [Department of Nuclear and Quantum Engineering, Korea Advanced Institute of Science and Technology, 373-1, Guseong-dong, Yuseong-gu, Daejeon 305-701 (Korea, Republic of); Sung Kim, Jong; Eun Jin, Tae [Korea Power Engineering Company, 360-9 Mabuk-ri, Guseong-eup, Yongin-si, Gyeonggi-do 449-713 (Korea, Republic of)

    2008-09-15

    In several locations of pressurized water reactors, dissimilar metal welds using Inconel welding wires are used to join the low alloy steel components to stainless-steel pipes. Because of the existence of different materials and chemistry variation within welds, mechanical properties, such as tensile and fracture properties, are expected to show spatial variation. For design and integrity assessment of the dissimilar welds, these variations should be evaluated. In this study, dissimilar metal welds composed of low alloy steel, Inconel 82/182 weld, and stainless steel were prepared by gas tungsten arc welding and shielded metal arc welding techniques. Microstructures were observed using optical and electron microscopes. Typical dendrite structures were observed in Inconel 82/182 welds. Tensile tests using standard and mini-sized specimens and micro-hardness tests were conducted to measure the variation in strength along the thickness of the weld as well as across the weld. In addition, fracture toughness specimens were taken at the bottom, middle, and top of the welds and tested to evaluate the spatial variation along the thickness. It was found that while the strength is about 50-70 MPa greater at the bottom of the weld than at the top of the weld, fracture toughness values at the top of the weld are about 70% greater than those at the bottom of the weld.

  2. Optically controlled welding system

    Science.gov (United States)

    Gordon, Stephen S. (Inventor)

    1989-01-01

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

  3. Development of laser welding techniques for vanadium alloys

    Energy Technology Data Exchange (ETDEWEB)

    Strain, R.V.; Leong, K.H.; Smith, D.L. [Argonne National Laboratory, IL (United States)

    1996-10-01

    Laser welding is potentially advantageous because of its flexibility and the reduced amount of material affected by the weld. Bead-on-plate and butt welds were previously performed to depths of about 4 mm with a 6-kW CO{sub 2} laser on V-4%Cr-4%Ti and V-5%Cr-5%Ti alloys. These welds were made at a speed of 0.042 m/s using argon purging at a flow rate of 2.8 m{sup 3}/s. The purge was distributed with a diffuser nozzle aimed just behind the laser beam during the welding operation. The fusion zones of welds made under these conditions consisted of very fine, needle-shaped grains and were also harder than the bulk metal (230-270 dph, compared to {approx}180 dph for the bulk metal). A limited number of impact tests showed that the as-welded ductile-brittle transition temperatures (DBTT) was above room temperature, but heat treatment at 1000{degrees}C for 1 h in vacuum reduced the DBTT to <{minus}25{degrees}C. Activities during this reporting period focused on improvements in the purging system and determination of the effect of welding speed on welds. A 2-kW continuous YAG laser at Lumonics Corp. in Livonia, MI, was used to make 34 test welds for this study.

  4. A round-robin test with thermal simulation of the welding HAZ to draw CCT diagrams: a need for harmonized procedures and microconstituent terminologies

    Directory of Open Access Journals (Sweden)

    Américo Scotti

    2014-09-01

    Full Text Available Thermal simulations of heat affected zone (HAZ have been widely used. This is an economic expedite process for phase transformation evaluations in steels when subjected to weld thermal cycles as well as to draw continuous cooling transformation (CCT diagrams. Different approaches for the simulation and parameter settings have been used by several researchers, yet leading to not always even results. Thus, it was proposed a round-robin test trial performed by different laboratories, aiming to evidence potential sources of error or inadequacy of the approaches. A High Strength Low Alloy (HSLA steel was used as a case study. Despite the limited number of tests, the results show low robustness when comparing the outcomes from the different laboratories and point out for the need to take three actions. The first one is to implement a cooperative and multi-institutional program to assess the effect of relevant simulation parameters, such as the heating rate and holding time at peak temperature, on the final microstructure and transformation temperatures as well as on the hardness for a given cooling rate. The second is to propose calibration procedures for the simulation and measurement systems. The third action is to stimulate experts in this area to develop a guideline of terminology for constituents in the heat affected zone of ferritic steels.

  5. Automatic welding technologies for long-distance pipelines by use of all-position self-shielded flux cored wires

    Directory of Open Access Journals (Sweden)

    Zeng Huilin

    2014-10-01

    Full Text Available In order to realize the automatic welding of pipes in a complex operation environment, an automatic welding system has been developed by use of all-position self-shielded flux cored wires due to their advantages, such as all-position weldability, good detachability, arc's stability, low incomplete fusion, no need for welding protective gas or protection against wind when the wind speed is < 8 m/s. This system consists of a welding carrier, a guide rail, an auto-control system, a welding source, a wire feeder, and so on. Welding experiments with this system were performed on the X-80 pipeline steel to determine proper welding parameters. The welding technique comprises root welding, filling welding and cover welding and their welding parameters were obtained from experimental analysis. On this basis, the mechanical properties tests were carried out on welded joints in this case. Results show that this system can help improve the continuity and stability of the whole welding process and the welded joints' inherent quality, appearance shape, and mechanical performance can all meet the welding criteria for X-80 pipeline steel; with no need for windbreak fences, the overall welding cost will be sharply reduced. Meanwhile, more positive proposals were presented herein for the further research and development of this self-shielded flux core wires.

  6. Study on fatigue experiment for transverse butt welds under 2G and 3G weld positions

    Directory of Open Access Journals (Sweden)

    Kang Sung-Wook

    2015-09-01

    Full Text Available Although the transverse butt weld method with ceramic backing strip has been widely used in various industrial fields for its fabricational convenience, it is rarely used in offshore industries since the fatigue strength of the weld joint has not been proved sufficiently. This study conducted fatigue tests for series of butt weld specimens with horizontal (2G and vertical (3G welding positions in order to verify the fatigue strength compared to S-N curve by DNV (Det Norske Veritas, IIW (International Institute of Welding and Eurocode 3. The difference of the 2G specimens and the 3G specimens are investigated in terms of angular distortion and the effect on the fatigue strength are analyzed.

  7. Weld Metallurgy and Mechanical Properties of High Manganese Ultra-high Strength Steel Dissimilar Welds

    Science.gov (United States)

    Dahmen, Martin; Lindner, Stefan; Monfort, Damien; Petring, Dirk

    The increasing demand for ultra-high strength steels in vehicle manufacturing leads to the application of new alloys. This poses a challenge on joining especially by fusion welding. A stainless high manganese steel sheet with excellent strength and deformation properties stands in the centre of the development. Similar and dissimilar welds with a metastable austenitic steel and a hot formed martensitic stainless steel were performed. An investigation of the mixing effects on the local microstructure and the hardness delivers the metallurgical features of the welds. Despite of carbon contents above 0.4 wt.% none of the welds have shown cracks. Mechanical properties drawn from tensile tests deliver high breaking forces enabling a high stiffness of the joints. The results show the potential for the application of laser beam welding for joining in assembly of structural parts.

  8. Joining characteristics of titanium-based orthodontic wires connected by laser and electrical welding methods.

    Science.gov (United States)

    Matsunaga, Junko; Watanabe, Ikuya; Nakao, Noriko; Watanabe, Etsuko; Elshahawy, Waleed; Yoshida, Noriaki

    2015-01-01

    This study investigated the possibility of electrical and laser welding to connect titanium-based alloy (beta-titanium and nickel-titanium) wires and stainless-steel or cobalt-chromium alloy wires for fabrication of combination arch-wires. Four kinds of straight orthodontic rectangular wires (0.017 × 0.025 inch) were used: stainless-steel (S-S), cobalt-chromium (Co-Cr), beta-titanium alloy (β-Ti), and nickel-titanium (Ni-Ti). Homogeneous and heterogeneous end-to-end joints (15 mm long each) were made by electrical welding and laser welding. Non-welded wires (30 mm long) were also used as a control. Maximum loads at fracture (N) and elongation (%) were measured by conducting tensile test. The data (n = 10) were statistically analyzed using analysis of variance/Tukey test (P welding and those of the S-S/S-S and Co-Cr/Co-Cr specimens welded by laser. On the other hand, the laser-welded Ni-Ti/Ni-Ti and β-Ti/β-Ti specimens exhibited higher values of the ML and EL compared to those of the corresponding specimens welded by electrical method. In the heterogeneously welded combinations, the electrically welded Ni-Ti/S-S, β-Ti/S-S and β-Ti/Co-Cr specimens showed significantly (P welded by laser. Electrical welding exhibited the higher values of maximum load at fracture and elongation for heterogeneously welded combinations than laser-welding.

  9. Joint performance of CO2 laser beam welding 5083-H321 aluminum alloy

    Institute of Scientific and Technical Information of China (English)

    Qi Junfeng; Zhang Dongyun; Xiao Rongshi; Chen Kai; Zuo Tiechuan

    2007-01-01

    Laser beam welding of aluminum alloys is expected to offer good mechanical properties of welded joints. In this experimental work reported, CO2 laser beam autogenous welding and wire feed welding are conducted on 4mm thick 5083-H321 aluminum alloy sheets at different welding variables. The mechanical properties and microstructure characteristics of the welds are evaluated through tensile tests, micro-hardness tests, optical microscopy and scanning electron microscopy (SEM). Experimental results indicate that both the tensile strength and hardness of laser beam welds are affected by the constitution of filler material, except the yield strength. The soften region of laser beam welds is not in the heat-affected zone (HAZ). The tensile fracture of laser beam welded specimens takes place in the weld zone and close to the weld boundary because of different filler materials. Some pores are found on the fracture face, including hydrogen porosities and blow holes, but these pores have no influence on the tensile strength of laser beam welds. Tensile strength values of laser beam welds with filler wire are up to 345.57MPa, 93% of base material values, and yield strengths of laser beam welds are equivalent to those of base metal (264.50MPa).

  10. VIBRATORY STRESS, SOLIDIFICATION AND MICROSTRUCTURE OF WELDMENTS UNDER VIBRATORY WELDING CONDITION-A REVIEW

    Directory of Open Access Journals (Sweden)

    AKANKSHA VERMA,

    2011-06-01

    Full Text Available Welding processes induce a state of residual stress into materials and jobs. This poses a series of problems, in terms of dimensional stability, corrosion cracking, reduced fatigue life and structural integrity . Thermal cycle produced near weld line generates residual stress and inhomogeneous plastic deformation in weldments. Understanding of grain nucleation and grain growth becomes necessary that are influenced under welding conditions. After completion of nucleation, the solidification process will continue with nucleus growth .With vibratory weld conditioning, the enhancement of weld metal microstructure can be achieved. The mechanical properties, level of residual stresses, and deformation can also be affected . Structural changes of the welds prepared under vibratory conditions affects the mechanical properties of the welds. The vibration duringwelding benefits energy absorbed in impact toughness test of weld metal and improves fracture behavior. This paper presents the microstructure, solidification behaviour and residual stress relaxation under vibratory welding condition.

  11. High Power Laser Welding. [of stainless steel and titanium alloy structures

    Science.gov (United States)

    Banas, C. M.

    1972-01-01

    A review of recent developments in high power, carbon dixoide laser welding is presented. Deep penetration welding in stainless steel to 0.5-in. thick, high speed welding in thin gage rimmed steel and gas shielded welding in Ti-6Al-4V alloy are described. The effects of laser power, power density, focusing optics, gas-shielding techniques, material properties and weld speed on weld quality and penetration are discussed. It is shown that laser welding performance in thin materials is comparable to that of electron beams. It is further shown that high quality welds, as evidenced by NDT, mechanical and metal-lographic tests, can be achieved. The potential of the laser for industrial welding applications is indicated.

  12. Development of laser welding techniques for vanadium alloys

    Energy Technology Data Exchange (ETDEWEB)

    Strain, R.V.; Leong, K.H.; Smith, D.L.

    1996-04-01

    Laser welding is potentially advantageous because of its flexibility and the reduced amount of material affected by the weld. Lasers do not require a vacuum (as do electron beam welders) and the welds they produce high depth-to-width ratios. Scoping with a small pulsed 50 J YAG laser indicated that lasers could produce successful welds in vanadium alloy (V-5%Cr-5%Ti) sheet (1 mm thick) when the fusion zone was isolated from air. The pulsed laser required an isolating chamber filled with inert gas to produce welds that did not contain cracks and showed only minor hardness increases. Following the initial scoping tests, a series of tests were preformed with a 6 kW continuous CO{sub 2} laser. Successful bead-on-plate welds were made on V-4%Cr-4%Ti and V-5%Cr-5%Ti alloys to depths of about 4 mm with this laser.

  13. Improved design bases of welded joints in seawater

    DEFF Research Database (Denmark)

    Ólafsson, Ólafur Magnús

    The presented work aims to investigate and establish a precise, thorough and detailed database from series of experimental testing of submerged arc welded, SAW, specimens of various thicknesses typically applied in offshore structures and foundations. Additionally, the testing was performed in two...... welded joints were thereafter compared directly to the traditional SAW specimens in order to investigate the two different welding techniques. The laser hybrid welding technique offers great potential in lowering the cost of energy associated with offshore structures....... therefore received much attention from universities, research institutions along with industry as it is of significant practical importance for all fatigue loaded structures, such as e.g. marine structures. As-welded SAW specimens of three different thicknesses, manufactured by Lindoe Welding Technology A...

  14. 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)

  15. Deflection load characteristics of laser-welded orthodontic wires.

    Science.gov (United States)

    Watanabe, Etsuko; Stigall, Garrett; Elshahawy, Waleed; Watanabe, Ikuya

    2012-07-01

    To compare the deflection load characteristics of homogeneous and heterogeneous joints made by laser welding using various types of orthodontic wires. Four kinds of straight orthodontic rectangular wires (0.017 inch × 0.025 inch) were used: stainless-steel (SS), cobalt-chromium-nickel (Co-Cr-Ni), beta-titanium alloy (β-Ti), and nickel-titanium (Ni-Ti). Homogeneous and heterogeneous end-to-end joints (12 mm long each) were made by Nd:YAG laser welding. Two types of welding methods were used: two-point welding and four-point welding. Nonwelded wires were also used as a control. Deflection load (N) was measured by conducting the three-point bending test. The data (n  =  5) were statistically analyzed using analysis of variance/Tukey test (P welded specimens showed lower deflection loads compared to corresponding control wires and exhibited higher deflection loads compared to heterogeneously welded combinations. For homogeneous combinations, Co-Cr-Ni/Co-Cr-Ni showed a significantly (P welded groups. In heterogeneous combinations, SS/Co-Cr-Ni and β-Ti/Ni-Ti showed higher deflection loads than those of the remaining heterogeneously welded combinations (significantly higher for SS/Co-Cr-Ni). Significance (P welding method). However, no significant difference in deflection load was found between four-point and two-point welding in each homogeneous or heterogeneous combination. Heterogeneously laser-welded SS/Co-Cr-Ni and β-Ti/Ni-Ti wires provide a deflection load that is comparable to that of homogeneously welded orthodontic wires.

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

    Energy Technology Data Exchange (ETDEWEB)

    Ghosh, D. [Southern Company Services, Inc., Birmingham, AL (United States)

    1995-02-01

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

  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

    findings, the hardness results for ESW were lower than those usually observed for other electric arc welding processes. In addition, specimens subject to bending tests performed in accordance with the current standards used for qualification of welding procedures were approved. These evidences allow the conclusion that the ESW process can provide deposits with high quality despite the high welding energy levels, in order to achieve the desired productivity, being an interesting alternative for AISI 904L weld overlays.

  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

    findings, the hardness results for ESW were lower than those usually observed for other electric arc welding processes. In addition, specimens subject to bending tests performed in accordance with the current standards used for qualification of welding procedures were approved. These evidences allow the conclusion that the ESW process can provide deposits with high quality despite the high welding energy levels, in order to achieve the desired productivity, being an interesting alternative for AISI 904L weld overlays.

  19. Residual Stress and Fatigue Strength of Hybrid Laser-MIG-Welded A7N01P-T4

    Science.gov (United States)

    Wang, Qiuying; Chen, Hui; Qiu, Peixian; Zhu, Zongtao

    2017-02-01

    A7N01P-T4 aluminum alloy is widely used in some important welded components of high-speed trains. The hybrid laser-metal inert gas (MIG) welding process was studied to solve problems associated with the MIG welding process, such as low welding efficiency, high residual stress and deformation, and serious loss of strength. A high-speed camera, a voltage and current collection system, and NI DAQ were used to acquire arc profiles, welding voltage, and welding current simultaneously. Thermal cycle tests were carried out. Residual stresses induced by the welding process and fatigue strength of the joint were investigated. Large-size fatigue specimens were used in fatigue tests. The results show that the energy of the hybrid welding process is focused, and the power density of hybrid welding process is intense. The heat input per unit of the hybrid welding process is only half of that of the MIG welding process. Compared with the MIG welded joint, the overall residual stress level of the hybrid-welded joint is lower. The peak longitudinal stress of the hybrid-welded joint is reduced by 20 pct. The fatigue strength of hybrid joints is 14 pct higher than that of MIG-welded joints. Narrow weld and HAZ, weak softening behavior, and low residual stress level are the causes of the improvement of fatigue strength.

  20. Residual Stress and Fatigue Strength of Hybrid Laser-MIG-Welded A7N01P-T4

    Science.gov (United States)

    Wang, Qiuying; Chen, Hui; Qiu, Peixian; Zhu, Zongtao

    2016-09-01

    A7N01P-T4 aluminum alloy is widely used in some important welded components of high-speed trains. The hybrid laser-metal inert gas (MIG) welding process was studied to solve problems associated with the MIG welding process, such as low welding efficiency, high residual stress and deformation, and serious loss of strength. A high-speed camera, a voltage and current collection system, and NI DAQ were used to acquire arc profiles, welding voltage, and welding current simultaneously. Thermal cycle tests were carried out. Residual stresses induced by the welding process and fatigue strength of the joint were investigated. Large-size fatigue specimens were used in fatigue tests. The results show that the energy of the hybrid welding process is focused, and the power density of hybrid welding process is intense. The heat input per unit of the hybrid welding process is only half of that of the MIG welding process. Compared with the MIG welded joint, the overall residual stress level of the hybrid-welded joint is lower. The peak longitudinal stress of the hybrid-welded joint is reduced by 20 pct. The fatigue strength of hybrid joints is 14 pct higher than that of MIG-welded joints. Narrow weld and HAZ, weak softening behavior, and low residual stress level are the causes of the improvement of fatigue strength.

  1. Laser welding of tailored blanks

    Directory of Open Access Journals (Sweden)

    Peças, P.

    1998-04-01

    Full Text Available Laser welding has an incrising role in the automotive industry, namely on the sub-assemblies manufacturing. Several sheet-shape parts are laser welded, on a dissimilar combination of thicknesses and materials, and are afterwards formed (stamped being transformed in a vehicle body component. In this paper low carbon CO2 laser welding, on the thicknesses of 1,25 and 0,75 mm, formability investigation is described. There will be a description of how the laser welded blanks behave in different forming tests, and the influence of misalignment and undercut on the formibility. The quality is evaluated by measuring the limit strain and limit effective strain for the laser welded sheets and the base material, which will be presented in a forming limit diagram.

    A soldadura laser assume um papel cada vez mais importante na indústria automóvel, principalmente para a fabricação de sub-conjuntos constituídos por varias partes de chapa de diferentes espessuras (e diferentes materiais, que depois de estampados constituem um componente para integrar num veículo. Descreve-se neste artigo o trabalho de investigação de enformabilidade de chapa de ac.o de baixo carbono soldada por laser de CO2, nas espessuras de 1,25 e 0,75 mm. Apresenta-se uma descrição do comportamento das chapas soldadas por laser em diferentes testes de enformação, e a influência dos defeitos das soldaduras (desalinhamento e queda do banho-undercut no comportamento à enformação. A qualidade é avaliada pela medição da extensão limite e da extensão limite efectiva no material base e no material soldado, que serão representadas num diagrama de limite de enformabilidade.

