Sample records for welding quality control

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

    Energy Technology Data Exchange (ETDEWEB)

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


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

  2. Vision of the Arc for Quality Documentation and for Closed Loop Control of the Welding Process

    DEFF Research Database (Denmark)

    Kristiansen, Morten; Kristiansen, Ewa; Jensen, Casper Houmann


    For gas metal arc welding a vision system was developed, which was robust to monitor the position of the arc. The monitoring documents the welding quality indirectly and a closed loop fuzzy control was implemented to control an even excess penetration. For welding experiments on a butt-joint with......For gas metal arc welding a vision system was developed, which was robust to monitor the position of the arc. The monitoring documents the welding quality indirectly and a closed loop fuzzy control was implemented to control an even excess penetration. For welding experiments on a butt...

  3. Quality control on crimping of large diameter welding pipe (United States)

    Fan, Lifeng; Gao, Ying; Li, Qiang; Xu, Hongshen


    Crimping is used in production of large diameter submerged-arc welding pipes. Many researches are focused on crimping in certain manufacturing mode of welding pipe. The application scopes of research achievements become limited due to lack of uniformity in theoretical analysis. In order to propose a crimping prediction method in order to control forming quality, the theory model of crimping based on elastic-plastic mechanics is established. The main technical parameters are determined by theoretical analysis, including length of crimping, base radius of punch, terminal angle of punch, base radius of die, terminal angle of die and horizontal distance between punch and die. In addition, a method used to evaluate the forming quality is presented, which investigates the bending angle after springback, forming force, straight edge length and equivalent radius of curvature. In order to investigate the effects of technical parameters on forming quality, a two-dimensional finite element model is established by finite element software ABAQUS. The finite element model is verified in that its shapes error is less than 5% by comparable experiments, which shows that their geometric precision meets demand. The crimping characteristics is obtained, such as the distribution of stress and strain and the changes of forming force, and the relation curves of technical parameters on forming quality are given by simulation analysis. The sensitivity analysis indicates that the effects of length of crimping, technical parameters of punch on forming quality are significant. In particular, the data from simulation analysis are regressed by response surface method (RSM) to establish prediction model. The feasible technical parameters are obtained from the prediction model. This method presented provides a new thought used to design technical parameters of crimping forming and makes a basis for improving crimping forming quality.

  4. Distortion Control during Welding


    Akbari Pazooki, A.M.


    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 methods to control welding distortion. In these methods local heating and/or cooling strategies are applied during welding. Additional heating and/or cooling sources can be implemented either stationa...

  5. Distortion Control during Welding

    NARCIS (Netherlands)

    Akbari Pazooki, A.M.


    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

  6. Guidelines for Controlling Indoor Air Quality Problems Associated with Kilns, Copiers, and Welding in Schools. Technical Bulletin. (United States)

    Turner, Ronald W.; And Others

    Guidelines for controlling indoor air quality problems associated with kilns, copiers, and welding in schools are provided in this document. Individual sections on kilns, duplicating equipment, and welding operations contain information on the following: sources of contaminants; health effects; methods of control; ventilation strategies; and…

  7. Sensors for quality control in welding Sensores para controle da qualidade em soldagem

    Directory of Open Access Journals (Sweden)

    Sadek Crisóstomo Absi Alfaro


    Full Text Available The classical inspection methods used for detecting and finding disturbances in welding process are based on direct measurement of its parameters as arc voltage, welding current, wire feed speed, etc. Using these inspection methods implies sensors insertion around the welding process and its presence could alter the metallic transference behavior and consequently an uneven quality as well as it can increase the production cost. For reducing these implications is necessary using a non intrusive inspection method. In this paper we will show nonintrusive methods to the weld quality inspection. These methods are based on sensor fusion, the extraction of global information coming from the interrelation data given by each sensor that, for example, sensing the spectroscopy radiation emission, the acoustic sensing of the electrical arc, the infrared emissions indicating the heat content of the weld. Finally, the fusion data will be applied to a statistical control for detecting and finding welding disturbances. The results will show that sensor fusion could be used as a tool to measure indirectly the weld quality in the GMAW process.Os métodos clássicos de inspeção utilizados para detectar e encontrar perturbações nos processos de soldagem são baseados comumente na medição direta de seus parâmetros como da tensão do arco, corrente de soldagem, velocidade de alimentação, etc. Usando esses métodos de inspeção implica inserção dos sensores em todo o processo de soldagem e sua presença poderia alterar o comportamento, por exemplo, da transferência metálica e, consequentemente, uma qualidade irregular da junta soldada, bem como provocaria o aumento do custo de produção. Para reduzir essas implicações é necessário usar um método de inspeção não intrusiva. Neste artigo mostrar-se métodos não intrusivos para a inspeção de qualidade de solda. Estes métodos baseiam-se na fusão de sensores, a extração da informação global

  8. Robot welding process control (United States)

    Romine, Peter L.