  2. Material properties of a dissimilar metal weld Inconel 600/ Inconel 82 weld filler/ Carbon Steel (Gr.106 B)

    Energy Technology Data Exchange (ETDEWEB)

    Knapp, S. [Univ. of Ottawa, Ottawa, Ontario (Canada); Duan, X. [CANDU Energy Inc., Mississauga, Ontario (Canada); Weck, A., E-mail: aweck@uottawa.ca [Univ. of Ottawa, Ottawa, Ontario (Canada)

    2012-07-01

    Inconel 600 pipes welded to Carbon-Steel are used in CANDU nuclear reactors. Fracture of these welded pipes has important consequences in term of safety, and therefore their mechanical properties need to be better understood. In this study, the weld region was analyzed at various length-scales using optical microscopy, micro hardness testing, small and large scale tensile testing, and Digital Image Correlation (DIC). Micro-hardness profiles showed variations across the weld and through thickness and were justified in terms of residual stresses. Local stress-strain curves were built using DIC and showed good agreement with stress-strain curves obtained from miniature tensile samples. (author)

  3. Joint Performance for Laser Cutting-welding of Zinc-coated Tailored Blanks

    Institute of Scientific and Technical Information of China (English)

    WANG Chunming; HU Lunji; LIU Jianhua; HU Xiyuan; DU Hanbin

    2005-01-01

    The process of laser butt welding of zinc-coated steel ( SGCD3 and WLZn ) blanks was presented, whose edges were prepared by laser cutting. The properties of the butt joints, such as tensile strength, bending, stamping, weld shape, and corrosion- resistant were tested. The experiments of laser cutting and welding were carried out on a custom-made system designed, which is a set of equipment for wide sheet butt welding based on a laser cutting-welding combination process. The experiments proved the technological feasibility of laser butt welding for thin zinc coated steel sheets whose edges were prepared by laser cutting on the same equipment.

  4. 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.

  5. 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

  6. Magnetarc Welding - peculiarities of joining thin wall tubes

    OpenAIRE

    2010-01-01

    The paper presents the MAGNETARC welding of thin tubes achieved with an original longitudinal magnetization system, designed to assure the magnetic flux concentration on tube wall. Process main stages are presented, from the arc initiation until the molten metal appears, upsetting is achieved and the weld forms. Infrared thermography was used for temperature measurements and process visualization. Macro and microstructural analysis accompanies the hardness tests made on correspondingly weld...

  7. Ultra high frequency induction welding of powder metal compacts

    Energy Technology Data Exchange (ETDEWEB)

    Cavdar, U.; Gulsahin, I.

    2014-10-01

    The application of the iron based Powder Metal (PM) compacts in Ultra High Frequency Induction Welding (UHFIW) were reviewed. These PM compacts are used to produce cogs. This study investigates the methods of joining PM materials enforceability with UHFIW in the industry application. Maximum stress and maximum strain of welded PM compacts were determined by three point bending and strength tests. Microhardness and microstructure of induction welded compacts were determined. (Author)

  8. FATIGUE WELDING JOINT RESISTANCE OF MINING DUMP TRUCK BEARING CONSTRUCTIONS

    Directory of Open Access Journals (Sweden)

    A. A. Rakitsky

    2010-01-01

    Full Text Available The paper investigates a possibility to apply European norms on designing of welded constructions for frames of heavy-load mining dump trucks. Comparison of results concerning tests of welding joint specimen made of local steel with recommended standards of fatigue curves is executed in the paper. The paper reveals that while forecasting resource of automotive constructions with the accepted practical accuracy it is possible to use generalized fatigue resistance characteristics of standard welding joints. 

  9. Residual stress distributions in a P91 steel-pipe girth weld before and after post weld heat treatment

    Energy Technology Data Exchange (ETDEWEB)

    Paddea, S., E-mail: s.paddea@open.ac.uk [Materials Engineering, Open University, Walton Hall, Milton Keynes MK7 6AA (United Kingdom); Francis, J.A. [School of Mechanical, Aerospace and Civil Engineering, University of Manchester, Manchester M13 9PL (United Kingdom); Paradowska, A.M. [ISIS Facility, Rutherford-Appleton Laboratory, Didcot OX11 0QX, Oxon (United Kingdom); Bouchard, P.J. [Materials Engineering, Open University, Walton Hall, Milton Keynes MK7 6AA (United Kingdom); Shibli, I.A. [European Technology Development Ltd., Leatherhead KT22 7RD, Surrey (United Kingdom)

    2012-02-01

    Highlights: Black-Right-Pointing-Pointer Residual stresses in a pipe girth weld in P91 steel have been measured in both the as-welded and PWHT conditions. Black-Right-Pointing-Pointer The highest tensile residual stresses coincided with the HAZ boundary and the microstructural region that is prone to type IV cracking. Black-Right-Pointing-Pointer Compressive residual stresses were measured in the weld metal, in a location corresponding to the final weld pass. Black-Right-Pointing-Pointer The location of the peak compressive stresses can be explained by the effect of solid-state phase transformation. - Abstract: In this study the residual stresses in a pipe girth weld in a ferritic-martensitic power plant steel were measured by neutron diffraction and compared with the corresponding metallurgical zones in the weld region. It was found that, in both the as-welded and post-weld heat treated condition, the highest tensile stresses resided near the outer boundary of the heat-affected zone (HAZ), and towards the weld root region. Substantial tensile direct and hydrostatic stresses existed across the HAZ, including the fine-grained and intercritically annealed regions, where premature type IV creep failures manifest in 9-12 Cr steel welds. Compressive stresses were found in the weld metal coinciding with the last weld bead to be deposited. Constrained cooling tests on test coupons illustrated that these compressive stresses can be explained in terms of the influence that solid-state phase transformations have on the accumulation of stress in welds.

  10. 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.

  11. 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.

  12. NASA welding assessment program

    Science.gov (United States)

    Stofel, E. J.

    1984-01-01

    A long duration test was conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules were thermally cycled for 36,000 cycles between -80 and +80 C. The environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the earth's shadow was simulated. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived this extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

  13. The study of measuring technology on the dynamic mechanical properties of welded joint with high strain rate

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    In this paper, to meet the needs of studying work of dynamic mechanical properties of welded joint, the dynamic mechanical properties of welded joint were measured by means of SHPB(Split Hopkinson Pressure Bar).The dynamic mechanical property's curves of every part of welded joint were obtained. For studying the dynamic behavior of mechanical heterogeneity of welded joint, important data were offered. The method of test creates a new way of studying dynamic mechanical properties of welded joint.

  14. Cost and Performance Report: Introduction and Validation of Chromium-Free Consumables for Welding Stainless Steels. Version 2

    Science.gov (United States)

    2015-04-01

    generation rate γ gamma GECRM gamma exposure and count rate meter GMAW gas metal arc welding vii GTAW gas tungsten arc welding HAP Hazardous Air...confined spaces Navy ships and DoD facilities where effective welding fume ventilation is impossible or impractical GTAW – gas tungsten arc...and ductility Joints – bend, tensile strength, fillet weld, fracture toughness Equivalent to existing welding performance tests for the

  15. Practical significance of weld strength matching

    Energy Technology Data Exchange (ETDEWEB)

    Sloterdijk, W. [N.V. Nederlandse Gasunie, Groningen (Netherlands); Schipaanboord, W.N. [N.V. Nederlandse Gasunie, Groningen (Netherlands)

    1996-10-01

    Defect tolerance in welds in pipelines constructed in modern high strength material depends on the balance in strength between weld material and pipe material. The Guidelines on the assessment of girth weld defects published by the European Pipeline Research Group (EPRG) define in Tier 2 defect limits assuming that the (actual) weld metal yield strength is equal or greater than the yield strength of the parent material. The defect limits according to Tier 2 exceed the defect limits in `workmanship standards` (l>25 mm). Nevertheless, the draft European welding standard EN 288 does not yet require a test to measure and verify the weld metal yield strength. Gasunie has performed a test program with the aim to look at the practical significance of weld strength matching in a strain controlled situation and to verify the relevance of limits given in the European welding and line pipe codes, in combination with the EPRG Guidelines. It is concluded that the results of the tests confirm the defect acceptance limits according to Tier 2 of the EPRG Guidelines. (orig.) [Deutsch] Die Zulaessigkeit von Fehlern in Rundschweissnaehten in Rohrleitungen aus modernen hochfesten Baustaehlen haengt von dem Verhaeltnis der Werkstofffestigkeit des Schweissgutes zu der des Grundwerkstoffs ab. Die von der European Pipeline Research Group (EPRG) veroeffentlichte Richtlinie zur Bewertung von Schweissnahtfehlern gibt in der zweiten Bewertungsstufe (Tier 2) Werte fuer zulaessige Schweissnahtfehlergroessen unter der Bedingung an, dass die Dehngrenze des Schweissgutes groesser oder gleich der Dehngrenze des Grundwerkstoffs ist. Die nach Tier 2 zulaessigen Fehler sind groesser als die in `Good-workmanship`-Regelwerken angegebenen Fehlerlaenge (l>25 mm). Demgegenueber fehlt im Entwurf der europaeischen Schweissnorm EN 288 bislang ein solcher Dehngrenzennachweis. Gasunie hat ein Versuchsprogramm durchgefuehrt, um die Bedeutung der Schweissgutfestigkeit bei dehnungskontrollierter Belastung sowie

  16. Critical Gap distance in Laser Butt-welding

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove

    1999-01-01

    In a number of systematic laboratory experiments the critical gap distance that results in sound beads in laser butt welding is sought identified. By grinding the edges of the sheets, a number of "reference" welds are made and compared to the sheets with shear cut edges. In the tests the gap...... was set at 0.00, 0.02, 0.05, 0.08 and 0.10 mm. Mild steel (St 1203) with a thickness of 0.75 and 1.25 mm with and without zinc coating were analysed. A total of 120 welds were made at different welding speeds.As quality norm DIN 8563 was used to divide the welds into quality classes. A number of welds...... were also x-ray photographed.Of the weld combinations analysed 80 % were of high quality and 17 % of a non-acceptable quality. 90 % of the bad welds had a gap distance larger than 0.05 mm. The results showed that 85 % of the bad welds were shear cut and only 15 % grinded. Two third of the bad welds...

  17. Remote Welding, NDE and Repair of DOE Standardized Canisters

    Energy Technology Data Exchange (ETDEWEB)

    Eric Larsen; Art Watkins; Timothy R. McJunkin; Dave Pace; Rodney Bitsoi

    2006-05-01

    The U.S. Department of Energy (DOE) created the National Spent Nuclear Fuel Program (NSNFP) to manage DOE’s spent nuclear fuel (SNF). One of the NSNFP’s tasks is to prepare spent nuclear fuel for storage, transportation, and disposal at the national repository. As part of this effort, the NSNFP developed a standardized canister for interim storage and transportation of SNF. These canisters will be built and sealed to American Society of Mechanical Engineers (ASME) Section III, Division 3 requirements. Packaging SNF usually is a three-step process: canister loading, closure welding, and closure weld verification. After loading SNF into the canisters, the canisters must be seal welded and the welds verified using a combination of visual, surface eddy current, and ultrasonic inspection or examination techniques. If unacceptable defects in the weld are detected, the defective sections of weld must be removed, re-welded, and re-inspected. Due to the high contamination and/or radiation fields involved with this process, all of these functions must be performed remotely in a hot cell. The prototype apparatus to perform these functions is a floor-mounted carousel that encircles the loaded canister; three stations perform the functions of welding, inspecting, and repairing the seal welds. A welding operator monitors and controls these functions remotely via a workstation located outside the hot cell. The discussion describes the hardware and software that have been developed and the results of testing that has been done to date.

  18. Stud welding for fixation of cryogenic insulation of membrane tanks in LNG ship building

    Institute of Scientific and Technical Information of China (English)

    Jeong-Soo LEE; Young-Soo RYU; Nam-In KIM; Bong-Joon KIM; Yoo-Kyung KIM; Myung-Hyun KIM

    2009-01-01

    The support plates including all of the inner hulls such as E grade steel, weld seams and SUS304L were considered to establish the optimal stud welding condition in LNG ship building. The stainless steel plate was especially applied to the bracket on the liquid dome. The polished and etched surfaces of the welded stud and support plate were examined if the bead was properly formed. With the micrographic examination, the fusion boundary of metal weld zone formed by stud welding was analyzed to optimize the welding parameters. And also the analysis of the unacceptable welding faults such as cold and hot weld were performed. The mechanical tests such as tensile tests and bending tests were carried out to reveal any abnormal variation in the relationship of process parameters and the strength.

  19. MICROSTRUCTURE AND FATIGUE PROPERTIES OF DISSIMILAR SPOT WELDED JOINTS OF AISI 304 AND AISI 1008

    Directory of Open Access Journals (Sweden)

    Nachimani Charde

    2013-06-01

    Full Text Available Carbon steel and stainless steel composites are being more frequently used for applications requiring a corrosion resistant and attractive exterior surface and a high strength structural substrate. Spot welding is a potentially useful and efficient jointing process for the production of components consisting of these two materials. The spot welding characteristics of weld joints between these two materials are discussed in this paper. The experiment was conducted on dissimilar weld joints using carbon steel and 304L (2B austenitic stainless steel by varying the welding currents and electrode pressing forces. Throughout the welding process; the electrical signals from the strain sensor, current transducer and terminal voltage clippers are measured in order to understand each and every millisecond of the welding process. In doing so, the dynamic resistances, heat distributions and forging forces are computed for various currents and force levels within the good welds’ regions. The other process controlling parameters, particularly the electrode tip and weld time, remained constant throughout the experiment. The weld growth was noted for the welding current increment, but in the electrode force increment it causes an adverse reaction to weld growth. Moreover, the effect of heat imbalance was clearly noted during the welding process due to the different electrical and chemical properties. The welded specimens finally underwent tensile, hardness and metallurgical testing to characterise the weld growth.

  20. 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...

  1. The influence of the weld toe grinding and wig remelting weld toe rehabilitation techniques, on variable stresses, in case of cross fillet welds, reinforced with additional welding rows

    Directory of Open Access Journals (Sweden)

    Babis Claudiu

    2017-01-01

    Full Text Available Variable stresses where the load value varies between a maximum and a minimum value, or varies the position in time, cause after accumulating a large number of load cycles in those structures, the emergence of drug fatigue. Fatigue is characterized by failure on values of the applied stress from the load cycles, below the material flow, values which in case of static stress would not have caused problems. Knowing that the variable stressed structures are sensitive to stress concentrators, the paper aims to highlight the influence of two techniques to reduce stress concentrator weld toe grinding and WIG remelting weld toe, on the behavior of variable tensile test of cross corner welded specimens, reinforced with additional welding rows.

  2. 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.

  3. Dual wire welding torch and method

    Science.gov (United States)

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

    2009-04-28

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

  4. Narrow groove gas tungsten arc welding of ASTM A508 Class 4 steel for improved toughness properties

    Energy Technology Data Exchange (ETDEWEB)

    Penik, M.A. Jr. [Rensselaer Polytechnic Inst., Troy, NY (United States)

    1997-04-01

    Welding of heavy section steel has traditionally used the automatic submerged arc welding (ASAW) process because of the high deposition rates achievable. However, the properties, particularly fracture toughness, of the weld are often inferior when compared to base material. This project evaluated the use of narrow groove gas tungsten arc welding (GTAW) to improve weld material properties. The welding procedures were developed for ASTM A508 Class 4 base material using a 1% Ni filler material complying to AWS Specification A.23-90-EF3-F3-N. A narrow groove joint preparation was used in conjunction with the GTAW process so competitive fabrication rates could be achieved when compared to the ASAW process. Weld procedures were developed to refine weld substructure to achieve better mechanical properties. Two heaters of weld wire were used to examine the effects of minor filler metal chemistry differences on weld mechanical properties. Extensive metallographic evaluations showed excellent weld quality with a refined microstructure. Chemical analysis of the weld metal showed minimal weld dilution by the base metal. Mechanical testing included bend and tensile tests to ensure weld quality and strength. A Charpy impact energy curve versus temperature and fracture toughness curve versus temperature were developed for each weld wire heat. Results of fracture toughness and Charpy impact testing indicated an improved transition temperature closer to that of the base material properties.

  5. Experimental Investigation of Fatigue Crack Growth Behavior in Friction Stir Welded 7075-T111 Aluminum Alloy Joints under Constant Stress Intensity Factor Range Control Testing (For L T Orientation Specimen)

    Energy Technology Data Exchange (ETDEWEB)

    Jeong, Yeui Han; Kim, Seon Jin [Pukyong Nat' l Univ., Busan (Korea, Republic of)

    2013-06-15

    In this study, as a series of studies aimed at investigating the spatial randomness of fatigue crack growth for friction stir welded (FSWed) 7075-T111 aluminum alloy joints, the fatigue crack growth behavior of FSWed 7075-T111 aluminum alloy joints was investigated for L T orientation specimens. Fatigue crack growth tests were conducted under constant stress intensity factor range (SEFOR) control for 5 specimens of the FSWed 7075-T111 aluminum alloy, including base metal (B M), heat affected zone (Haz), and weld metal (W M) specimens. The mean fatigue crack growth rate of W M specimens was found to be the highest, whereas that of Haz and W M specimens was the lowest. Furthermore, the variability of fatigue crack growth rate was found to be the highest in W M specimens and lowest in B M specimens.

  6. Challenges to Resistance Welding

    DEFF Research Database (Denmark)

    Song, Quanfeng

    This report originates from the compulsory defense during my Ph.D. study at the Technical University of Denmark. Resistance welding is an old and well-proven technology. Yet the emergence of more and more new materials, new designs, invention off new joining techniques, and more stringent...... requirement in quality have imposed challenges to the resistance welding. More some research and development have to be done to adapt the old technology to the manufacturing industry of the 21st century. In the 1st part of the report, the challenging factors to the resistance welding are reviewed. Numerical...... simulation of resistance welding has been under development for many years. Yet it is no easy to make simulation results reliable and accurate because of the complexity of resistance welding process. In the 2nd part of the report numerical modeling of resistance welding is reviewed, some critical factors...

  7. Ultrasonic Stir Welding

    Science.gov (United States)

    Nabors, Sammy

    2015-01-01

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

  8. Challenges to Resistance Welding

    DEFF Research Database (Denmark)

    Song, Quanfeng

    This report originates from the compulsory defense during my Ph.D. study at the Technical University of Denmark. Resistance welding is an old and well-proven technology. Yet the emergence of more and more new materials, new designs, invention off new joining techniques, and more stringent...... requirement in quality have imposed challenges to the resistance welding. More some research and development have to be done to adapt the old technology to the manufacturing industry of the 21st century. In the 1st part of the report, the challenging factors to the resistance welding are reviewed. Numerical...... simulation of resistance welding has been under development for many years. Yet it is no easy to make simulation results reliable and accurate because of the complexity of resistance welding process. In the 2nd part of the report numerical modeling of resistance welding is reviewed, some critical factors...

  9. Manganese Content Control in Weld Metal During MAG Welding

    Science.gov (United States)

    Chinakhov, D. A.; Chinakhova, E. D.; Sapozhkov, A. S.

    2016-08-01

    The influence of the welding current and method of gas shielding in MAG welding on the content of manganese is considered in the paper. Results of study of the welded specimens of steels 45 when applying welding wire of different formulas and different types of gas shielding (traditional shielding and double-jet shielding) are given. It is found that in MAG welding the value of the welding current and the speed of the gas flow from the welding nozzle have a considerable impact on the chemical composition of the weld metal. The consumable electrode welding under double-jet gas shielding provides the directed gas-dynamics in the welding area and enables controlling the electrode metal transfer and the chemical composition of a weld.

  10. Critical Gap distance in Laser Butt-welding

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove

    of "reference" welds are made and compared to sheets with the edges shear cut. The gap distance is precisely controlled by inserting spacers between the sheets. In the tests the gap is set at 0.00, 0.02, 0.05, 0.08 and 0.10 mm. Mild steel (St 1203) with thickness? of 0.75 and 1.25 mm with and without zinc...... % of the bad welds have a gap distance larger than 0.05 mm. The results also show that 85 % of the bad welds are shear cut and only 15 % ground. Furthermore the results show that two third of the bad welds are zinc coated.X-ray pictures revealed that welding at "low" welding speeds (2 m/min. for 0.75 mm and 1...

  11. Multilayered titanium-steel composite produced by explosive welding

    Science.gov (United States)

    Malyutina, Yu. N.; Skorohod, K. A.; Shevtsova, K. E.; Chesnokova, A. V.

    2015-10-01

    Multilayered titanium-steel composite consisting of alternating high-strength and ductile metallic materials were produced by explosive welding. Different types of weld joints formed in the composite were recognized by methods of microstructural analysis. Wave-shaped and flat geometry of welds are typical of steel and titanium layers, respectively. Structural features such as lack of penetration, shear bands, recrystallized metals and martensitic structure were detected in the vortex and weld-adjacent zones of impacted materials. The impact strength of the layered composite was 65% higher as compared to that of VT23 titanium alloy. A favorable role of interlayers in the multilayered composite has been confirmed by toughness tests.

  12. Investigation of aluminum-steel joint formed by explosion welding

    Science.gov (United States)

    Kovacs-Coskun, T.; Volgyi, B.; Sikari-Nagl, I.

    2015-04-01

    Explosion welding is a solid state welding process that is used for the metallurgical joining of metals. Explosion cladding can be used to join a wide variety of dissimilar or similar metals [1]. This process uses the controlled detonation of explosives to accelerate one or both of the constituent metals into each other in such a manner as to cause the collision to fuse them together [2]. In this study, bonding ability of aluminum and steel with explosion welding was investigated. Experimental studies, microscopy, microhardness, tensile and bend test showed out that, aluminum and steel could be bonded with a good quality of bonding properties with explosion welding.

  13. Electron beam welding of copper lids. Status report up to 2001-12-31

    Energy Technology Data Exchange (ETDEWEB)

    Claesson, Soeren; Ronneteg, Ulf

    2003-10-01

    The report describes a summary of achieved results from 21 lid welds and numerous test block welds, performed at SKB Canister Laboratory in Oskarshamn for the period 1999-02-12 to 2001-12-31. Good weld quality has been achieved and some welds fulfilled the preliminary interpretation criteria, but the weld process need to be further developed before process qualification. Many different parameter settings have been tested and the influence on the weld profile has been mapped and documented. Deformations of the canister after welding have been measured and found to be very small. The preliminary inspection methods of the weld quality works satisfactory for the need of the development of the weld process. The welding machine is a new design developed for welding of thick copper in reduced pressure and performs well, but suffers from teething problems, which has delayed the work with development of the weld process. The welding system needs to be further developed and improved to work more reliably in a production plant.

  14. Electron beam welding of copper lids. Status report up to 2001-12-31

    Energy Technology Data Exchange (ETDEWEB)

    Claesson, Soeren; Ronneteg, Ulf

    2003-10-01

    The report describes a summary of achieved results from 21 lid welds and numerous test block welds, performed at SKB Canister Laboratory in Oskarshamn for the period 1999-02-12 to 2001-12-31. Good weld quality has been achieved and some welds fulfilled the preliminary interpretation criteria, but the weld process need to be further developed before process qualification. Many different parameter settings have been tested and the influence on the weld profile has been mapped and documented. Deformations of the canister after welding have been measured and found to be very small. The preliminary inspection methods of the weld quality works satisfactory for the need of the development of the weld process. The welding machine is a new design developed for welding of thick copper in reduced pressure and performs well, but suffers from teething problems, which has delayed the work with development of the weld process. The welding system needs to be further developed and improved to work more reliably in a production plant.

  15. Explosive Welding of Pipes

    Science.gov (United States)

    Drennov, Oleg; Drennov, Andrey; Burtseva, Olga

    2013-06-01

    For connection by welding it is suggested to use the explosive welding method. This method is rather new. Nevertheless, it has become commonly used among the technological developments. This method can be advantageous (saving material and physical resources) comparing to its statical analogs (electron-beam welding, argon-arc welding, plasma welding, gas welding, etc.), in particular, in hard-to-reach areas due to their geographic and climatic conditions. Explosive welding of cylindrical surfaces is performed by launching of welded layer along longitudinal axis of construction. During this procedure, it is required to provide reliable resistance against radial convergent strains. The traditional method is application of fillers of pipe cavity, which are dense cylindrical objects having special designs. However, when connecting pipes consecutively in pipelines by explosive welding, removal of the fillers becomes difficult and sometimes impossible. The suggestion is to use water as filler. The principle of non-compressibility of liquid under quasi-dynamic loading is used. In one-dimensional gasdynamic and elastic-plastic calculations we determined non-deformed mass of water (perturbations, which are moving in the axial direction with sound velocity, should not reach the layer end boundaries for 5-7 circulations of shock waves in the radial direction). Linear dimension of the water layer from the zone of pipe coupling along axis in each direction is >= 2R, where R is the internal radius of pipe.

  16. Explosive welding of pipes

    Energy Technology Data Exchange (ETDEWEB)

    Drennov, O.; Burtseva, O.; Kitin, A. [Russian Federal Nuclear Center, Sarov (Russian Federation)

    2006-08-15

    Arrangement of pipelines for the transportation of oil and gas is a complicated problem. In this paper it is suggested to use the explosive welding method to weld pipes together. This method is rather new. This method can be advantageous (saving material and physical resources) comparing to its static analogs (electron-beam welding, argon-arc welding, plasma welding, gas welding, etc.), in particular, in hard-to-reach areas due to their geographic and climatic conditions. We suggest to perform explosive welding according to the following scheme: the ends of the 2 pipes are connected, the external surfaces are kept at a similar level. A cylindrical steel layer of diameter larger than the pipe diameter is set around the pipe joint and an explosive charge is placed on its external surface. The basic problem is the elimination of strains and reduction of pipe diameter in the area of the dynamic effect. The suggestion is to use water as filler: the volume of pipes in the area adjacent to the zone of explosive welding is totally filled with water. The principle of non-compressibility of liquid under quasi-dynamic loading is used. In one-dimensional gas dynamic and elastic-plastic calculations we determined non-deformed mass of water. Model experiments with pipes having radii R = 57 mm confirmed results of the calculations and the possibility in principle to weld pipes by explosion with use of water as filler.

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

    Science.gov (United States)

    Zadpoor, Amir Abbas; Sinke, Jos

    2011-01-01

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

  18. Effect of welding current on strength and microstructure in resistance spot welding of AZ31 Mg alloy

    Institute of Scientific and Technical Information of China (English)

    Wang Yarong; Zhang Zhongdian; Feng Jicai

    2007-01-01

    In this paper, resistance spot welding were performed on 1mm-thickness magnesium AZ31B plates. The effect of welding current on the microstructure and tensile shear force was investigated. It was found that the welding current governed the nugget growth, and the nugget could not form if current levels were insufficient. The nugget revealed a homogeneous, equiaxed, fine-grained structure, which consisted of non-equilibrium microstructure of α-phase dendrites surrounded by eutectic mixtures of α and β (Mg17Al12) in the grain boundaries. With increasing welding current, the size of grains in nugget would be more smaller and uniform, and the width of plastic rings would be larger. Tensile shear tests showed that tensile shear force of the joints increased with increasing welding current when the welding current was smaller than 17 000 A.The maximum tensile shear force was up to 1980 N.

  19. Effect of Welding Speeds on Mechanical Properties of Level Compensation Friction Stir Welded 6061-T6 Aluminum Alloy

    Science.gov (United States)

    Wen, Quan; Yue, Yumei; Ji, Shude; Li, Zhengwei; Gao, Shuangsheng

    2016-04-01

    In order to eliminate the flash, arc corrugation and concave in weld zone, level compensation friction stir welding (LCFSW) was put forward and successfully applied to weld 6061-T6 aluminum alloy with varied welding speed at a constant tool rotational speed of 1,800 rpm in the present study. The glossy joint with equal thickness of base material can be attained, and the shoulder affected zone (SAZ) was obviously reduced. The results of transverse tensile test indicate that the tensile strength and elongation reach the maximum values of 248 MPa and 7.1% when the welding speed is 600 mm/min. The microhardness of weld nugget (WN) is lower than that of base material. The tensile fracture position locates at the heat affected zone (HAZ) of the advancing side (AS), where the microhardness is the minimum. The fracture surface morphology represents the typical ductile fracture.

  20. Microstructural Aspects of Bifocal Laser Welding of Trip Steels

    Directory of Open Access Journals (Sweden)

    Grajcar A.

    2017-06-01

    Full Text Available This work is concerned with comparative tests involving single-spot and twin-spot laser welding of thermomechanically rolled TRIP steel. The welding tests were carried out using keyhole welding and a solid state laser. In the case of twin-spot laser beam welding, the power distribution of beams was 50%:50%. The changes in macro- and microstructures were investigated using light and scanning electron microscopy. Three main zones subjected to the tests included the fusion zone, the heat affected zone and the intercritical heat affected zone (transition zone between the base material and the HAZ. Special attention was paid to the effect of various thermal cycles on the microstructure of each zone and on martensite morphology. The tests involved hardness measurements carried out in order to investigate the effect of different microstructures on mechanical properties of welds.

  1. Occupational urticaria from welding polyurethane

    Energy Technology Data Exchange (ETDEWEB)

    Kanerva, L.; Estlander, T.; Jolanki, R.; Laehteenmaeki, M.T.Ke.; Keskinen, H. (Institute of Occupational Health, Helsinki (Finland))

    1991-05-01

    An urticarial reaction associated with high fever developed in a welder on four occasions while he was welding steel profiles filled with polyurethane. The fumes emitted during pyrolysis of polyurethane and inhaled by the patient probably caused the urticarial reaction. Provocation tests with two pyrolysis products, 4,4-diphenylmethane diisocyanate and 4,4-diaminophenylmethane, were negative. This case demonstrates the difficulty in detecting the cause of urticaria induced by airborne chemicals.

  2. Welding of Prosthetic Alloys

    Directory of Open Access Journals (Sweden)

    Wojciechowska M.

    2015-04-01

    Full Text Available This paper presents the techniques of joining metal denture elements, used in prosthetic dentistry: the traditional soldering technique with a gas burner and a new technique of welding with a laser beam; the aim of the study was to make a comparative assessment of the quality of the joints in view of the possibility of applying them in prosthetic structures. Fractographic examinations were conducted along with tensile strength and impact strength tests, and the quality of the joints was assessed compared to the solid metal. The experiments have shown that the metal elements used to make dentures, joined by the technique which employs a laser beam, have better strength properties than those achieved with a gas burner.

  3. An investigation into geometry and microstructural effects upon the ultimate tensile strengths of butt welds

    Science.gov (United States)

    Gordon, Stephen S.

    1992-01-01

    A mathematical theory was evaluated empirically. This theory predicts weld ultimate tensile strength based on material properties and fusion line angles, mismatch, peaking, and weld widths. Welds were made on 1/4 and 1/2 in. aluminum 2219-T87, their geometries were measured, they were tensile tested, and these results were compared to theoretical predictions. Statistical analysis of results was performed to evaluate correlation of theory to results for many different categories of weld geometries.

  4. 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.

  5. Numerical aspects for efficient welding computational mechanics

    Directory of Open Access Journals (Sweden)

    Aburuga Tarek Kh.S.

    2014-01-01

    Full Text Available The effect of the residual stresses and strains is one of the most important parameter in the structure integrity assessment. A finite element model is constructed in order to simulate the multi passes mismatched submerged arc welding SAW which used in the welded tensile test specimen. Sequentially coupled thermal mechanical analysis is done by using ABAQUS software for calculating the residual stresses and distortion due to welding. In this work, three main issues were studied in order to reduce the time consuming during welding simulation which is the major problem in the computational welding mechanics (CWM. The first issue is dimensionality of the problem. Both two- and three-dimensional models are constructed for the same analysis type, shell element for two dimension simulation shows good performance comparing with brick element. The conventional method to calculate residual stress is by using implicit scheme that because of the welding and cooling time is relatively high. In this work, the author shows that it could use the explicit scheme with the mass scaling technique, and time consuming during the analysis will be reduced very efficiently. By using this new technique, it will be possible to simulate relatively large three dimensional structures.

  6. Optimal welding of beta titanium orthodontic wires.

    Science.gov (United States)

    Nelson, K R; Burstone, C J; Goldberg, A J

    1987-09-01

    Today the orthodontist is confronted by an array of new orthodontic wire materials that, when applied to appliance design, can vastly increase the flexibility and versatility of therapy. Welded joints, especially for the newer titanium alloy wires, provide a means to extend the useful applications of these materials. The purpose of this study was to determine the optimum settings for electrical resistance welding of various configurations of titanium-molybdenum (TMA) wires. Specimens were of a t-joint configuration and were mechanically tested in torsion to simulate the failure mode most often observed in clinical practice. Variables included wire size, wire orientation, and welding voltage. Results indicated that excellent welds can be obtained with very little loss of strength and ductility in the area of the weld joint. Torsional loads at failure were at least 90% of the unwelded base material. Although a wide range of voltage settings resulted in high-strength welds, typically a narrow range of voltages yielded optimal ductility.

  7. Improved diffusion welding and roll welding of titanium alloys

    Science.gov (United States)

    Holko, K. H.

    1973-01-01

    Auto-vacuum cleaning technique was applied to titanium parts prior to welding. This provides oxide-free welding surfaces. Diffusion welding can be accomplished in as little as five minutes of hot pressing. Roll welding can be accomplished with only ten percent deformation.

  8. EXPERIMENTAL INVESTIGATIONS OF WELD CHARACTERISTICS FOR A SINGLE PASS TIG WELDING WITH SS304

    Directory of Open Access Journals (Sweden)

    S. P. GADEWAR,

    2010-08-01

    Full Text Available This paper tries to investigate the effect of process parameters like weld current, gas flow and work piece thickness on the Bead Geometry (Front width and Back width of the welded joint. The working range of the experimentation is decided by test experiments. For joining the work piece by TIG welding for 304 stainless steel (SS304, the process parameters play an important role. During experimentation it is found that, increase in the welding current result in increase in heat input. This increased heat is utilized to melt the base metal.Similarly as thickness of the work piece increases rate of gas flow need to be increased to increase the heat diffusion rate. Increase in gas flow avoids the vaporization of the molten metal. It also increases the penetration. The increase in weld current and gas flow results in change in Bead Geometry of the welded joint which dominates the weld characteristics. The variations in the process parameters affect the mechanical properties with great extent.

  9. 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

  10. 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.

  11. 厚壁铸造奥氏体不锈钢管道焊缝超声相控阵检测技术概述%Review of Phased Array Ultrasonic Testing for Thick Wall Cast Austenitic Stainless Steel Pipeline Welds

    Institute of Scientific and Technical Information of China (English)

    林莉; 杨平华; 张东辉; 赵天伟; 杨会敏; 李喜孟

    2012-01-01

    The welding quality of cast austenitic stainless steel (CASS) pipeline welds is critical to nuclear reactors. The mandatory requirements of NDT have been raised in inspection code of nuclear power plant, which is about the welding quality and service condition of CASS welds. However, the complex structure of welds makes the ultrasonic testing of CASS welds challenging. Phased array ultrasonic testing (PAUT) technique is promising to solve this problem. The difficulties of PAUT for thick wall CASS pipeline welds are analyzed, the corresponding key issues and solving strategies are summarized. Furthermore, the research progress and latest research results at home and abroad are described, which provides reference for the PAUT of thick wall CASS pipeline welds.%铸造奥氏体不锈钢(Cast austenitic stainless steel,CASS)管道的焊接质量直接关系到核反应堆的安全,在核动力装置的检验规范中,对此类焊缝加工质量及服役期间状况提出无损检测的强制性要求,但CASS焊缝组织状态的复杂性给超声检测工作带来困难,研究采用相控阵超声检测(Phased array ultrasonic testing,PAUT)技术解决这一难题已成为国内外无损检测工作者关注的热点.概述厚壁CASS管道焊缝PAUT技术的难点,归纳相应的关键技术及解决策略,并简述近期国内外相关研究工作的进展和成果,以期为厚壁CASS管道焊缝的PAUT技术提供借鉴和参考.

  12. Assessment of Hot Crack Properties of Laser Welded Stainless Steel

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove

    2003-01-01

    Crack testing concerning small and fast solidifying laser welds in austenitic stainless steel has been studied. A set of methods has been applied to investigate alloy properties, including (1) Application of known information to predict solidification phases, (2) Weld metal solidification rate...

  13. 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.

  14. Mechanical properties of TIG and EB weld joints of F82H

    Energy Technology Data Exchange (ETDEWEB)

    Hirose, Takanori, E-mail: hirose.takanori@jaea.go.jp; Sakasegawa, Hideo; Nakajima, Motoki; Tanigawa, Hiroyasu

    2015-10-15

    Highlights: • Narrow groove TIG minimized volume of F82H weld. • Mechanical properties of TIG and EB welds of F82H have been characterized. • Post weld heat treatment successfully moderate the toughness of weld metal without softening the base metal. - Abstract: This work investigates mechanical properties of weld joints of a reduced activation ferritic/martensitic steel, F82H and effects of post weld heat treatment on the welds. Vickers hardness, tensile and Charpy impact tests were conducted on F82H weld joints prepared using tungsten-inert-gas and electron beam after various heat treatments. Although narrow groove tungsten-inert-gas welding reduced volume of weld bead, significant embrittlement was observed in a heat affected zone transformed due to heat input. Post weld heat treatment above 993 K successfully moderated the brittle transformed region. The hardness of the brittle region strongly depends on the heat treatment temperature. Meanwhile, strength of base metal was slightly reduced by the treatment at temperature ranging from 993 to 1053 K. Moreover, softening due to double welding was observed only in the weld metal, but negligible in base metal.

  15. Distribution of tensile property and microstructure in friction stir weld of 6063 aluminum

    Science.gov (United States)

    Sato, Yutaka S.; Kokawa, Hiroyuki

    2001-12-01

    Dominant microstructural factors governing the global tensile properties of a friction-stir-welded joint of 6063 aluminum were examined by estimating distribution of local tensile properties corresponding to local microstructure and hardness. Yield and ultimate tensile strengths of the as-welded weld were significantly lower than those of the base material. Postweld aging and postweld solution heat-treatment and aging (SHTA) restored the strengths of the weld to the levels of the base material. Elongation was found to increase with increasing strength. Hardness tests showed that the as-welded weld was soft around the weld center and that the aged weld and the SHTA weld had relatively homogeneous distributions of high hardness. Hardness profiles of the welds were explained by precipitate distributions and precipitation sequences during the postweld heat treatments. The strengths of the welds were related to each minimum hardness value. In a weld having a heterogeneous hardness profile, the fracture occurred in the region with minimum hardness. When a weld had a homogeneous hardness profile, its fracture site depended on both crystallographic-orientation distribution of the matrix grains and strain tensor of the imposed deformation, i.e., it fractured in the region with a minimum average Taylor factor.

  16. Characterisation of Dynamic Mechanical Properties of Resistance Welding Machines

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels

    2005-01-01

    The dynamic mechanical properties of a resistance welding machine have significant influence on weld quality, which must be considered when simulating the welding process numerically. However, due to the complexity of the machine structure and the mutual coupling of components of the machine system...... characterizing the dynamic mechanical characteristics of resistance welding machines is suggested, and a test set-up is designed determining the basic, independent machine parameters required in the model. The model is verified by performing a series of mechanical tests as well as real projection welds......., it is very difficult to measure or calculate the basic, independent machine parameters required in a mathematical model of the machine dynamics, and no test method has so far been presented in literature, which can be applied directly in an industrial environment. In this paper, a mathematical model...

  17. Characterisation of Dynamic Mechanical Properties of Resistance Welding Machines

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels

    2005-01-01

    The dynamic mechanical properties of a resistance welding machine have significant influence on weld quality, which must be considered when simulating the welding process numerically. However, due to the complexity of the machine structure and the mutual coupling of components of the machine system......, it is very difficult to measure or calculate the basic, independent machine parameters required in a mathematical model of the machine dynamics, and no test method has so far been presented in literature, which can be applied directly in an industrial environment. In this paper, a mathematical model...... characterizing the dynamic mechanical characteristics of resistance welding machines is suggested, and a test set-up is designed determining the basic, independent machine parameters required in the model. The model is verified by performing a series of mechanical tests as well as real projection welds....