    This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon.

  9. MFDC - technological improvement in resistance welding controls

    Energy Technology Data Exchange (ETDEWEB)

    Somani, A.K.; Naga Bhaskar, V.; Chandramouli, J.; Rameshwara Rao, A. [Nuclear Fuel Complex, Dept. of Atomic Energy, Hyderabad (India)


    Among the various Resistance Welding operations carried out in the production line of a fuel bundle end plug welding is the most critical operation. Welding controllers play a very vital role in obtaining consistent weld quality by regulating and controlling the weld current. Conventional mains synchronized welding controllers are at best capable of controlling the weld current at a maximum speed of the mains frequency. In view of the very short welding durations involved in the various stages of a fuel bundle fabrication, a need was felt for superior welding controllers. Medium Frequency Welding Controllers offer a solution to these limitations in addition to offering other advantages. Medium Frequency power sources offer precise welding current control as they regulate and correct the welding current faster, typically twenty times faster when operated at 1000Hz. An MFDC was employed on one of the welding machines and its performance was studied. This paper discusses about the various advantages of MFDCs with other controllers employed at NFC to end plug welding operation. (author)

  10. Quality status display for a vibration welding process (United States)

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


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

  11. Modelling and control for laser based welding processes: modern methods of process control to improve quality of laser-based joining methods (United States)

    Zäh, Ralf-Kilian; Mosbach, Benedikt; Hollwich, Jan; Faupel, Benedikt


    To ensure the competitiveness of manufacturing companies it is indispensable to optimize their manufacturing processes. Slight variations of process parameters and machine settings have only marginally effects on the product quality. Therefore, the largest possible editing window is required. Such parameters are, for example, the movement of the laser beam across the component for the laser keyhole welding. That`s why it is necessary to keep the formation of welding seams within specified limits. Therefore, the quality of laser welding processes is ensured, by using post-process methods, like ultrasonic inspection, or special in-process methods. These in-process systems only achieve a simple evaluation which shows whether the weld seam is acceptable or not. Furthermore, in-process systems use no feedback for changing the control variables such as speed of the laser or adjustment of laser power. In this paper the research group presents current results of the research field of Online Monitoring, Online Controlling and Model predictive controlling in laser welding processes to increase the product quality. To record the characteristics of the welding process, tested online methods are used during the process. Based on the measurement data, a state space model is ascertained, which includes all the control variables of the system. Depending on simulation tools the model predictive controller (MPC) is designed for the model and integrated into an NI-Real-Time-System.

  12. Effect of Pulse Parameters on Weld Quality in Pulsed Gas Metal Arc Welding: A Review (United States)

    Pal, Kamal; Pal, Surjya K.


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

  13. Automatic orbital GTAW welding: Highest quality welds for tomorrow's high-performance systems (United States)

    Henon, B. K.


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

  14. Quality status display for a vibration welding process

    Energy Technology Data Exchange (ETDEWEB)

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


    A method includes receiving, during a vibration welding process, a set of sensory signals from a collection of sensors positioned with respect to a work piece during formation of a weld on or within the work piece. The method also includes receiving control signals from a welding controller during the process, with the control signals causing the welding horn to vibrate at a calibrated frequency, and processing the received sensory and control signals using a host machine. Additionally, the method includes displaying a predicted weld quality status on a surface of the work piece using a status projector. The method may include identifying and display a quality status of a suspect weld. The laser projector may project a laser beam directly onto or immediately adjacent to the suspect welds, e.g., as a red, green, blue laser or a gas laser having a switched color filter.

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

    Directory of Open Access Journals (Sweden)

    Jan PIWNIK


    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.

  16. Control system of power supply for resistance welding machine

    Directory of Open Access Journals (Sweden)

    Світлана Костянтинівна Поднебенна


    Full Text Available This article describes the existing methods of heat energy stabilizing, which are realized in thyristor power supplies for resistance welding machines. The advantages and features of thyristor power supplies have been described. A control system of power supply for resistance welding machine with stabilization of heat energy in a welding spot has been developed. Measurements are performed in primary winding of a welding transformer. Weld spot heating energy is calculated as the difference between the energy, consumed from the mains, and the energy losses in the primary and secondary circuits of the welding transformer as well as the energy losses in the transformer core. Algorithms of digital signal processing of the developed control system are described in the article. All measurements and calculations are preformed automatically in real-time. Input signals to the control system are: transformer primary voltage and current, temperature of the welding circuit. The designed control system ensures control of the welding heat energy and is not influenced by the supply voltage and impedance changes caused by insertion of the ferromagnetic mass in the welding circuit, the temperature change during the welding process. The developed control system for resistance welding machine makes it possible to improve the quality of welded joints, increase the efficiency of the resistance welding machine