  18. Weldability with Process Parameters During Fiber Laser Welding of a Titanium Plate (II) - The Effect of Control of Heat Input on Weldability -

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Jong Do; Kim, Ji Sung [Korea Maritime and Ocean Univ., Busan (Korea, Republic of)

    2016-12-15

    Laser welding is a high-density energy welding method. Hence, deep penetration and high welding speed can be realized with lower heat input as compared with conventional welding. The heat input of a CW laser welding is determined by laser power and welding speed. In this study, bead and lap welding of 0.5 mmt pure titanium was performed using a fiber laser. Its weldability with laser power and welding speed was evaluated. Penetration, bead width, joining length, and bead shape were investigated, and the mechanical properties were examined through tensile-shear strength tests. Welds with sound joining length were obtained when the laser power and welding speed were respectively 0.5 kW and 2.5 m/min, and 1.5 kW and 6 m/min, and the weld obtained at low output presented better ductility than that obtained at high output.

  19. The Effect of Tool Press Force to Weldability of AA5754 and AA6061 Alloys with Friction Stir Welding Method

    Directory of Open Access Journals (Sweden)

    Tevfik Küçükömeroğlu

    2013-07-01

    Full Text Available In this study AA5754 and A6061 alloys have been butt welded to each other by using friction stir welding (FSW. At constant tool geometry and tool angle experiments were carried out, joints were performed using different welding speed, rotation speed and especially tool press force. The mechanical properties of the welded samples were determined by using tensile test, bending test and micro hardness. Generated microstructure and hardness profile was obtained in the welding zone. In this friction stir welding study the parameters which affect the joint structure are the tool press force, welding speed and tool rotation speed which were determined. At the end of study it is determined that AA5754 and AA6061 alloys can be successfully welded by using Friction Stir Welding method under different tool press forces at least 6kN.

  20. Automatic welding quality classification for the spot welding based on the Hopfield associative memory neural network and Chernoff face description of the electrode displacement signal features

    Science.gov (United States)

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

    2017-02-01

    To develop an automatic welding quality classification method for the spot welding based on the Chernoff face image created by the electrode displacement signal features, an effective pattern feature extraction method was proposed by which the Chernoff face images were converted to binary ones, and each binary image could be characterized by a binary matrix. According to expression categories on the Chernoff face images, welding quality was classified into five levels and each level just corresponded to a kind of expression. The Hopfield associative memory neural network was used to build a welding quality classifier in which the pattern feature matrices of some weld samples with different welding quality levels were remembered as the stable states. When the pattern feature matrix of a test weld is input into the classifier, it can be converged to the most similar stable state through associative memory, thus, welding quality corresponding to this finally locked stable state can represent the welding quality of the test weld. The classification performance test results show that the proposed method significantly improves the applicability and efficiency of the Chernoff faces technique for spot welding quality evaluation and it is feasible, effective and reliable.

  1. 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)

  2. 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...

  3. Fine welding with lasers.

    Science.gov (United States)

    MacLellan, D

    2008-01-01

    The need for micro joining metallic alloys for surgical instruments, implants and advanced medical devices is driving a rapid increase in the implementation of laser welding technology in research, development and volume production. This article discusses the advantages of this welding method and the types of lasers used in the process.

  4. Simulation of welding

    Institute of Scientific and Technical Information of China (English)

    Chuan-Song WU; Michael RETHMEIER; Christopher SCHWENK

    2011-01-01

    @@ Welding has become the most important materials processing technology in manufacturing, and has critical effects on the quality, reliability and life of products as well as production cost, efficiency and response speed to market.As various kinds of high performance metallic materials are widely used in engineering, there are more demands in manufacturing industry for advanced welding technology.

  5. 管节点焊缝超声波检测模拟试块的设计与制作%Design and Manufacture of Simulation Test Block for Weld Pipe Node in Ultrasonic Inspection

    Institute of Scientific and Technical Information of China (English)

    黄扬雄; 林东文; 郭志贤

    2015-01-01

    To accelerate the application of phased array ultrasonic technology in weld pipe joint in lieu of conventional ultrasonic technology, inspection procedure should be demonstrated on a simulation test block to perform acceptability. The Phased array technology standards or the Weld pipe node test case speciifcation cannot guide us how to manufacture the simulation test block in detail. In order to solve the problem mentioned above, simulation test block was designed and manufactured as combined with engineering reality. It showed that with the help of simulation test block, the phased array ultrasonic technology is feasible for the weld pipe node joints.%为推动超声相控阵检测技术在管节点焊缝上的应用,替代传统的超声检测技术,需要在管节点焊缝模拟试块上进行演示,验证工艺的可行性。而关于相控阵技术标准或管节点焊缝检测的案例规范中并无关于模拟试块的制作要求。为了解决该问题,结合工程实际,设计并制作了典型的Y型管节点焊缝模拟试块,并在试块上验证了超声相控阵检测技术的可行性。

  6. Vacuum Gas Tungsten Arc Welding

    Science.gov (United States)

    Weeks, J. L.; Todd, D. T.; Wooten, J. R.

    1997-01-01

    A two-year program investigated vacuum gas tungsten arc welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. After a vacuum chamber and GTAW power supply were modified, several difficult-to-weld materials were studied and key parameters developed. Finally, Incoloy 903 weld overlays were produced without microfissures.

  7. 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.

  8. Different analysis of welder qualification test on two typical codes in submarine pipelines welding%两种石油管道焊接典型标准的焊工评定区别分析

    Institute of Scientific and Technical Information of China (English)

    许威; 李彦胜; 尚用甲; 权利

    2012-01-01

    API 1104 (2007) and DNV-os-f-101 (2007) are applied to the welding of submarine pipeline.The welder performance is important to assure the pipelines safety.And the welder qualification is the key to quality control.The welder performance qualification includes three aspects such as essential variables,test examination and range of qualification.From a practical view,this paper mainly focuses on the discrepancies by adopting a contrastive analysis method.According to analysis, there are significant differences in welding processes,welding positions,joint design,welding consumables,methods of tests and acceptance criteria.The welder qualification accuracy can be improved and the pipelines welding quality and efficiency guaranteed.%焊接海底管道常用的两个标准是API1104(2007)和DNV-OS-F101(2007).焊工的操作技能对于石油管线的安全至关重要,焊工资质评定是控制焊接质量的重要切入点.焊工资质评定包括重要变素、焊缝检验方法、评定范围三方面的内容,结合实际工作,对比分析了两个标准在焊工资质评定方面的差异.分析表明,评定标准在焊接方法、焊接位置的表示,接头型式,填充金属材料的分类,焊缝检验方法与验收标准,母材(包括规格尺寸)评定覆盖范围等存在着显著差异.掌握标准的要求有助于提高资质评定的有效性,保证项目施工的效率和质量.

  9. Dynamic character analysis for the arc welding power source based on fuzzy logic

    Institute of Scientific and Technical Information of China (English)

    Wang Zhenmin; Xue Jiaxiang; Wang Fuguang

    2007-01-01

    A lot of experimental methods have been brought forth to assess the dynamic character of the arc welding power source, but up to now, this issue has not been solved very well. In this paper, based on the fuzzy logic reasoning method, a dynamic character assessing model for the arc welding power source was established and used to analyze the dynamic character of the welding power source. Three different types of welding machine have been tested, and the characteristic information of the electrical signals such as re-striking arc voltage, low welding current and so on of the welding process were extracted accurately by using a self-developed welding dynamic arc wavelet analyzer. The experimental results indicate that this model can be used as a new assessing method for the dynamic character of the arc welding power source.

  10. Cold Cracking of Flux Cored Arc Welded Armour Grade High Strength Steel Weldments

    Institute of Scientific and Technical Information of China (English)

    G.Magudeeswaran; V.Balasubramanian; G.Madhusudhan Reddy

    2009-01-01

    In this investigation, an attempt has been made to study the influence of welding consumables on the factors that influence cold cracking of armour grade quenched and tempered (Q&T) steel welds. Flux cored arc welding (FCAW) process were used making welds using austenitic stainless steel (ASS) and low hydrogen ferritic steel (LHF) consumables. The diffusible hydrogen levels in the weld metal of the ASS and LHF consumables were determined by mercury method. Residual stresses were evaluated using X-ray stress analyzer and implant test was carried out to study the cold cracking of the welds. Results indicate that ASS welds offer a greater resistance to cold cracking of armour grade Q&T steel welds.

  11. 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.

  12. Comparative study of TIG and SMAW root welding passes on ductile iron cast weldability

    Directory of Open Access Journals (Sweden)

    J. Cárcel-Carrasco

    2017-01-01

    Full Text Available This work compares the weldability of ductile iron when: (I a root weld is applied with a tungsten inert gas (TIG process using an Inconel 625 source rod and filler welds are subsequently applied using coated electrodes with 97,6%Ni; and (II welds on ductile iron exclusively made using the manual shielded metal arc welding technique (SMAW. Both types of welds are performed on ductile iron specimen test plates that are subjected to preheat and post-weld annealing treatments. Samples with TIG root-welding pass shown higher hardness but slightly lower ductility and strength. Both types of welding achieved better ductile and strength properties than ones found in literature.

  13. Reduction of Defects in Al-6061 Friction Stir Welding and Verified by Radiography

    Science.gov (United States)

    Kumaravel, D.; Bupesh Raja, V. K., Dr; Potnuru, Chakravarthy; Polina, Navakanth

    2017-05-01

    Friction Stir Welding is a new innovating process of joining of two work pieces. It is an relatively a new joining process and highly useful in welding method, which can produce high strength weld without using any toxic materials like electrodes. In this method, weld is obtained by frictional produced between shoulder and work piece [1, 2]. Main parameters which are to be considered for FSW are spindle speed and feed rate. By providing suitable parameter during welding defects will not be occurring. Also, FSW is an eco-friendly process because there is no fumes production and no filler material. To get high quality of weld, then high heat should be generated. In this paper, Al-6061 material is welded by H-13 tool with different parameters and quality of weld is examined by using a non destructive testing method called Radiography.

  14. Studies on corrosion protection of laser hybrid welded AISI 316 by laser remelting

    DEFF Research Database (Denmark)

    Olsen, Flemming Ove; Ambat, Rajan; Rasmussen, A.J.

    2005-01-01

    Unlike in autogenous laser welding, hybrid laser welding of stainless steel could introduce grain boundary carbides due to low cooling rates. Formation of grain boundary carbides leads to reduced corrosion properties. Studies have initially been carried out on hybrid laser welding and subsequent...... laser surface melting on microstructure and corrosion behaviour of AISI 316L welds. Welding and laser treatment parameters were varied. General corrosion behaviour of the weld and laser treated surface was characterised using a gel visualization test. The local electrochemistry of the weld and laser...... treated surface was investigated using a novel micro electrochemical technique with a tip resolution of ~1 mm. Results show that hybrid laser welding of 316L has increased corrosion susceptibility probably as a result of grain boundary carbide formation. However a suitable post laser treatment could...

  15. Studies on corrosion protection of laser hybrid welded AISI 316 by laser remelting

    DEFF Research Database (Denmark)

    Olsen, Flemming Ove; Ambat, Rajan; Rasmussen, A.J.

    2005-01-01

    Unlike in autogenous laser welding, hybrid laser welding of stainless steel could introduce grain boundary carbides due to low cooling rates. Formation of grain boundary carbides leads to reduced corrosion properties. Studies have initially been carried out on hybrid laser welding and subsequent...... laser surface melting on microstructure and corrosion behaviour of AISI 316L welds. Welding and laser treatment parameters were varied. General corrosion behaviour of the weld and laser treated surface was characterised using a gel visualization test. The local electrochemistry of the weld and laser...... treated surface was investigated using a novel micro electrochemical technique with a tip resolution of ~1 mm. Results show that hybrid laser welding of 316L has increased corrosion susceptibility probably as a result of grain boundary carbide formation. However a suitable post laser treatment could...

  16. Research on Phased Array Automatically Ultrasonic Testing Technique of Tube to Tube-sheet Welds in Heat Exchanger%换热器管板角焊缝相控阵自动超声检测技术研究

    Institute of Scientific and Technical Information of China (English)

    郭伟灿; 钱盛杰; 凌张伟

    2015-01-01

    在换热器的制作过程中,换热管与管板常采用焊接形式,焊缝的质量是保证换热器长期正常运行的关键。常规的超声检测方法具有系统复杂、检测效率低等缺点。因此,提出了相控阵超声检测技术,并开发了相控阵超声检测系统,以实现对管板角焊缝的自动超声检测。系统由周向步进电机实现周向扫查,纵向扫查采用相控阵探头电子线扫查,从而实现超声 C 扫描检测。通过带有气孔、未熔合等典型缺陷对检测系统进行试验研究。结果表明,该技术可以有效地检测出换热器管板角焊缝中的典型缺陷。%In the process of produce heat exchangers,heat exchanger′s tube and tube sheet conjunction adopt the form of welding,the quality of welding is the key insurance for the long and normal operation of the heat exchangers.The conventional ultrasonic testing method has many disadvantages like complicated system and low efficiency of detection.Thus,it puts forward the phased array ultrasonic testing technique and develops the ultrasonic testing system to accomplish the automatically ultrasonic testing of the tube to tube-sheet welds.The ultrasonic C-scan was carried out by the ultrasonic testing system with its circumfer-ential scanning by a mechanical scanning device while the axial electronic linear scanning by the phased array probe.At last,the tests on samples with typical flaws such as porosity flaws and the incomplete fu-sion flaws were performed by the ultrasonic testing system.Experiment results showed that the phased ar-ray ultrasonic technique could effectively detect the typical flaws in the tube to tube-sheet welds of heat exchanger.

  17. Analysis on the joint tensile strength and fractography of TiNi shape memory alloy precise pulse resistance butt welding

    Institute of Scientific and Technical Information of China (English)

    赵熹华; 韩立军; 赵蕾

    2002-01-01

    This paper studies mechanical property and fractography of the welded joints obtained in different welding parameters such as welding heat and welding press with/without gas shield in TiNi shape memory alloy precise pulse resistance butt welding using tensile strength test, XRD, SEM and TEM measures. The optimum welding parameters obtaining high tensile strength welded joint are got. On the condition of welding press magneting current 2 A and welding heat 75%, the joint strength is the highest. This is important for to study other properties of TiNi shape memory alloy further. The experimental results state that argon gas shield have different effects on different welding parameters, less on welding press, but great on welding heat. But excessive welding press and welding heat have great effects on joint tensile strength. Too high welding heat can produce the new intermetallic compound, this intermetallic compound lead to dislocation density to increase and form the potential crack initiation, which can easily make the joint fracture under stress effect and decrease the shape memory ratio of joint for high density dislocation groups existing in the twinned martensite.

  18. Multispot fiber laser welding

    DEFF Research Database (Denmark)

    Schutt Hansen, Klaus

    This dissertation presents work and results achieved in the field of multi beam fiber laser welding. The project has had a practical approach, in which simulations and modelling have been kept at a minimum. Different methods to produce spot patterns with high power single mode fiber lasers have...... been possible to control the welding width in incremental steps by adding more beams in a row. The laser power was used to independently control the keyhole and consequently the depth of fusion. An example of inline repair of a laser weld in butt joint configuration was examined. Zinc powder was placed...... in the weld causing expulsion of the melt pool. Trailing beams were applied to melt additional material and ensure a melt pool. The method showed good results for increasing tolerances to impurities and reduction of scrapped parts from blowouts during laser welding....

  19. Rheomorphism of welded tuffs

    Science.gov (United States)

    Wolff, J. A.; Wright, J. V.

    1981-05-01

    Peralkaline welded tuffs from the islands of Gran Canaria, Canary Islands, and Pantelleria, Italy, show abundant evidence for post-depositional flow. It is demonstrated that rheomorphism, or secondary mass flowage, can occur in welded tuffs of ignimbrite and air-fall origin. The presence of a linear fabric is taken as the diagnostic criterion for the recognition of the process. Deposition on a slope is an essential condition for the development of rheomorphism after compaction and welding. Internal structures produced during rheomorphic flow can be studied by the methods of structural geology and show similar dispositions to comparable features in sedimentary slump sheets. It is shown that secondary flowage can occur in welded tuffs emplaced on gentle slopes, provided that the apparent viscosity of the magma is sufficiently low. Compositional factors favor the development of rheomorphism in densely welded tuffs of peralkaline type.

  20. Cyclic loading test on welded connection of high strength steel Q460C%Q460C高强度钢材焊缝连接循环加载试验研究

    Institute of Scientific and Technical Information of China (English)

    施刚; 王飞; 戴国欣; 王元清; 石永久

    2012-01-01

    为研究高强度钢材Q460C焊缝连接在地震作用下的反应,对11个Q460C焊缝连接试件进行了8种不同加载制度的单调和循环加载试验,分析比较了不同加载制度下的应力-应变关系,研究其本构模型、力学性能、破坏模式、变形和延性特征以及损伤退化特性,并和母材的性能进行了对比。利用Ramberg-Osgood公式对其循环骨架曲线进行了拟合,确定了拟合计算式中的待定参数;通过试验标定了循环荷载作用下本构模型的参数,采用有限元程序ABAQUS利用混合模型对上述循环加载试验进行了较为准确的有限元模拟。研究结果表明:所有加载制度下试件最终均在焊缝和热影响区交界面拉断,这和焊缝连接处的应力集中有关;与母材单调拉伸性质相比,焊缝连接试件延性下降显著,说明焊接过程对钢材有严重影响,应采取措施避免破坏发生在焊缝区域。%In order to study the behavior of the weld of high strength structural steel Q460C under earthquake loading, 11 welded high strength structural steel Q460C specimens were tested by 8 different monotonic and cyclic loading regimes. The corresponding stress-strain relationships under these different loading regimes were analyzed. The constitutive model, mechanical properties, failure modes, deformation, ductility and the cumulative damage deterioration were also studied and compared with the behavior of the base metal. Based on the test results, the cyclic skeleton curves were fitted by the Ramberg-Osgood model. The key parameters in the formula were determined. Furthermore the key parameters of the stress-strain constitutive model of the weld of high strength structural steel Q460c under cyclic loading were calibrated by the test results and accurately simulated using ABAQUS with the mixed cyclic constitutive model. The results show that all specimens of welded connection fracture at the weld heat affected zone, which may be caused

  1. 铝-钢脉冲DE-GMAW与CMT熔钎焊热循环曲线测试与对比%Test of thermal cycling curve of pulsed melting-soldering welding DE-GMAW and CMT for bonding steel with aluminum

    Institute of Scientific and Technical Information of China (English)

    石玗; 王钊; 董兵天; 卢立晖; 黄健康; 樊丁

    2012-01-01

    介绍一种新的铝-钢异种金属焊接方法——脉冲旁路耦合电弧MIG焊(pulsed DE-GMAW),将该方法应用于铝和镀锌钢板的焊接,得到成型良好的焊缝.采用接触式测量法测量pulsed DE-GMAW法在不同焊接参数下的热循环曲线,并与CMT进行对比分析,结果表明:CMT法通过推拉丝及短路波形控制能减小焊接过程中的热输入;而pulsed DE-GMAW法通过增加旁路电流达到分流的目的,也可以降低输入母材的热量,2种方法的热输入控制效果相当,均能较好实现铝-钢异种金属的焊接.%A new method for heterogeneous metal welding of aluminum and steel (pulsed DE-GMAW) was introduced. A well-formed weld was obtained with this method to weld aluminum and galvanized steel plate. The contact-type measurement method was employed to test the thermal cycling curve of welding with pulsed DE-GMAW with different welding parameters. Then the test result was compared to that with CMT. The results showed that CMT could reduce welding heat-input by means of pushing-drawing the welding wire and controlling the short-circuit waveform. And by using the pulsed DE-GMAW, the heat-input could be reduced by adding by-pass current. Whether pulsed DE-GMAW Or CMT could equally control the heat-input better to realize welding heterogeneous metal of aluminum and steel.

  2. Laboratory work for preparation of scraping tests of high-frequency welded pipes using electrodynamic, ultrasonic transducers. Laboruntersuchungen zur Schabungspruefung hochfrequenzgeschweisster Rohre mittels elektrodynamischer US-Wandler

    Energy Technology Data Exchange (ETDEWEB)

    Koch, R.; Maurer, A. (Nuklear-Chemie und -Metallurgie GmbH (NUKEM), Alzenau (Germany, F.R.))

    1990-01-01

    High-resolution examinations for which coupling agents cannot be used are done with dry-coupled, electrodynamic ultrasonic transducers. A specific electrodynamic transducer supported by an air cushion has been used for measuring the wall thickness curve directly behind a high-frequency weld seam. The paper presents wall thickness profiles in unwelded zones and in scraped zones. (DG).

  3. Investigations of the contact bounce behaviors and relative dynamic welding phenomena for electromechanical relay

    Science.gov (United States)

    Ren, Wanbin; He, Yuan; Jin, Jianbing; Man, Sida

    2016-06-01

    Dynamic welding, being the principal mechanism of sticking failure, correlates closely with the contact bounce of electromechanical relay. The typical waveforms of dynamic contact force and contact voltage at making and breaking process are obtained with the use of a new designed test rig. The variations in bounce time, bounce numbers, last bounce duration, and relevant welding force are investigated in the electrical endurance test. It is determined that the welding strength and the welding probability are increased with the reduced stationary force. The degradation physical mechanism is present to better understand the relationship between dynamic welding and operation characteristics of electromechanical relay.

  4. Influence of welding passes on grain orientation - The example of a multi-pass V-weld

    Energy Technology Data Exchange (ETDEWEB)

    Ye, Jing, E-mail: yejing@skku.edu [School of Mechanical Engineering, Sungkyunkwan University, 300 Chunchun-dong, Jangan-gu 440-746 (Korea, Republic of); Moysan, Joseph, E-mail: joseph.moysan@univmed.fr [Aix-Marseille Universite, Laboratoire de Mecanique et d' Acoustique, site du LCND, Av. Gaston Berger, 13625 Aix en Provence (France); Song, Sung-Jin, E-mail: sjsong@skku.edu [School of Mechanical Engineering, Sungkyunkwan University, 300 Chunchun-dong, Jangan-gu 440-746 (Korea, Republic of); Kim, Hak-Joon, E-mail: hjkim21c@skku.edu [School of Mechanical Engineering, Sungkyunkwan University, 300 Chunchun-dong, Jangan-gu 440-746 (Korea, Republic of); Chassignole, Bertrand, E-mail: bertrand.chassignole@edf.fr [Departement MMC, EDF R and D, Site des Renardieres, 77818 Moret-sur-Loing (France); Gueudre, Cecile, E-mail: cecile.gueudre@univ-amu.fr [Aix-Marseille Universite, Laboratoire de Mecanique et d' Acoustique, site du LCND, Av. Gaston Berger, 13625 Aix en Provence (France); Dupond, Olivier, E-mail: olivier.dupond@edf.fr [Departement MMC, EDF R and D, Site des Renardieres, 77818 Moret-sur-Loing (France)

    2012-05-15

    The accurate modelling of grain orientations in a weld is important, when accurate ultrasonic test predictions of a welded assembly are needed. To achieve this objective, Electricite de France (EDF) and the Laboratoire de Caracterisation Non Destructive (LCND) have developed a dedicated code, which makes use of information recorded in the welding procedure. Among the welding parameters recorded, although the order in which the welding passes are made is of primary importance in the welding process, this information is not always well known or accurately described. In the present paper we analyse in greater detail the influence of the order of welding passes, using data obtained from the Centre for Advanced Non Destructive Evaluation (CANDE), derived from a dissimilar metal weld (DMW) with buttering. Comparisons are made using grain orientation measurements on a macrograph. - Highlights: Black-Right-Pointing-Pointer Influence of welding process on grain structure is studied using the MINA model. Black-Right-Pointing-Pointer For the first time the importance of a slight slope of the layers is evaluated. Black-Right-Pointing-Pointer Two orders of passes are compared for the modelling approach. Black-Right-Pointing-Pointer A major effect is observed due to a change in the order of passes.

  5. Laser welding and syncristallization techniques comparison: "Ex vivo" study.

    Science.gov (United States)

    Fornaini, Carlo; Meleti, Marco; Vescovi, Paolo; Merigo, Elisabetta; Rocca, Jean-Paul

    2013-12-30

    Stabilization of implant abutments through electric impulses at high voltage for a very short time (electrowelding) was developed in the Eighties. In 2009, the same procedure was performed through the use of laser (laser welding) The aim of this study is to compare electrowelding and laser welding for intra-oral implant abutments stabilization on "ex vivo models" (pig jaws). Six bars were welded with two different devices (Nd:YAG laser and Electrowelder) to eighteen titanium implant abutment inserted in three pig jaws. During the welding process, thermal increase was recorded, through the use of k-thermocouples, in the bone close to the implants. The strength of the welded joints was evaluated by a traction test after the removal of the implants. For temperature measurements a descriptive analysis and for traction test "values unpaired t test with Welch's correction" were performed: the significance level was set at PLaser welding gives a lower thermal increase than Electrowelding at the bone close to implants (Mean: 1.97 and 5.27); the strength of laser welded joints was higher than that of Electrowelding even if nor statistically significant. (Mean: 184.75 and 168.29) CONCLUSION: Electrowelding seems to have no advantages, in term of thermal elevation and strength, while laser welding may be employed to connect titanium implants for immediate load without risks of thermal damage at surrounding tissues.

  6. Initiation and growth of microcracks in high strength steel butt welds

    Science.gov (United States)

    Olsen, Edward

    1993-05-01

    Early tests such as the explosion bulge test created a preference for overmatched welds (welds which are stronger than the base metal) which eventually became codified for many structural applications. While an overmatched system offers advantages such as the shedding of strain to the base plate, it requires the use of expensive fabrication procedures to avoid cracking. Undermatched welding of some high strength steels may offer reductions in welding costs with little sacrifice in weld performance or low cycle fatigue integrity. An experimental study was carried out to observe microcrack initiation and growth of overmatched and undermatched butt welded high strength steel samples using globally elastic low cycle fatigue testing. First, 1 inch thick HY-80 and HY-100 base plates were multipass, spray gas metal arc welded (GMAW) with overmatching and undermatching filler metal using a semiautomatic welding machine. Second, 1/4 inch thick MIL-A-46100 high hardness armor plates (HHA) were manually, two pass spray GMAW welded with two grades of undermatching consumables. Weld reinforcements were removed from all HY specimens and six HHA specimens. All specimens had a crack initiator slit machined in the test section. The specimens were fatigue tested by transverse tensile loading with a 12 to 13 Hz tension-tension profile. The loading range was from 10% to 85% of the tensile strength of the HY steel base plate and HHA weld metal respectively. Crack initiation and propagation was observed in situ using a confocal scanning laser microscope.

  7. Welding method, and welding device for use therein, and method of analysis for evaluating welds

    NARCIS (Netherlands)

    Aendenroomer, A.J.; Den Ouden, G.; Xiao, Y.H.; Brabander, W.A.J.

    1995-01-01

    Described is a method of automatically welding pipes, comprising welding with a pulsation welding current and monitoring, by means of a sensor, the variations occurring in the arc voltage caused by weld pool oscillations. The occurrence of voltage variations with only frequency components below 100

  8. Thermoplastic welding apparatus and method

    Energy Technology Data Exchange (ETDEWEB)

    Matsen, Marc R.; Negley, Mark A.; Geren, William Preston; Miller, Robert James

    2017-03-07

    A thermoplastic welding apparatus includes a thermoplastic welding tool, at least one tooling surface in the thermoplastic welding tool, a magnetic induction coil in the thermoplastic welding tool and generally encircling the at least one tooling surface and at least one smart susceptor in the thermoplastic welding tool at the at least one tooling surface. The magnetic induction coil is adapted to generate a magnetic flux field oriented generally parallel to a plane of the at least one smart susceptor.

  9. 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.

  10. Guidelines for Friction Stir Welding

    Science.gov (United States)

    2011-03-29

    in a large void at the termination point of the weld, the effects the exit hole will have on structural integrity must be considered. The...3.6 Cavity. A void -type discontinuity within a solid-state weld. See Figure 3.4. 3.7 Complex weld joint. A continuous weld...except as affected by corner radii. 3.61 Underfill . A depression resulting when the weld face is below the adjacent parent material surface. See

  11. Tensile and Fatigue Testing and Material Hardening Model Development for 508 LAS Base Metal and 316 SS Similar Metal Weld under In-air and PWR Primary Loop Water Conditions

    Energy Technology Data Exchange (ETDEWEB)

    Mohanty, Subhasish [Argonne National Lab. (ANL), Argonne, IL (United States); Soppet, William [Argonne National Lab. (ANL), Argonne, IL (United States); Majumdar, Saurin [Argonne National Lab. (ANL), Argonne, IL (United States); Natesan, Ken [Argonne National Lab. (ANL), Argonne, IL (United States)

    2015-09-01

    This report provides an update on an assessment of environmentally assisted fatigue for light water reactor components under extended service conditions. This report is a deliverable in September 2015 under the work package for environmentally assisted fatigue under DOE’s Light Water Reactor Sustainability program. In an April 2015 report we presented a baseline mechanistic finite element model of a two-loop pressurized water reactor (PWR) for systemlevel heat transfer analysis and subsequent thermal-mechanical stress analysis and fatigue life estimation under reactor thermal-mechanical cycles. In the present report, we provide tensile and fatigue test data for 508 low-alloy steel (LAS) base metal, 508 LAS heat-affected zone metal in 508 LAS–316 stainless steel (SS) dissimilar metal welds, and 316 SS-316 SS similar metal welds. The test was conducted under different conditions such as in air at room temperature, in air at 300 oC, and under PWR primary loop water conditions. Data are provided on materials properties related to time-independent tensile tests and time-dependent cyclic tests, such as elastic modulus, elastic and offset strain yield limit stress, and linear and nonlinear kinematic hardening model parameters. The overall objective of this report is to provide guidance to estimate tensile/fatigue hardening parameters from test data. Also, the material models and parameters reported here can directly be used in commercially available finite element codes for fatigue and ratcheting evaluation of reactor components under in-air and PWR water conditions.

  12. Effect of Interfacial Reaction on the Mechanical Performance of Steel to Aluminum Dissimilar Ultrasonic Spot Welds

    Science.gov (United States)

    Xu, Lei; Wang, Li; Chen, Ying-Chun; Robson, Joe D.; Prangnell, Philip B.

    2016-01-01

    The early stages of formation of intermetallic compounds (IMC) have been investigated in dissimilar aluminum to steel welds, manufactured by high power (2.5 kW) ultrasonic spot welding (USW). To better understand the influence of alloy composition, welds were produced between a low-carbon steel (DC04) and two different aluminum alloys (6111 and 7055). The joint strengths were measured in lap shear tests and the formation and growth behavior of IMCs at the weld interface were characterized by electron microscopy, for welding times from 0.2 to 2.4 seconds. With the material combinations studied, the η (Fe2Al5) intermetallic phase was found to form first, very rapidly in the initial stage of welding, with a discontinuous island morphology. Continuous layers of η and then θ (FeAl3) phase were subsequently seen to develop on extending the welding time to greater than 0.7 second. The IMC layer formed in the DC04-AA7055 combination grew thicker than for the DC04-AA6111 welds, despite both weld sets having near identical thermal histories. Zinc was also found to be dissolved in the IMC phases when welding with the AA7055 alloy. After post-weld aging of the aluminum alloy, fracture in the lap shear tests always occurred along the joint interface; however, the DC04-AA6111 welds had higher fracture energy than the DC04-AA7055 combination.

  13. 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.

  14. 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.

  15. Preliminary PINC(Program for the Inspection of Nickel Alloy Components) RRT(Round Robin Test) - Pressurizer Dissimilar Metal Weld

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kyung Cho; Kang, Sung Sik; Shin, Ho Sang; Chung, Ku Kab; Song, Myung Ho; Chung, Hae Dong [Korea Institute of Nuclear Safety, Daejeon (Korea, Republic of)

    2009-06-15

    After several damages by PWSCC were found in the world, USNRC and PNNL(Pacific Northwest National Laboratory) started the research on PWSCC under the project name of PINC. The aim of the project was 1) to fabricate representative NDE mock-ups with flaws to simulate PWSCCs, 2) to identify and quantitatively assess NDE methods for accurately detecting, sizing and characterizing PWSCCs, 3) to document the range of locations and morphologies of PWSCCs and 4) to incorporate results with other results of ongoing PWSCC research programs, as appropriate. Korea nuclear industries have also been participating in the project. Thermally and mechanically cracked-four mockups were prepared and phased array and manual ultrasonic testing(UT) techniques were applied. The results and lessons learned from the preliminary RRT are summarized as follows: 1) Korea RRT teams performed the RRT successfully. 2) Crack detection probability of the participating organizations was an average 87%, 80% and 80% respectively. 3) RMS error of the crack sizing showed comparatively good results. 4) The lessons learned may be helpful to perform the PINC RRT and PSI /ISI in Korea in the future.

  16. Model of Layered Weld Formation Under Narrow Gap Pulse Welding

    Science.gov (United States)

    Krampit, A. G.

    2016-04-01

    The model parameters of narrow gap pulse welding can be divided into input, internal and output ones. The breadth of gap, that is, clearance breadth between upright edges is one of key parameters securing high quality of a weld joint. The paper presents theoretical outcomes for the model of layered weld formation under narrow gap pulse welding. Based on these studies is developed model of processes, which occur in the weld pool under pulse grove welding. It comprises the scheme of liquid metal motion in the weld pool, scheme of fusion with the side edge and in the bottom part, and the scheme of welding current impulse effect on the structure of a weld joint.

  17. 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...

  18. An investigation of the microstructures and properties of metal inert gas and friction stir welds in aluminum alloy 5083

    Indian Academy of Sciences (India)

    A R Yazdipour; A Shafiei M; H Jamshidi Aval

    2011-08-01

    Two different types of welds, Metal Inert Gas (MIG) and Friction Stir Welding (FSW), have been used to weld aluminum alloy 5083. The microstructure of the welds, including the nugget zone and heat affected zone, has been compared in these two methods using optical microscopy. The mechanical properties of the weld have been also investigated using the hardness and tensile tests. The results show that both the methods could successfully be used to weld such alloy. The strength of the joints is comparable to the strength of the base metal in both cases. However, FSWed samples have shown higher strength in comparison to the MIG samples. The results also show that the extension of the heat affected zone is higher in the MIG method in comparison to the FSW method. The weld metal microstructure of MIG welded specimen contains equiaxed dendrites as a result of solidification process during MIG welding while FSWed samples have wrought microstructures.

  19. 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.

  20. Mechanical properties of thin films of laser-welded titanium and their associated welding defects.

    Science.gov (United States)

    Wu, Yulu; Xin, Haitao; Zhang, Chunbao; Tang, Zhongbin; Zhang, Zhiyuan; Wang, Weifeng

    2014-11-01

    The aim of this study was to evaluate the mechanical properties of thin films of laser-welded cast titanium using an interference strain/displacement gauge (ISDG) and to analyze factors that affect laser welding. Dog-bone-shaped small specimens of cast titanium were prepared by wire cutting after they were laser-welded. The specimens were divided into three groups according to the gap distance of the laser weld; the control was non-welded titanium. Small specimens without cast defects detected by X-ray screening were measured by a tensile test machine using ISDG, and stress-strain curves were drawn. Finally, the fracture texture was analyzed. The ultimate tensile strengths (UTSs) of specimens with a gap distance of 0.00, 0.25, and 0.50 mm were 492.16 ± 33.19, 488.09 ± 43.18, and 558.45 ± 10.80 MPa, respectively. There were no significant differences in UTS between the test groups and the control group (p > 0.05). However, the plastic deformation and the percent elongation increased as the gap distance increased. Incomplete penetration defects appeared in groups that had small gap distances, which may have affected the properties of the laser-welded titanium. However, the welding material was still pure titanium. These results suggest that an appropriate gap distance should be maintained to improve the application of dental laser welding.

  1. Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

    Energy Technology Data Exchange (ETDEWEB)

    Mohamed, Mohamed Ackiel [University Kuala Lumpur Malaysia France Institute, Bandar Baru Bangi (Malaysia); Manurung, Yupiter HP; Berhan, Mohamed Nor [Universiti Teknologi MARA, Shah Alam (Malaysia)

    2015-06-15

    This study presents the effect of the governing parameters in friction stir welding (FSW) on the mechanical properties and weld quality of a 6mm thick 6061 T651 Aluminum alloy butt joint. The main FSW parameters, the rotational and traverse speed were optimized based on multiple mechanical properties and quality features, which focus on the tensile strength, hardness and the weld quality class using the multi-objective Taguchi method (MTM). Multi signal to noise ratio (MSNR) was employed to determine the optimum welding parameters for MTM while further analysis concerning the significant level determination was accomplished via the well-established analysis of variance (ANOVA). Furthermore, the first order model for predicting the mechanical properties and weld quality class is derived by applying response surface methodology (RSM). Based on the experimental confirmation test, the proposed method can effectively estimate the mechanical properties and weld quality class which can be used to enhance the welding performance in FSW or other applications.

  2. Application of explosive welding to heat exchangers

    Energy Technology Data Exchange (ETDEWEB)

    Arthur, G.

    1983-10-01

    The subject is discussed under the headings: advantages of explosive welding; principle of explosive welding; explosive welding of tubes; metallurgy of explosive welds (micrographs; microhardness); tubular heat exchangers; plugging; sleeving; retubing; construction of new heat exchangers; thermal sleeves.

  3. Thermal stir welding apparatus

    Science.gov (United States)

    Ding, R. Jeffrey (Inventor)

    2011-01-01

    A welding method and apparatus are 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.

  4. 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.

  5. Fusion Welding Research.

    Science.gov (United States)

    2014-09-26

    RD-AlSO 253 FUSION WELDING RESEARCH(U) MASSACHUSETTS INST OF TECH L/I CAMBRIDGE DEPT OF MATERIALS SCIENCE AND ENGINEERING T W EAGAR ET AL. 30 RPR 85...NUMBER 12. GOV’ ACCESSION NO. 3. RECICIE-S CATALOG NUMBER 4. T TL V nd Subtitle) S. P OFRPR PERIOD COVERED 5t h A~nnual Technical Report Fusion Welding ...research S on welding processes. Studies include metal vapors in the arc, development of a high speed infrared temperature monitor, digital signal

  6. Review of Welding Terminology

    Directory of Open Access Journals (Sweden)

    Angelika Petrėtienė

    2011-04-01

    Full Text Available The paper discusses welding terms in accordance with the Lithuanian standard LST EN 1792 „Welding. The multilingual list of welding terms and similar processes”, „The Russian–Lithuanian dictionary of the terms of mechanical engineering technology and welding“ and the examples from postgraduates‘ final works. It analyses the infringement of lexical, word-building and morphological rules. First-year students should already be familiar with the standardized terms of their speciality. More active propagation of the terms should help to avoid terminology mistakes in various scientific spheres.

  7. Characterization of the mechanical properties and structural integrity of T-welded connections repaired by grinding and wet welding

    Energy Technology Data Exchange (ETDEWEB)

    Terán, G., E-mail: gteran@imp.mx [Instituto Mexicano del Petróleo, Eje central Lázaro Cárdenas 152, Col. San Bartolo Atepehuacan, México D.F. CP 07730, México (Mexico); Cuamatzi-Meléndez, R., E-mail: rcuamatzi@imp.mx [Instituto Mexicano del Petróleo, Eje central Lázaro Cárdenas 152, Col. San Bartolo Atepehuacan, México D.F. CP 07730, México (Mexico); Albiter, A., E-mail: aalbiter@imp.mx [Instituto Mexicano del Petróleo, Eje central Lázaro Cárdenas 152, Col. San Bartolo Atepehuacan, México D.F. CP 07730, México (Mexico); Maldonado, C., E-mail: cmzepeda@umich.mx [Instituto de Investigaciones Metalúrgicas, UMSNH, PO Box 52-B, 58000, México (Mexico); Bracarense, A.Q., E-mail: bracarense@ufmg.br [UFMG Departamento de Engeharia Mecánica Belo Horizonte, MG (Brazil)

    2014-04-01

    This paper presents an experimental methodology to characterize the structural integrity and mechanical properties of repaired T-welded connections using in fixed offshore structures. Grinding is employed to remove localized damage like cracking and corrosion and subsequent wet welding can be used to fill the grinded material. But it is important to define the grinding depth and profile in order to maintain structural integrity during the repair. Therefore, in this work different grinding depths were performed, for damage material removal, at the weld toe of the T-welded connections. The grinding was filled by wet welding in a hyperbaric chamber, simulating three different water depths: 50 m, 70 m and 100 m. The electrodes were coated with vinilic varnish, which is cheap and easy to apply. The characterization of the mechanical properties of the T-welded connections was done with standard tensile, hardness and Charpy tests; microstructure and porosity analysis were also performed. The samples were obtained from the welded connections in regions of the wet weld beads. The test results were compared with the mechanical properties of the T-welded connections welded in air conditions performed by other authors. The results showed that the wet welding technique performed in this work produced good mechanical properties of the repaired T-welded connection. The mechanical properties, measured in wet conditions, for 6 mm grinding depth, were similar for the 3 different water depths measured in air conditions. But for 10 mm grinding depth, the values of the mechanical properties measured in wet conditions were quite lower than that for air conditions for the 3 water depths. However a porosity analysis, performed with a Scanning Electronic Microscopy (SEM), showed that the level of porosity in the resulted wet weld beads is in the range of that published in the literature and some samples revealed lower level of porosity. The main resulting microstructure was polygonal

  8. Role of ferrite and phosphorus plus sulphur in the crack sensitivity of autogenously welded type 309 stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Lambert, Jr., F. J.