  17. IIW guidelines on weld quality in relationship to fatigue strength

    CERN Document Server

    Jonsson, Bertil; Hobbacher, A F; Kassner, M; Marquis, G


    This book presents guidelines on quantitative and qualitative measures of the geometric features and imperfections of welds to ensure that it meets the fatigue strength requirements laid out in the recommendations of the IIW (International Institute of Welding). Welds that satisfy these quality criteria can be assessed in accordance with existing IIW recommendations based on nominal stress, structural stress, notch stress or linear fracture mechanics. Further, the book defines more restrictive acceptance criteria based on weld geometry features and imperfections with increased fatigue strength. Fatigue strength for these welds is defined as S-N curves expressed in terms of nominal applied stress or hot spot stress. Where appropriate, reference is made to existing quality systems for welds.In addition to the acceptance criteria and fatigue assessment curves, the book also provides guidance on their inspection and quality control. The successful implementation of these methods depends on adequate training for o...

  18. Weld formation control at electron beam welding with beam oscillations


    Trushnikov, Dmitriy; Koleva, Elena; Mladenov, Georgy; A. Shcherbakov


    Electron beam welding is used extensively to produce essential machine parts. The control of the basic beam parameters beam power or beam current at constant accelerating voltage, welding speed, current of focusing lens and distance between electron gun and welded sample surface is not enough to obtain at most of the regimes sound welds. Control of the focus position using analysis of the high frequency component of the current, collected by plasma, at periodic interactions on the beam (the o...

  19. Weld Nugget Temperature Control in Thermal Stir Welding (United States)

    Ding, R. Jeffrey (Inventor)


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

  20. Welding process modelling and control (United States)

    Romine, Peter L.; Adenwala, Jinen A.


    The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control.

  1. Control of resistance plug welding using quantitative feedback theory

    Energy Technology Data Exchange (ETDEWEB)

    Bentley, A.E. [Sandia National Lab., Albuquerque, NM (United States); Horowitz, I. [Univ. of California, Davis, CA (United States)]|[Weizmann Inst. of Science, Rehovot (Israel)]|[Wright Patterson Air Force Base, Dayton, OH (United States); Chait, Y.; Rodrigues, J. [Univ. of Massachusetts, Amherst, MA (United States)


    Resistance welding is used extensively throughout the manufacturing industry. Variations in weld quality often result in costly post-weld inspections. Applications of feed-back control to such processes have been limited by the lack of accurate models describing the nonlinear dynamics of this process. A new system based on electrode displacement feedback is developed that greatly improves quality control of the resistance plug welding process. The system is capable of producing repeatable welds of consistent displacement (and thus consistent quality), with wide variations in weld parameters. This paper describes the feedback design of a robust controller using Quantitative Feedback Theory for this highly complex process, and the experimental results of the applied system.

  2. Real time computer controlled weld skate (United States)

    Wall, W. A., Jr.


    A real time, adaptive control, automatic welding system was developed. This system utilizes the general case geometrical relationships between a weldment and a weld skate to precisely maintain constant weld speed and torch angle along a contoured workplace. The system is compatible with the gas tungsten arc weld process or can be adapted to other weld processes. Heli-arc cutting and machine tool routing operations are possible applications.

  3. Automatic Control Of Length Of Welding Arc (United States)

    Iceland, William F.


    Nonlinear relationships among current, voltage, and length stored in electronic memory. Conceptual microprocessor-based control subsystem maintains constant length of welding arc in gas/tungsten arc-welding system, even when welding current varied. Uses feedback of current and voltage from welding arc. Directs motor to set position of torch according to previously measured relationships among current, voltage, and length of arc. Signal paths marked "calibration" or "welding" used during those processes only. Other signal paths used during both processes. Control subsystem added to existing manual or automatic welding system equipped with automatic voltage control.

  4. Control of Welding Processes. (United States)


    Structures, Office of Deputy Under Secretary of Defense for R&E (ET), Department of Defense, Washington, D.C. CHARLES ZANIS, Assistant Director for Platform... CHARLES NULL, Head, Metals Branch, Naval Sea Systems Command, Washington, D.C. ROBERT A. WEBER, Welding Engineering and Metallurgy, U.S. Army Corps of...Needs. Pp. 487-90. in Papers Presented at the August 3-8, 1Q80, AIME Syi,.posium. Essers, W . ., and R. Walter. Heat transfer and penet ration

  5. Operation of a Fuzzy Controlled Half-Bridge DC-Converter as a Welding Current-Source

    Directory of Open Access Journals (Sweden)

    Kourosh Mahmoodi


    Full Text Available In This paper a new Fuzzy Controlled Welding current source is introduced and the results of the new control method are explained. The Fuzzy controller is applied to the welding machine to improve some problems of welding process. The new intelligent controller guaranties a constant current during welding to improve welding quality. It also provides some features such as hot-start and anti-stuck function and a standby mode for energy saving. The effectiveness of this intelligent welding machine was proven by the experimental results and durable test. The results show that designed FCWM (Fuzzy Controlled Welding Machine can be used in mobile welding industries.