    1976-07-01

    A study on autogenous welding of Type 309 thin stainless steel sheet was made after experiencing cracking difficulties on several commercial heats. A relationship exists between the sum of the phosphorus plus sulfur, the ferrite control of the weld metal, and the crack sensitivity of autogenously made welds. A new simple weld test for thin-gage sheet is utilized for studying the susceptibility to cracking. A chemistry modification is suggested to alleviate possible weld cracking when autogenously welding this grade. The principles of crack sensitivity prediction could apply to other austenitic stainless steel types where chemistry limits are such that ferrite is possible.

  9. Corrosion behavior of a welded stainless-steel orthopedic implant.

    Science.gov (United States)

    Reclaru, L; Lerf, R; Eschler, P Y; Meyer, J M

    2001-02-01

    The corrosion behavior of combinations of materials used in an orthopedic implant: the spherical part (forged or forged and annealed) constituting the head, the weld (tungsten inert gas (TIG) or electron beam (EB) techniques), and the cylindrical part (annealed) constituting the shaft of a femoral prosthesis - has been investigated. Open-circuit potentials, potentiodynamic curves, Tafel slope, mixed potential theory and susceptibility to intergranular attack are electrochemical and chemical procedures selected for this work. Electrochemical measurements using a microelectrode have been made in the following zones: spherical part, cylindrical part, weld, and weld/sphere, and weld/shaft interfaces. To detect intergranular attack, the Strauss test has been used. At the interfaces, corrosion currents, measured (Icorr) and predicted (Icouple) are low, in the order of the pico- to nanoampere. The electrochemical behavior of the electron beam (EB) weld is better than that of the tungsten inert gas (TIG). Welds at interfaces can behave either anodically or cathodically. It is better if welds, which are sensitive parts of the femoral prosthesis, behave cathodically. In this way, the risk of starting localized corrosion (pitting, crevice or intergranular corrosion) from a galvanic couple, remains low. From this point of view, the sample with the EB weld offers the best behavior. All the other samples containing a TIG type of weld exhibit a less favorable behavior. The mechanical treatments (forged, and forged and annealed) of the steel sphere did not show any difference in the corrosion behavior. No intergranular corrosion has been observed at the weld/steel interface for unsensitized samples. With sensitized samples, however, a TIG sample has exhibited some localized intergranular corrosion at a distance of 500 microm along the weld/stainless steel (sphere) interface.

  10. Butt Welding of 2205/X65 Bimetallic Sheet and Study on the Inhomogeneity of the Properties of the Welded Joint

    Science.gov (United States)

    Gou, Ning-Nian; Zhang, Jian-Xun; Wang, Jian-Long; Bi, Zong-Yue

    2017-03-01

    The explosively welded 2205 duplex stainless steel/X65 pipe steel bimetallic sheets were butt jointed by multilayer and multi-pass welding (gas tungsten arc welding for the flyer and gas metal arc welding for the transition and parent layers of the bimetallic sheets). The microstructure and mechanical properties of the welded joint were investigated. The results showed that in the thickness direction, microstructure and mechanical properties of the welded joint exhibited obvious inhomogeneity. The microstructures of parent filler layers consisted of acicular ferrite, widmanstatten ferrite, and a small amount of blocky ferrite. The microstructure of the transition layer and flyer layer consisted of both austenite and ferrite structures; however, the transition layer of weld had a higher volume fraction of austenite. The results of the microhardness test showed that in both weld metal (WM) and heat-affected zone (HAZ) of the parent filler layers, the average hardness decreased with the increasing (from parent filler layer 1 to parent filler layer 3) welding heat input. The results of hardness test also indicated that the hardness of the WM and the HAZ for the flyer and transition layers was equivalent. The tensile test combined with Digital Specklegram Processing Technology demonstrated that the fracturing of the welded joint started at the HAZ of the flyer, and then the fracture grew toward the base metal of the parent flyer near the parent HAZ. The stratified impact test at -5 °C showed that the WM and HAZ of the flyer exhibited lower impact toughness, and the fracture mode was ductile and brittle mixed fracture.

  11. 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.

  12. 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.

  13. Hybrid laser-arc welding

    DEFF Research Database (Denmark)

    Hybrid laser-arc welding (HLAW) is a combination of laser welding with arc welding that overcomes many of the shortfalls of both processes. This important book gives a comprehensive account of hybrid laser-arc welding technology and applications. The first part of the book reviews...... the characteristics of the process, including the properties of joints produced by hybrid laser-arc welding and ways of assessing weld quality. Part II discusses applications of the process to such metals as magnesium alloys, aluminium and steel as well as the use of hybrid laser-arc welding in such sectors as ship...... building and the automotive industry. With its distinguished editor and international team of contributors, Hybrid laser-arc welding, will be a valuable source of reference for all those using this important welding technology. Professor Flemming Ove Olsen works in the Department of Manufacturing...

  14. 主管道环焊缝横向拉伸试验要求和验收准则的标准对比%Standard Comparison of Tensile Test Requirements and Acceptance Criteria on Ring Welds of Main Pipe

    Institute of Scientific and Technical Information of China (English)

    焦殿辉; 杜爱玲

    2011-01-01

    Main Pipe is the aortic of nuclear power plant reactor coolant system.In a factory,tensile test results of ring welds of main pipe during the simulated weld do not meet RCC-M.Tensile test requirements and acceptance criteria about ring welds of main pipe are compared under different standards.The strict requirements of the regulatory principles were drawn.Then the establishment of standards of nuclear power is the key to the localization of nuclear power,and is the basis for standardization,series and regulation of nuclear power development.Construction of nuclear power needs to establish a set of the national, uniform and complete standards system for pressurized water reactor nuclear power plants in China.%主管道是核电厂反应堆冷却剂系统的主动脉。某制造厂在主管道预制资质取证模拟件制作过程中出现环焊缝横向拉伸试验结果不满足RCC-M标准规范要求,通过对比不同标准规范下的管道环焊缝横向拉伸试验要求和验收准则,得出从严要求的监管原则。从而得出核电标准与规范的编制是核电国产化的关键,是核电发展实现系列化、标准化和规范化的基础,我国核电建设亟需建立一套适应国情的、统一完整的压水堆核电厂标准体系。

  15. Influence of the Tilt Parts on the Phased Array Ultrasonic Testing of the Irregular Structure of Welds%管道不规则接头内外斜台对相控阵超声检测的影响

    Institute of Scientific and Technical Information of China (English)

    蒙殿武; 马君鹏; 张俊; 史亚琨; 张建堂; 李晓红

    2015-01-01

    针对电站管道带台阶不规则接头的相控阵超声检测时,存在声束传播复杂、工艺设计和信号源分析困难等问题,首先建立了相控阵声束在管道不规则接头中的传播模型;其次利用该模型计算和分析了典型斜台结构对声束的遮挡、探头最佳入射点、内斜台产生反射声束的偏转方向等影响;最后利用该模型对现场管道三通与弯头处不规则接头相控阵超声检测工艺及结果进行辅助分析。结果表明:所提出的声线分析模型可以准确评估内外斜台对声束传播造成的影响,预测结构回波,为相控阵超声检测管道不规则接头的工艺和信号分析提供了重要的依据。%The phased array ultrasonic test of the irregular structures of welds with the tilt parts in power plant is difficult because of the complexity on the procedure design and signal analysis.Firstly,the acoustic line model for the propagation of phased array ultrasonic filed in the weld of irregular structures is established based on Snell law. Secondly,the model is used to calculate and analyze the influence of the tilt parts on the shielding beams,incident points,reflection beams.Finally,the model was applied to analyze the ultrasonic phased array testing process and the results of the in-situ irregular structures of welded joint at the tee bend and elbow.The results indicate that the established model provide an efficient tool for the procedure design and signal analysis of the phased array ultrasonic testing of the irregular structures of welds.

  16. CO2 laser welding of magnesium alloys

    Science.gov (United States)

    Dhahri, Mohammed; Masse, Jean Eric; Mathieu, J. F.; Barreau, Gerard; Autric, Michel L.

    2000-02-01

    Metallic alloys with a low mass density can be considered to be basic materials in aeronautic and automotive industry. Magnesium alloys have better properties than aluminum alloys in respect of their low density and high resistance to traction. The main problems of magnesium alloy welding are the inflammability, the crack formation and the appearance of porosity during the solidification. The laser tool is efficient to overcome the difficulties of manufacturing by conventional processing. Besides, the laser processing mainly using shielding gases allows an effective protection of the metal against the action of oxygen and a small heat affected zone. In this paper, we present experimental results about 5 kW CO2 laser welding of 4 mm-thick magnesium alloy plates provided by Eurocopter France. The focused laser beam has about 0.15 mm of diameter. We have investigated the following sample: WE43, alloy recommended in aeronautic and space applications, is constituted with Mg, Y, Zr, rare earth. More ductile, it can be used at high temperatures until 250 degrees Celsius for times longer than 5000 hours without effects on its mechanical properties. A sample of RZ5 (French Norm: GZ4TR, United States Norm ZE41) is composed of Mg, Zn, Zr, La, rare earth. This alloy has excellent properties of foundry and it allows to the realization of components with complex form. Also, it has a good resistance and important properties of tightness. The parameters of the process were optimized in the following fields: laser power: 2 to 5 kW, welding speed: 1 to 4.5 m/min, focal position: -3 mm to +3 mm below or on the top of the metal surface, shielding gas: helium with a flow of 10 to 60 l/min at 4 bars. Metallurgical analyses and mechanical control are made (macroscopic structure, microscopic structure, interpretations of the structures and localization of possible defects, analyse phases, chemical composition, hardness, tensile test etc.) to understand the parameters influence of welding

  17. Effect of Welding Parameters on Microstructure and Mechanical Properties of Cast Fe-40Al Alloy

    Directory of Open Access Journals (Sweden)

    Osman Torun

    2016-09-01

    Full Text Available Friction welding of cast Fe-40Al alloy was carried out at 1000 rmp for various friction times, friction pressures, and forging pressures. The microstructures of the interface of welded samples were analyzed by optical and scanning electron microscopy (SEM. Micrographs demonstrated that excellent welding formed continuously along the interface, except for samples welded for 3 s. Chemical compositions of the interface of the friction welded samples and of the fractured surface of all the specimens were determined using energy dispersive spectroscopy (EDS. After the welding process, shear tests were applied to the welded samples to determine the shear strength of joints. Test results indicated that the maximum shear strength was 469.5 MPa.

  18. 超超临界锅炉小径管焊缝的超声相控阵检测工艺%Ultrasonic Phased Array Testing for Small Diameter Tube Weld of Ultra-supercritical Boiler

    Institute of Scientific and Technical Information of China (English)

    王维东; 王亦民; 孟倩倩; 曹云峰; 张振华

    2015-01-01

    A series of ultrasonic phased array inspection contrast test blocks were developed according to the distribution range of the boiler pipe weld defect,and at the same time tests were conducted on the simulation and natural defects,respectively.By making distance amplitude curve for 1 mm diameter horizontal hole,we quantified and measured indicating length of defects both inside and outside of the tube with different diameter and thickness, and thus corrected the errors of the traditional detection and established the testing method of ultrasonic phased array for small pipe weld.%根据锅炉小径管焊缝的缺陷分布范围,研制出系列超声相控阵检测的对比试块,并进行了模拟与自然缺陷的检测试验。测试采用ϕ1 mm横孔制作距离-波幅曲线,对不同外径与壁厚的内外壁缺陷进行定量与指示长度测定,修正了传统检测的误区,建立了超声相控阵小径管焊缝的检测工艺方法。

  19. Influence of Friction Stir Welding on Corrosion Properties of Aw-7020M Alloy in Sea Water

    Directory of Open Access Journals (Sweden)

    Dudzik K.

    2015-03-01

    Full Text Available Friction Stir Welding (FSW, provides an alternative to MIG and TIG welding methods for joining aluminium alloys. The article presents the results of electrochemical corrosion resistance test of alloy AW- 7020M and its joints welded by FSW. The study was performed using the method of electrochemical impedance spectroscopy (EIS. Impedance spectroscopy studies showed that both, the FSW welded joint and base material AW-7020M has a good resistance to electrochemical corrosion in sea water environment, wherein the welded joint has a higher susceptibility to this type of corrosion. Research has indicated the desirability of applying the FSW method for joining AW-7020M alloy in shipbuilding industry.

  20. Effects of surface treatments of galvanized steels on projection welding procedure

    Institute of Scientific and Technical Information of China (English)

    王敏; 王宸煜

    2003-01-01

    A group of projection welding experiments and joints tension-shear tests are carried out for cold-rolled steel sheets, galvanized steel sheets (GSS) without treatment, GSS with phosphating and GSS with surface greasing, respectively. The experimental results are regressively analyzed on the computers, then the projection welded joint tension-shear strength curve and the perfect welding currents range of each material are obtained. The results show that surface treatments of galvanized steels have effects on their spot weldabilities. Among the four kinds of materials, GSS with surface greasing have the worst spot weldability, for they need higher welding current and have a narrow welding current range.

  1. Studies on corrosion protection of laser hybrid welded AISI 316 by laser remelting

    DEFF Research Database (Denmark)

    Olsen, Flemming Ove; Ambat, Rajan; Rasmussen, A.J.

    2005-01-01

    laser surface melting on microstructure and corrosion behaviour of AISI 316L welds. Welding and laser treatment parameters were varied. General corrosion behaviour of the weld and laser treated surface was characterised using a gel visualization test. The local electrochemistry of the weld and laser...... treated surface was investigated using a novel micro electrochemical technique with a tip resolution of ~1 mm. Results show that hybrid laser welding of 316L has increased corrosion susceptibility probably as a result of grain boundary carbide formation. However a suitable post laser treatment could...

  2. Cold Cracking Of Underwater Wet Welded S355G10+N High Strength Steel

    Directory of Open Access Journals (Sweden)

    Fydrych D.

    2015-09-01

    Full Text Available Water as the welding environment determines some essential problems influencing steel weldability. Underwater welding of high strength steel joints causes increase susceptibility to cold cracking, which is an effect of much faster heat transfer from the weld area and presence of diffusible hydrogen causing increased metal fragility. The paper evaluates the susceptibility to cold cracking of the high strength S355G10+N steel used, among others, for ocean engineering and hydrotechnical structures, which require underwater welding. It has been found from the CTS test results that the investigated steel is susceptible to cold cracking in the wet welding process.

  3. 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.

  4. 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.

  5. 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.

  6. Precipitation of Niobium Boride Phases at the Base Metal/Weld Metal Interface in Dissimilar Weld Joints

    Science.gov (United States)

    Výrostková, Anna; Kepič, Ján; Homolová, Viera; Falat, Ladislav

    2015-07-01

    In this work, the analysis of failure mechanism in the heat affected zone is described in dissimilar weld joints between advanced martensitic steel T92 and Ni-base weld metal. The joints were treated with two different post-weld heat treatments and tested. For the creep, tensile, and Charpy impact tests, the samples with interfacially located notch were used. Moreover long term aging at 625 °C was applied before the tensile and notch toughness tests. Decohesion fractures ran along carbides at the T92 BM/WM interfaces in case of the modified PWHT, whereas type IV cracking was the prevailing failure mechanism after the classical PWHT in the creep test. In the notch tensile and Charpy impact tests, with the notch at T92 base metal/weld metal interface, fractures ran along the interface with a hard phase on the fracture surface along with the ductile dimple and brittle quasi-cleavage fracture. The phase identified as niobium boride (either NbB and/or Nb3B2) was produced during welding at the end of the solidification process. It was found in the welds regardless of the post-weld heat treatment and long-term aging.

  7. GAP WIDTH STUDY IN LASER BUTT-WELDING

    DEFF Research Database (Denmark)

    Gong, Hui; Olsen, Flemming Ove

    In this paper the maximum allowable gap width in laser butt-welding is intensively studied. The gap width study (GWS) is performed on the material of SST of W1.4401 (AISI 316) under various welding conditions, which are the gap width : 0.00-0.50 mm, the welding speed : 0.5-2.0 m/min, the laser...... to the welding speed, (2) the larger laser power leads to the bigger maximum allowable gap width and (3) the focal point position has very little influence on the maximum gap width....... power : 2 and 2.6 kW and the focal point position : 0 and -1.2 mm. Quality of all the butt welds are destructively tested according to ISO 13919-1.Influences of the variable process parameters to the maximum allowable gap width are observed as (1) the maximum gap width is inversely related...

  8. Laser Welding Of Thin Sheet Of AISI 301 Stainless Steel

    Science.gov (United States)

    Vilar, R.; Miranda, R. M.

    1989-01-01

    Preliminary results of an investigation on laser welding of AISI 301 stainless steel thin sheet are presented. Welds were made with a CO2 continuous wave laser, varying power density and welding speed. The welds were studied by optical and electron scanning microscopy, X-ray diffraction and hardness tests. Experimental results show that under appropriate conditions, sound welds are obtained, with a negligeable heat affected zoneanda fine microstructure in the fusion zone. The fusion zone shows a cellular - dendritic microstructure, with austenite and ferrite as the major constituents. Ferrite, whose content is 5 to 7%, is predominantly intradendritic with both vermicular and acicular morphologies. However some interdendritic ferrite may also be present. The characteristics of the structure suggest that the solidification mode of AISI 301 stainless steel is essentially ferritic.

  9. HIGH FREQUENCY INDUCTION WELDING OF HIGH SILICON STEEL TUBES

    Directory of Open Access Journals (Sweden)

    Ricardo Miranda Alé

    2012-06-01

    Full Text Available High-Si steel is a low cost alternative for the fabrication of tubular structures resistant to atmospheric corrosion. However, the literature has often pointed out that steels presenting a higher Si content and/or a lower Mn/Si ratio have higher susceptibility to defects at the weld bond line during HFIW (High Frequency Induction Welding process, which has been widely used for manufacturing small diameter tubes. In this study the effect of the HFIW conditions on the quality of steel tubes with high-Si content and low Mn/Si ratio is investigated. The quality of welded tubes was determined by flare test and the defects in the bond line were identified by SEM. It has been found that higher welding speeds, V-convergence angles and power input should be applied in welding of high-Si steel, when compared to similar strength C-Mn steel.

  10. Welding technique studies on the "West-East" pipeline project

    Institute of Scientific and Technical Information of China (English)

    Sui Yongli; Du Zeyu; Huang Fuxiang; Qi Lichun

    2006-01-01

    This paper described the work of welding process design for the "West-East" pipeline project, which is high pressure, large diameter and heavy wall thickness. According to the different geographical situation, climate, culture and the flexibility of the welding methods, this work recommended the semi-automatic process at the east and middle sections and automatic process at the west section of the pipeline project. The manual process is recommended on the tie-in joints and repairs. The double joint pipe and the 3 joint pipe are recommended at the water net place and some in-ditch welding place to reduce the welding volume. Also the special redesigned bevels are recommended for the automatic process and the semiautomatic process. Through all destructive tests, the results shows the welds are meet the requirements of related standards,specifications and design documents.

  11. Development of simplified finite element models for welded joints

    Energy Technology Data Exchange (ETDEWEB)

    Song, Seong Il; Ahn, Sung Wook; Kim, Young Geul; Kim, Hyun Gyu [Dept. of Mechanical and Automotive Engineering, Seoul National University of Science and Technology, Seoul (Korea, Republic of)

    2015-11-15

    In this paper, we develop simplified finite element (FE) models for butt-, lap- and T-welded joints by performing numerical and experimental experiments. Three-point bending tests of butt- and lap-welded specimens are performed to obtain the stiffness of the specimens and the strains at points near the welding beads. Similarly the stiffness and strains of T-welded specimen are measured by applying a point load at the end of the specimen. To develop simplified FE models, we consider the shape parameters of width, thickness and the angle of weld elements in the numerical simulations. The shape parameters of the simplified FE models are determined by building linear regression models for the experimental data sets.

  12. Corrosion of friction stir welded magnesium alloy AM50

    Energy Technology Data Exchange (ETDEWEB)

    Zeng Rongchang [School of Material Science and Engineering, Chongqing University of Technology, Xingshenglu Rd. 4, Chongqing 400050 (China)], E-mail: rczeng2001@yahoo.com.cn; Chen Jun [School of Material Science and Engineering, Chongqing University of Technology, Xingshenglu Rd. 4, Chongqing 400050 (China); Dietzel, Wolfgang; Zettler, Rudolf; Santos, Jorge F. dos [GKSS-Forschungszentrum Geesthacht GmbH, Max Planck Strasse 1, 21502 Geesthacht (Germany); Lucia Nascimento, M. [Technische Universitaet Berlin, Fachgebiet Werkstofftechnik, Strasse des 17. Juni 135, 10623 Berlin (Germany); Kainer, Karl Ulrich [GKSS-Forschungszentrum Geesthacht GmbH, Max Planck Strasse 1, 21502 Geesthacht (Germany)

    2009-08-15

    The microstructure of a friction stir welded magnesium alloy AM50 was examined by means of optical light microscopy. The chemical composition, particularly the iron content, and morphology of the oxide film were analyzed and discerned via auger electron spectroscopy (AES) and X-ray photoelectron spectroscopy (XPS). Corrosion behaviour of the welds and base materials were investigated by virtue of neutral salt spray tests and potentiodynamic polarization measurements in conventional cells and in a mini cell. The results demonstrate that minor increases in iron concentration as might be speculated to occur as a consequence of tool/work piece interaction during the welding process on the corrosion resistance of the weld can be ignored. The corrosion morphology was predominantly influenced by the distribution of the Mg{sub 17}Al{sub 12} phase. Here, it was also found that the corrosion resistance of the friction stir weld varied in response to changes in the joint microstructure.

  13. Development of Simplified Finite Element Models for Welded Joints

    Energy Technology Data Exchange (ETDEWEB)

    Song, Seong Il; Ahn, Sung Wook; Kim, Young Geul; Kim, Hyun Gyu [Seoul National Univ. of Sci. and Tech., Seoul (Korea, Republic of)

    2015-11-15

    In this paper, we develop simplified finite element (FE) models for butt-, lap- and T-welded joints by performing numerical and experimental experiments. Three-point bending tests of butt- and lap-welded specimens are performed to obtain the stiffness of the specimens and the strains at points near the welding beads. Similarly the stiffness and strains of T-welded specimen are measured by applying a point load at the end of the specimen. To develop simplified FE models, we consider the shape parameters of width, thickness and the angle of weld elements in the numerical simulations. The shape parameters of the simplified FE models are determined by building linear regression models for the experimental data sets.

  14. Bonding mechanisms in spot welded three layer combinations

    DEFF Research Database (Denmark)

    Moghadam, Marcel; Tiedje, Niels Skat; Seyyedian Choobi, Mahsa;

    2016-01-01

    this interface. It has been shown previously that such a joint can reach relatively high strength resulting in plug failure in tensileshear testing. Additional strength due to these bonding mechanisms is also obtained in common spot welds in the so-called corona band around the weld nugget.......The strength of a spot weld generally stems from fusion bonding of the metal layers, but other solid state bonding mechanisms also contribute to the overall strength. Metallographic analyses are presented to identify the phases formed near and across the weld interfaces and to identify...... the occurring bonding mechanisms. When welding a combination of three galvanized steel layers where one outer layer is a thin low-carbon steel it is a common challenge to obtain nugget penetration into the thin low-carbon steel. It therefore happens in real production that no nugget is formed across...

  15. Friction stir welding tool

    Science.gov (United States)

    Tolle; Charles R. , Clark; Denis E. , Barnes; Timothy A.

    2008-04-15

    A friction stir welding tool is described and which includes a shank portion; a shoulder portion which is releasably engageable with the shank portion; and a pin which is releasably engageable with the shoulder portion.

  16. Magnetic Pulse Welding Technology

    Directory of Open Access Journals (Sweden)

    Ahmad K. Jassim

    2011-12-01

    Full Text Available In this paper, the benefits of using Magnetic Pulse machine which is belong to Non-conventional machine instead of conventional machine. Magnetic Pulse Technology is used for joining dissimilar metals, and for forming and cutting metals. It is a non contact technique. Magnetic field is used to generate impact magnetic pressure for welding and forming the work piece by converted the electrical energy to mechanical energy. It is enable us to design previously not possible by welding dissimilar materials and allowing to welds light and stronger materials together. It can be used to weld metallic with non metallic materials to created mechanical lock on ceramics, polymers, rubbers and composites. It is green process; there is no heat, no radiation, no gas, no smoke and sparks, therefore the emissions are negligible.

  17. Study of fatigue behavior of longitudinal welded pipes

    Science.gov (United States)

    Simion, P.; Dia, V.; Istrate, B.; Hrituleac, G.; Hrituleac, I.; Munteanu, C.

    2016-08-01

    During transport and storage of the various fluids, welded pipes are subjected to cyclic loading due to pressure fluctuations that often exceed the prescribed values for normal operation. These cyclic loading can significantly reduce the life of the pipes; as a result the design should be based on the fatigue strength not only on static resistance. In general the fatigue strength of pipes is dependent by strength, pipe geometry and surface quality. In case of the electric longitudinal welded pipes, the fatigue strength is significantly limited by concentration of residual stress and the size of existing defects in the weld seam. This paper presents the fatigue behaviour of the electric welded pipes by high frequency, under conditions that simulate real operating conditions pipes. Fatigue testing was performed on welded pipes made of micro alloyed carbon steels. Some of these pipes were previously subjected to a heat treatment of normalization, in order to also determine the influence of heat treatment on the fatigue strength of welded pipes. To determine and correlate the different factors affecting the fatigue strength, welded pipes were also subjected to various tests: tensile tests, impact tests, measurement of micro hardness, microstructural analysis by optical microscopy and scanning electron microscopy.

  18. Weld overlay cladding with iron aluminides

    Energy Technology Data Exchange (ETDEWEB)

    Goodwin, G.M. [Oak Ridge National Lab., TN (United States)

    1997-12-01

    The author has established a range of compositions for these alloys within which hot cracking resistance is very good, and within which cold cracking can be avoided in many instances by careful control of welding conditions, particularly preheat and postweld heat treatment. For example, crack-free butt welds have been produced for the first time in 12-mm thick wrought Fe{sub 3}Al plate. Cold cracking, however, still remains an issue in many cases. The author has developed a commercial source for composite weld filler metals spanning a wide range of achievable aluminum levels, and are pursuing the application of these filler metals in a variety of industrial environments. Welding techniques have been developed for both the gas tungsten arc and gas metal arc processes, and preliminary work has been done to utilize the wire arc process for coating of boiler tubes. Clad specimens have been prepared for environmental testing in-house, and a number of components have been modified and placed in service in operating kraft recovery boilers. In collaboration with a commercial producer of spiral weld overlay tubing, the author is attempting to utilize the new filler metals for this novel application.

  19. Method for laser spot welding monitoring

    Science.gov (United States)

    Manassero, Giorgio

    1994-09-01

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

  20. Explosive Welding with Nitroguanidine.

    Science.gov (United States)

    Sadwin, L D

    1964-03-13

    By using the explosive nitroguanidine, continuous welds can be made between similar and dissimilar metals. Since low detonation pressures are attainable, pressure transfer media are not required between the explosive and the metal surface. The need for either a space or an angle between the metals is eliminated, and very low atmospheric pressures are not required. Successful welds have been made between tantalum and 4140 steel, 3003H14 aluminum and 4140 steel, and 304 stainless steel and 3003H14 aluminum.

  1. Laser Impact Welding

    OpenAIRE

    Daehn, Glenn S.; Lippold, John; Liu, Deijan; Taber, Geoff; Wang, Huimin

    2012-01-01

    Laser impact welding is a solid-state, collision-based welding process. In this process, laser-generated optical energy is converted to kinetic energy through the ablation at the surface and confinement of the gas generated between a flyer and backing plate. The launch of the flyer can be affected by many factors, for example, backing material, ablative layer, and flyer thickness. In this paper, the effect of three backing materials: glass, polycarbonate and cellophane tape, we...

  2. Welding of solid wood

    OpenAIRE

    Ivica Župčić; Goran Mihulja; Andrija Bogner; Ivica Grbac; Ivica @up~i}, Goran Mihulja, Andrija Bogner, Ivica Grbac,; Božidar Hrovat

    2008-01-01

    This paper presents the up-to-date knowledge and results of the application of wood welding techniques at the Faculty of Forestry University of Zagreb. Wood welding technologies have been developed as a new way of bonding timber by using high temperature generatedby friction and pressure. Timber is assembled without any adhesives. During the process the surface layer of timber (lignin), which is in direct contact with its counterpart, melts due to high pressure and temperature, which is usual...

  3. Characterization of Cassini GPHS Fueled-Clad Production Girth Welds

    Energy Technology Data Exchange (ETDEWEB)

    Franco-Ferreira, E.A.

    2000-03-23

    Fueled clads for radioisotope power systems are produced by encapsulating {sup 238}PuO{sub 2} in iridium alloy cups, which are joined at their equators by gas tungsten arc welding. Cracking problems at the girth weld tie-in area during production of the Galileo/Ulysses GPHS capsules led to the development of a first-generation ultrasonic test for girth weld inspection at the Savannah River Plant. A second-generation test and equipment with significantly improved sensitivity and accuracy were jointly developed by the Oak Ridge Y-12 Plant and Westinghouse Savannah River Company for use during the production of Cassini GPHS capsules by the Los Alamos National Laboratory. The test consisted of Lamb wave ultrasonic scanning of the entire girth weld from each end of the capsule combined with a time-of-flight evaluation to aid in characterizing nonrelevant indications. Tangential radiography was also used as a supplementary test for further evaluation of reflector geometry. Each of the 317 fueled GPHS capsules, which were girth welded for the Cassini Program, was subjected to a series of nondestructive tests that included visual, dimensional, helium leak rate, and ultrasonic testing. Thirty-three capsules were rejected prior to ultrasonic testing. Of the 44 capsules rejected by the standard ultrasonic test, 22 were upgraded to flight quality through supplementary testing for an overall process acceptance rate of 82.6%. No confirmed instances of weld cracking were found.

  4. 2205不锈钢焊接接头疲劳裂纹扩展试验及分析%2205 Duplex Stainless Steel Welded Joint Fatigue Crack Growth Test and Analysis

    Institute of Scientific and Technical Information of China (English)

    张帅谋; 张雪峰; 陈彪

    2015-01-01

    2205 duplex stainless steel was welded using IGTB inverter type CO 2 gas shielded welding .Ac-cording to the standard GB6398-2000, the fatigue crack growth test of welded joint was carried out .Through testing the fatigue crack growth rate , and using Matlab software and Paris equation of linear regression analysis of data, the fatigue crack growth rate lg ( da /dN ) -lgΔK curve of different regions of the butt joint was gotten . The results show that the difference between butt joint's fatigue crack growth rates is remarkable at the same stress ratio.The heat affected zone's fatigue crack growth rate is the fastest while the welding zone is the lowest .The fa-tigue fracture was observed using SEM method , and the reason why the difference between butt joint's fatigue crack growth rates is remarkable was interpreted .%采用IGTB逆变式CO2气体保护焊对2205双相不锈钢进行焊接,形成焊接接头;并根据标准GB6398-2000对接头进行疲劳裂纹扩展试验。通过疲劳裂纹扩展速率测试,利用Matlab软件和Paris线性回归方程分析数据,得到对接接头上焊缝区、热影响区和母材区的疲劳裂纹扩展速率lg( da /dN )-lgΔK曲线。结果显示,给定的应力比工作条件下,疲劳裂纹在对接接头各区域的扩展速率差别较大,热影响区的扩展速率较快,母材次之,焊缝金属最慢。并利用SEM方法观察了疲劳断口,分析了产生疲劳裂纹扩展速率不同的原因。

  5. Método integral configurable y flexible de ensayo de materiales consumibles de soldadura por arco eléctrico. // Integral, flexible and shaped method for electric arc welding consumable materials test.

    Directory of Open Access Journals (Sweden)

    A. García Rodríguez

    2005-05-01

    Full Text Available La presente publicación propone un método integral configurable y flexible para facilitar el ensayo de materialesconsumibles de soldadura por arco eléctrico en las condiciones tecnológicas para las que han sido diseñados estosmateriales, en relación a la calidad de la unión soldada. Se puede llegar a conclusiones definitivas sobre la calidad de lasoldadura usando un determinado material consumible mediante: la relación operacional de técnicas de inteligencia naturaly/o artificial, el uso de sistemas expertos, el trabajo con bases de datos, la simulación y la realización práctica del procesomientras se registran ciertos parámetros del arco eléctrico, digitalmente procesados estadísticamente y relacionados a losresultados de la caracterización de la unión soldada. El método permite registrar adecuadamente la información referente acada aspecto del proceso exigida en los procesos de certificación de la calidad de los consumibles, así como en lainvestigación dirigida a optimizar la composición química y las propiedades físicas de un material, para obtener calidadesóptimas en un determinado proceso; además es posible obtener las bases de datos de parámetros del arco eléctrico útilespara investigar, desarrollar y valorar métodos y algoritmos para el monitoreo en tiempo real de la calidad de la soldaduradurante un determinado proceso tecnológico de soldadura con arco eléctrico.Palabras Clave: Ensayo, materiales, soldadura, arco eléctrico, estabilidad, calidad, simulación, optimización,unión soldada.___________________________________________________________________________Abstract.This paper presenst an integral, flexible and shaped method that make easy the electric arc welding consumable materials test at thedesigned technological conditions, related to the quality of the welding joint. It is possible to arrive to definitive conclusions about thewelding quality using a fixed material through: operational

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

    Science.gov (United States)

    Shoja Razavi, Reza

    2016-08-01

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

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

    Science.gov (United States)

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

    2017-08-01

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

  8. Welding development for V-Cr-Ti alloys

    Energy Technology Data Exchange (ETDEWEB)

    King, J.F.; Goodwin, G.M.; Alexander, D.J. [Oak Ridge National Lab., TN (United States)

    1995-04-01

    A vanadium structure, cooled with helium, is a favored concept for an advanced breeding blanket for fusion systems. The objective of this task is to develop the metallurgical and technological base for the welding of thick sections of V-Cr-Ti. The subsize Charpy test results for electron beam weld metal from the V-5Cr-5Ti alloy has shown significant improvement in Charpy fracture energy compared to both gas tungsten arc weld metal and the base metal itself. These results are preliminary, however, and additional confirmation testing and analysis will be required to explain this improvement in properties.

  9. 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

  10. Investigations into the microstructure-toughness relation in high frequency induction welded pipes

    Energy Technology Data Exchange (ETDEWEB)

    Gungor, O. E.; Thibaux, P.; Liebeherr, M. [ArcelorMittal Global RnD Ghent, Zelzate, (Belgium); Yan, P.; Bhadeshia, H. K. D. H. [Material Science and Mettalurgy, University of Cambridge, (United Kingdom); Quidord, D. [ArcelorMittal Commercial FCE, Fos-sur-Mer, (France)

    2010-07-01

    High frequency induction is frequently used in the production of longitudinally welded pipes for gas transmission but there is some concern about the lower toughness of the weld metal. The HFI welds require in-line post-weld heat treatment (PWHT) to ensure better weld properties. This study investigated the effect of the high frequency induction (HFI) welding process and in-line post-weld heat treatment on weld properties. Tests were performed on HFI welded X65 pipes with a diameter of 24''. Mechanical properties of the pipes were evaluated using Charpy impact (V-notch) and tensile tests before and after PWHT. The EBSD technique was used to study the microtexture and grain structure of the welds. The results showed that the toughness of the bond line after PWHT was sufficiently high, but it is still lower than that of the base material. The coarse crystallographic grain size at the junction of the welds was found to be one of the main reasons for the low toughness.

  11. The Effect of Tool Position for Aluminum and Copper at High Rotational Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Recep Çakır

    2015-12-01

    Full Text Available Friction Stir Welding (FSW is a solid state welding process used for welding similar and dissimilar materials. This welding technique allows welding of Aluminum alloys which present difficulties in fusion joining and allows different material couples to be welded continuously. In this study, 1050 aluminum alloy and commercially pure copper to increase heat input were produced at high rotation rate (2440 rev/min with four different pin position (0-1-1.5-2 mm and three different weld speeds (20-30-50 mm/min by friction stir welding. The influence of welding parameters on microstructure and mechanical properties of the joints was investigated. Tensile and bending tests and microhardness measurements were used to determine of mechanical properties. Nugget zone microstructures were investigated by optical microscope and scanning electron microscope (SEM and were analyzed in energy-dispersive X-ray spectroscopy (EDX. Depending on the XRD analysis results intermetallic phase was observed to form in the interfacial region. In the tensile test results, 83.55% weld performance was obtained in the friction stir welding merge of Al-Cu.

  12. Fatigue Properties of Welded Butt Joint and Base Metal of MB8 Magnesium Alloy

    Directory of Open Access Journals (Sweden)

    Ying-xia YU

    2016-09-01

    Full Text Available The fatigue properties of welded butt joint and base metal of MB8 magnesium alloy were investigated. The comparative fatigue tests were carried out using EHF-EM200K2-070-1A fatigue testing machine for both welded butt joint and base metal specimens with the same size and shape. The fatigue fractures were observed and analyzed by a scanning electron microscope of 6360 LA type. The experimental results show that the fatigue performance of the welded butt joint of MB8 magnesium alloy is sharply decreased. The conditional fatigue limit (1×107 of base metal and welded butt joint is about 69.41 and 32.76 MPa, respectively. The conditional fatigue limit (1×107 of the welded butt joint is 47.2 % of that of base metal. The main reasons are that the welding can lead to stress concentration in the weld toe area, tensile welding residual stress in the welded joint, as well as grain coarsening in the welding seam. The cleavage steps or quasi-cleavage patterns present on the fatigue fracture surface, indicating the fracture type of the welded butt joint belongs to a brittle fracture.DOI: http://dx.doi.org/10.5755/j01.ms.22.3.9132

  13. 超声衍射时差法检测汽水管道环焊缝根部腐蚀减薄%Time-of-Flight-Diffraction Testing of Steam and Water Piping Circumferential Weld Roots Local Wall-thinning

    Institute of Scientific and Technical Information of China (English)

    钟志民; 张维; 汪明辉

    2016-01-01

    The field feedbacks show that the industry should pay more attention to secondary loop steam and water piping circumferential weld root flow-accelerated corrosion(FAC)in Nuclear Power Plants from field feedbacks. Without effective inspection and supervision, it will lead to serious consequences such as high energy pipe leakage or rupture. The weld root Ultrasonic Time of Flight Diffraction(TOFD) inspection principle and testing results were discussed in detail. It was shown that TOFD can be applied to inspect local wall-thinning ,caused by flow-accelerated corrosion, at circumferential weld roots of secondary loop steam & water piping in nuclear power plants.%工程经验反馈表明,过往关注较少的核电站二回路汽水管道环焊缝根部由流动加速腐蚀引起的局部减薄现象应引起业界重视,如不进行有效的检测和监督,也会导致高能管道泄漏或破裂.本文重点探讨了核电站二回路汽水管道环焊缝根部局部减薄超声衍射时差法的检测原理、试验情况.结果表明,超声衍射时差法可用于检测流动加速腐蚀引起的汽水管道环焊缝根部局部减薄.

  14. The study on the properties of AISI 4140 and AISI 1040 steel rods welded by friction welding

    Directory of Open Access Journals (Sweden)

    Thanee Toomprasen

    2014-06-01

    Full Text Available This paper is aimed to investigate the properties of joint between AISI 4140 and AISI 1040 welded by friction welding. The specimens were prepared in round shape of 13 mm diameter and 100 mm long. They were welded by friction welding method under the following conditions; friction pressure of 183 MPa, friction time of 12 sec, upset pressure of 428 MPa, upset time of 7 sec. and rotational speed of 1400 rpm. The strength and hardness were tested on the welded area. The result showed finer grains. in the welded area. This is the result of friction pressure and upset pressure in the welding process. In addition, the observation result indicated some changes of Ferrite and Pearlite in welded zone. This phase change resulted in the increment of hardness in AISI 4140 at the contact area and adjacent. In part of AISI 1040, the portion of Pearlite and Ferrite are not significantly changed, therefore the value of hardness is almost constant.

  15. Assessment of Nugget Size of Spot Weld using Neutron Radiography

    Directory of Open Access Journals (Sweden)

    Triyono

    2011-08-01

    Full Text Available Resistance spot welding (RSW has been widely used for many years in the fabrication of car body structures, mainly due to the cost and time considerations. The weld quality as well as the nugget size is an issue in various manufacturing and processes due to the strong link between the weld quality and safety. It has led to the development of various destructive and non-destructive tests for spot welding such as peel testing, ultrasonic inspections, digital shearography, and infrared thermography. However, such methods cannot show spot weld nugget visually and the results are very operator’s skill dependent. The present work proposes a method to visualize the nugget size of spot welds using neutron radiography. Water, oil and various concentrations of gadolinium oxide-alcohol mixture were evaluated as a contrast media to obtain the best quality of radiography. Results show that mixture of 5 g gadolinium oxide (Gd2O3 in 25 ml alcohol produces the best contrast. It provides the possibility to visualize the shape and size of the nugget spot weld. Furthermore, it can discriminate between nugget and corona bond. The result of neutron radiography evaluation shows reasonable agreement with that of destructive test.

  16. Prediction of Weld Penetration in FCAW of HSLA steel using Artificial Neural Networks

    Science.gov (United States)

    Asl, Y. Dadgar; Mostafa, N. B.; Panahizadeh R., V.; Seyedkashi, S. M. H.

    2011-01-01

    Flux-cored arc welding (FCAW) is a semiautomatic or automatic arc welding process that requires a continuously-fed consumable tubular electrode containing a flux. The main FCAW process parameters affecting the depth of penetration are welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed. Shallow depth of penetration may contribute to failure of a welded structure since penetration determines the stress-carrying capacity of a welded joint. To avoid such occurrences; the welding process parameters influencing the weld penetration must be properly selected to obtain an acceptable weld penetration and hence a high quality joint. Artificial neural networks (ANN), also called neural networks (NN), are computational models used to express complex non-linear relationships between input and output data. In this paper, artificial neural network (ANN) method is used to predict the effects of welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed on weld penetration depth in gas shielded FCAW of a grade of high strength low alloy steel. 32 experimental runs were carried out using the bead-on-plate welding technique. Weld penetrations were measured and on the basis of these 32 sets of experimental data, a feed-forward back-propagation neural network was created. 28 sets of the experiments were used as the training data and the remaining 4 sets were used for the testing phase of the network. The ANN has one hidden layer with eight neurons and is trained after 840 iterations. The comparison between the experimental results and ANN results showed that the trained network could predict the effects of the FCAW process parameters on weld penetration adequately.

  17. Welding of nickel free high nitrogen stainless steel: Microstructure and mechanical properties

    Directory of Open Access Journals (Sweden)

    Raffi Mohammed

    2017-04-01

    Full Text Available High nitrogen stainless steel (HNS is a nickel free austenitic stainless steel that is used as a structural component in defence applications for manufacturing battle tanks as a replacement of the existing armour grade steel owing to its low cost, excellent mechanical properties and better corrosion resistance. Conventional fusion welding causes problems like nitrogen desorption, solidification cracking in weld zone, liquation cracking in heat affected zone, nitrogen induced porosity and poor mechanical properties. The above problems can be overcome by proper selection and procedure of joining process. In the present work, an attempt has been made to correlate the microstructural changes with mechanical properties of fusion and solid state welds of high nitrogen steel. Shielded metal arc welding (SMAW, gas tungsten arc welding (GTAW, electron beam welding (EBW and friction stir welding (FSW processes were used in the present work. Optical microscopy, scanning electron microscopy and electron backscatter diffraction were used to characterize microstructural changes. Hardness, tensile and bend tests were performed to evaluate the mechanical properties of welds. The results of the present investigation established that fully austenitic dendritic structure was found in welds of SMAW. Reverted austenite pools in the martensite matrix in weld zone and unmixed zones near the fusion boundary were observed in GTA welds. Discontinuous ferrite network in austenite matrix was observed in electron beam welds. Fine recrystallized austenite grain structure was observed in the nugget zone of friction stir welds. Improved mechanical properties are obtained in friction stir welds when compared to fusion welds. This is attributed to the refined microstructure consisting of equiaxed and homogenous austenite grains.

  18. Certification of a weld produced by friction stir welding

    Science.gov (United States)

    Obaditch, Chris; Grant, Glenn J

    2013-10-01

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

  19. Nanoindentation of Electropolished FeCrAl Alloy Welds

    Energy Technology Data Exchange (ETDEWEB)

    Weaver, Jordan [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Aydogan, Eda [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Mara, Nathan Allan [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Maloy, Stuart Andrew [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-02-13

    The present report summarizes Berkovich nanoindentation modulus and hardness measurements on two candidate FeCrAl alloys (C35M and C37M) on as-received (AR) and welded samples. In addition, spherical nanoindentation stress-strain measurements were performed on individual grains to provide further information and demonstrate the applicability of these protocols to mechanically characterizing welds in FeCrAl alloys. The indentation results are compared against the reported tensile properties for these alloys to provide relationships between nanoindentation and tensile tests and insight into weldsoftening for these FeCrAl alloys. Hardness measurements revealed weld-softening for both alloys in good agreement with tensile test results. C35M showed a larger reduction in hardness at the weld center from the AR material compared to C37M; this is also consistent with tensile tests. In general, nanohardness was shown to be a good predictor of tensile yield strength and ultimate tensile stress for FeCrAl alloys. Spherical nanoindentation measurements revealed that the fusion zone (FZ) + heat affected zone (HAZ) has a very low defect density typical of well-annealed metals as indicated by the frequent pop-in events. Spherical nanoindentation yield strength, Berkovich hardness, and tensile yield strength measurements on the welded material all show that the C37M welded material has a higher strength than C35M welded material. From the comparison of nanoindentation and tensile tests, EBSD microstructure analysis, and information on the processing history, it can be deduced that the primary driver for weld-softening is a change in the defect structure at the grain-scale between the AR and welded material. These measurements serve as baseline data for utilizing nanoindentation for studying the effects of radiation damage on these alloys.

  20. Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding.

    Science.gov (United States)

    Ampaiboon, Anusit; Lasunon, On-Uma; Bubphachot, Bopit

    2015-01-01

    We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10-20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%.

  1. Mechanism of Action of Rare Earths in High Effective Fe Powder Welding Rods

    Institute of Scientific and Technical Information of China (English)

    Han Yongquan; Li Jianguo; Yao Qinghu; Liu Yan; Huang Lihong

    2007-01-01

    The optimum coating composition of alkali Fe powder welding rods was designed by orthogonal experiment with mix rates. A new kind of effective RE-Fe powder welding rod was prepared which could be used at the condition of direct and indirect current. The arc characteristics and stabilities of effective Fe powder welding rods containing RE were analyzed by HANNOVER analyzer. The efficiency of Fe powder welding rods was tested by weighting method. It wag found that the stability of Fe powder welding rods Wag improved when it was added with rare earths. The results of impact experiment at low temperatures and SEM analysis on impact break showed that the grain was refined, the welding joint was cleaned, and the mechanical properties of joint was enhanced with proper RE content. It was provided with good processing property for this effective RE-Fe powder welding rod, and its efficiency could arrive at 180%.

  2. Optimization of parameters and study of joint microstructure of resistance spot welding of magnesium alloy

    Institute of Scientific and Technical Information of China (English)

    Wang Yarong; Zhang Zhongdian; Li Dongqing

    2006-01-01

    Experimental investigations on the DC spot welding of Mg alloy AZ31B are presented. Experiments are carried out to study the influence of spot welding parameters (electrode force, welding heat input and welding time) on the tensile shear load and the diameter of nugget, based on an orthogonal test and analysis method. The optimum parameters are as follows:electrode force is 2 000 N, welding heat input is 80% and welding time is 6 cycles. The microstructure of spot weld is single fine equiaxed crystals in the nugget, of which the structure is β-Mg17Al12 precipitated on α-Mg boundaries induced by nonequilibrium freezing. And the surface condition of the workpiece has great influence on the joint quality.

  3. Application of artificial neural network to predict Vickers microhardness of AA6061 friction stir welded sheets

    Institute of Scientific and Technical Information of China (English)

    Vahid Moosabeiki Dehabadi; Saeede Ghorbanpour; Ghasem Azimi

    2016-01-01

    The application of friction stir welding (FSW) is growing owing to the omission of difficulties in traditional welding processes. In the current investigation, artificial neural network (ANN) technique was employed to predict the microhardness of AA6061 friction stir welded plates. Specimens were welded employing triangular and tapered cylindrical pins. The effects of thread and conical shoulder of each pin profile on the microhardness of welded zone were studied using tow ANNs through the different distances from weld centerline. It is observed that using conical shoulder tools enhances the quality of welded area. Besides, in both pin profiles threaded pins and conical shoulders increase yield strength and ultimate tensile strength. Mean absolute percentage error (MAPE) for train and test data sets did not exceed 5.4% and 7.48%, respectively. Considering the accurate results and acceptable errors in the models’ responses, the ANN method can be used to economize material and time.

  4. Resistance welding of carbon fibre reinforced polyetheretherketone composites using metal mesh and PEI film

    Institute of Scientific and Technical Information of China (English)

    闫久春; 王晓林; 秦明; 赵新英; 杨士勤

    2004-01-01

    Weldability of polyetheretherketone(PEEK) with polyetherimide(PEI) is tested. And carbon fiber reinforced PEEK laminates are resistance welded using stainless steel mesh heating element. The effects of the welding time and welding pressure on the lap shear strength of joints are investigated. Results show that PEEK can heal with PEI well in welding condition and the lap shear strength of PEEK/CF(carbon fibre) joint increases linearly with welding time, but reaches a maximum value when welding pressure ranging from 0.3MPa to 0.5MPa with constant welding time. The fracture characteristics of surface are analyzed by SEM techniques, and four types of fracture modes of lap shear joints are suggested.

  5. Effect of tool geometry on friction stir spot welding of polypropylene sheets

    Directory of Open Access Journals (Sweden)

    M. K. Bilici

    2012-10-01

    Full Text Available The effects of tool geometry and properties on friction stir spot welding properties of polypropylene sheets were studied. Four different tool pin geometries, with varying pin angles, pin lengths, shoulder diameters and shoulder angles were used for friction stir spot welding. All the welding operations were done at the room temperature. Lap-shear tensile tests were carried out to find the weld static strength. Weld cross section appearance observations were also done. From the experiments the effect of tool geometry on friction stir spot weld formation and weld strength were determined. The optimum tool geometry for 4 mm thick polypropylene sheets were determined. The tapered cylindrical pin gave the biggest and the straight cylindrical pin gave the lowest lap-shear fracture load.

  6. Characterization of Microstructure and Mechanical Properties of Resistance Spot Welded DP600 Steel

    Directory of Open Access Journals (Sweden)

    Ali Ramazani

    2015-09-01

    Full Text Available Resistance spot welding (RSW as a predominant welding technique used for joining steels in automotive applications needs to be studied carefully in order to improve the mechanical properties of the spot welds. The objectives of the present work are to characterize the resistance spot weldment of DP600 sheet steels. The mechanical properties of the welded joints were evaluated using tensile-shear and cross-tensile tests. The time-temperature evolution during the welding cycle was measured. The microstructures observed in different sites of the welds were correlated to thermal history recorded by thermocouples in the corresponding areas. It was found that cracks initiated in the periphery region of weld nuggets with a martensitic microstructure and a pull-out failure mode was observed. It was also concluded that tempering during RSW was the main reason for hardness decrease in HAZ.

  7. Joint performance of laser-TIG double-side welded 5A06 aluminum alloy

    Institute of Scientific and Technical Information of China (English)

    CHEN Yan-bin; MIAO Yu-gang; LI Li-qun; WU Lin

    2009-01-01

    The influence of welding parameters on mechanical properties and microstructure of the welds of laser-TIG double-side welded 5A06 aluminum alloy was investigated. The results show that the weld cross-sectional shape has an intimate relation with the mechanical properties and microstructure of the welds. The symmetrical "X" cross-section possesses a relatively higher tensile strength and elongation than the others, about 91% and 58% of those of base metal, respectively. The good weld profiles and free defects are responsible for the improvement of tensile properties. Due to low hardness of the fusion zone, this region is the weakest area in the tensile test and much easier to fracture. The loss of Mg element is responsible for the decrease of mechanical properties of the joints. The microstructure of "X" cross-section has an obvious difference along the direction of weld depth, and that of the "H" cross-section is consistent and coarse.

  8. The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

    Science.gov (United States)

    Güler, Hande

    2014-10-01

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

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

    Science.gov (United States)

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

    2014-01-01

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

  10. Application of new GMAW welding methods used in prefabrication of P92 (X10CrWMoVNb9-2) pipe butt welds

    Energy Technology Data Exchange (ETDEWEB)

    Urzynicok, Michal [Boiler Elements Factory ' ZELKOT' , Koszecin (Poland); Kwiecinski, Krzysztof; Slania, Jacek [Instytut Spawalnictwa, Gliwice (Poland); Szubryt, Marian [TUEV Nord, Katowice (Poland)

    2010-07-01

    Welding of collector pipes, flat heads, dished ends and connector pipes performed with high temperature and creep-resistant steels most often has been performed using TIG process combined with MMA processes. Progress in MAG process and availability of high quality filler materials (solid wires) enables welding of the above connections also using this method. In order to prove its efficiency, this article presents the results of related tests. The range of tests was similar to that applied during the qualification of welding technology. The investigation also involved microscopic and fractographic examinations. The results reveal that welding with new methods such as GMAW is by no means inferior to a currently applied MMA method yet the time of the process is shorter by 50%. The article present the world's first known positive results in welding of P92 grade steel using GMAW welding method. (orig.)

  11. 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

  12. Computational Analysis and Experimental Validation of the Friction-Stir Welding Behaviour of Ti-6Al-4V

    Science.gov (United States)

    2013-05-04

    investigated using various optical and scanning electron microscopy techni- ques, while the weld properties were investigated using microhardness ...measurements, transverse and all-weld tensile testing techniques, as well as surface profilometry. The main findings/observations made in refer- ences [16...formation in the centre of the weld. 9. Material microhardness within the weld nugget is typically found to be affected by the workpiece thickness

  13. On-line quality monitoring in short-circuit gas metal arc welding

    Energy Technology Data Exchange (ETDEWEB)

    Adolfsson, S. [Univ. of Karlskrono/Ronneby (Sweden). Dept. of Signal Processing]|[Lund Univ. (Sweden). Dept. of Production and Materials Engineering; Bahrami, A. [Technology Center of Kronoberg, Vaexjoe (Sweden)]|[Lund Univ. (Sweden); Bolmsjoe, G. [Lund Univ. (Sweden); Claesson, I. [Univ. of Karlskrono/Ronneby (Sweden)

    1999-02-01

    This paper addresses the problems involved in the automatic monitoring of the weld quality produced by robotized short-arc welding. A simple statistical change detection algorithm for the weld quality, the repeated Sequential Probability Ratio Test (SPRT), was used. The algorithm may similarly be viewed as a cumulative sum (CUSUM) type test, and is well-suited to detecting sudden minor changes in the monitored test statistic. The test statistic is based on the variance of the weld voltage, wherein it will be shown that the variance decreases when the welding process is not operating under optimal conditions. The performance of the algorithm is assessed through the use of experimental data. The results obtained from the algorithm show that it is possible to detect changes in weld quality automatically and on-line.

  14. Measurement of local creep properties in stainless steel welds

    OpenAIRE

    Sakanashi, Y.; Gungor, S; Bouchard, J.

    2012-01-01

    A high temperature measurement system for creep deformation based on the digital image correlation (DIC) technique is described. The new system is applied to study the behaviour of a multi-pass welded joint in a high temperature tensile test and a load controlled creep test at 545°C. Spatially resolved tensile properties and time dependent creep deformation properties across a thick section type 316 stainless steel multi-pass welded joint are presented and discussed. Significantly lower creep...

  15. MINERVA, qualification of dissimilar welds for HTR-application

    Energy Technology Data Exchange (ETDEWEB)

    Baumann, B.; Gnirss, G.; Neureuther, H.; Schneider, K.

    1989-03-01

    The component test ''MINERVA'' is part of an overall concept to qualify dissimilar welds in pipings of advanced gas-cooled high temperature reactors. ''MINERVA'' is designed for a testing time of 20000 h. The experiment started in January 1987. The paper describes the concept, the manufacuring parameters including the basis of selection of materials and welding procedures. The experiment MINERVA and the operating conditions are described.

  16. Welding defects at friction stir welding

    Directory of Open Access Journals (Sweden)

    P. Podržaj

    2015-04-01

    Full Text Available The paper presents an overview of different types of defects at friction stir welding. In order to explain the reasons for their occurrence a short theoretical background of the process is given first. The main emphasis is on the parameters that influence the process. An energy supply based division of defects into three disjoint groups was used. The occurring defects are demonstrated on various materials.

  17. Metallography of Battery Resistance Spot Welds

    Science.gov (United States)

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

    2015-01-01

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

  18. E-beam welding characteristic of the ARAA steel for the KO HCCR TBM

    Energy Technology Data Exchange (ETDEWEB)

    Yoon, Jae Sung; Kim, Suk-Kwon; Lee, Eo Hwak; Jin, Hyung Gon; Lee, Dong Won [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of); Cho, Seungyon [National Fusion Research Institute, Daejeon (Korea, Republic of)

    2015-10-15

    To develop the next generation technologies, the one of the important objects of ITER project is to investigate the heat extraction from the blanket module in a fusion reactor and tritium extraction experiments. Korea has decided to test a helium cooled ceramic reflector (HCCR) test blanket module (TBM) in the ITER. The HCCR TBM is composed of four sub-modules and a back manipulator (BM). And each sub-module is composed of a first wall (FW), a breeding box with s even-layer breeding zone (BZ), and side walls (SW) with the cooling path. In addition, Korea is being developed and evaluated advanced reduced activation alloy (ARAA) material as the HCCR TBM structure. In this study, two thickness of ARAA plates, 8 and 13 mm, were carried out by electron beam (E-beam) weld to optimize the welding procedure considering weld speed and current, and investigated the variations in the weld bead width, an amount of dross, and the weld depth in both ARAA plates to optimize the fabrication procedure. Moreover, post weld heat treatment (PWHT) conditions were also carried out considering a different temperature and a cooling time. The micro-hardness measurements and Charpy Impact test in Base, heat affected zone (HAZ), and weld metal (WM) were carried out on E-beam welded joints after PWHT. The microstructural observation in the E-beam weld joints was also analyzed before and after PWHT condition. The purpose of this study is to find the optimized Ebeam weld condition, and analyze the mechanical properties and the influence of microstructure by Ebeam weld of ARAA materials. To optimize the E-beam welding procedure from ARAA material, two kinds of ARAA plates, 8 and 13 mm, were prepared and carried out E-beam weld considering the weld speed and the current, and investigated the variations in the weld bead width, an amount of dross, and the weld depth. Based on the results 1200 mm/min of welding speed and 65 mA current in 8 mm thickness and 110 mA weld current in 13 mm thickness in

  19. Welding. Performance Objectives. Intermediate Course.

    Science.gov (United States)

    Vincent, Kenneth

    Several intermediate performance objectives and corresponding criterion measures are listed for each of nine terminal objectives for an intermediate welding course. The materials were developed for a 36-week (3 hours daily) course designed to prepare the student for employment in the field of welding. Electric welding and specialized (TIG & MIG)…

  20. Welding. Performance Objectives. Basic Course.

    Science.gov (United States)

    Vincent, Kenneth

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