  6. Welding skate with computerized controls (United States)

    Wall, W. A., Jr.


    New welding skate concept for automatic TIG welding of contoured or double-contoured parts combines lightweight welding apparatus with electrical circuitry which computes the desired torch angle and positions a torch and cold-wire guide angle manipulator.

  7. Weld procedure produces quality welds for thick sections of Hastelloy-X (United States)

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


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

  8. Advanced Control Methods for Optimization of Arc Welding

    DEFF Research Database (Denmark)

    Thomsen, J. S.

    Gas Metal Arc Welding (GMAW) is a proces used for joining pieces of metal. Probably, the GMAW process is the most successful and widely used welding method in the industry today. A key issue in welding is the quality of the welds produced. The quality of a weld is influenced by several factors in...

  9. Grain refinement control in TIG arc welding (United States)

    Iceland, W. F.; Whiffen, E. L. (Inventor)


    A method for controlling grain size and weld puddle agitation in a tungsten electrode inert gas welding system to produce fine, even grain size and distribution is disclosed. In the method the frequency of dc welding voltage pulses supplied to the welding electrode is varied over a preselected frequency range and the arc gas voltage is monitored. At some frequency in the preselected range the arc gas voltage will pass through a maximum. By maintaining the operating frequency of the system at this value, maximum weld puddle agitation and fine grain structure are produced.

  10. Controlling Arc Length in Plasma Welding (United States)

    Iceland, W. F.


    Circuit maintains arc length on irregularly shaped workpieces. Length of plasma arc continuously adjusted by control circuit to maintain commanded value. After pilot arc is established, contactor closed and transfers arc to workpiece. Control circuit then half-wave rectifies ac arc voltage to produce dc control signal proportional to arc length. Circuit added to plasma arc welding machines with few wiring changes. Welds made with circuit cleaner and require less rework than welds made without it. Beads smooth and free of inclusions.

  11. High quality joining techniques: in-process assurance (IPA) welding system

    Energy Technology Data Exchange (ETDEWEB)

    Kaihara, Shoichiro [Ishikawajima-Harima Heavy Industries Co. Ltd., Tokyo (Japan)


    On July 1, 1995, the Product Liability Law was enforced, and in industrial world, further reliability has been demanded. Recently, accompanying the progress of electronics, the proportion taken by automatic welders and robots increased in welding. By memorizing proper welding conditions, the welding from initial to final passes can be done fully automatically. Also feedback mechanism was equipped to mechanized welders, and the in-process control has become to be feasible. The way of thinking on confirming in process welding quality in arc welding is explained. IPA welding system utilizes the multi-media collecting images and sound, samples the change of welding conditions and the state of arc on a same screen, and monitors the deviation from the range of proper welding conditions. At the time of abnormality, inspector or a computer carries out image diagnosis and welding control, and the system indicates the soundness of welded parts. The basic concept and the flow chart of this system are shown. The experiment of applying the system to arc welding is reported. The correlation of welding phenomena and welding conditions is examined. (K.I.)

  12. Intelligent Control of Welding Gun Pose for Pipeline Welding Robot Based on Improved Radial Basis Function Network and Expert System

    Directory of Open Access Journals (Sweden)

    Jingwen Tian


    Full Text Available Since the control system of the welding gun pose in whole-position welding is complicated and nonlinear, an intelligent control system of welding gun pose for a pipeline welding robot based on an improved radial basis function neural network (IRBFNN and expert system (ES is presented in this paper. The structure of the IRBFNN is constructed and the improved genetic algorithm is adopted to optimize the network structure. This control system makes full use of the characteristics of the IRBFNN and the ES. The ADXRS300 micro-mechanical gyro is used as the welding gun position sensor in this system. When the welding gun position is obtained, an appropriate pitch angle can be obtained through expert knowledge and the numeric reasoning capacity of the IRBFNN. ARM is used as the controller to drive the welding gun pitch angle step motor in order to adjust the pitch angle of the welding gun in real-time. The experiment results show that the intelligent control system of the welding gun pose using the IRBFNN and expert system is feasible and it enhances the welding quality. This system has wide prospects for application.

  13. [Study on the arc spectral information for welding quality diagnosis]. (United States)

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


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

  14. Torque Control of Friction Stir Welding Project (United States)

    National Aeronautics and Space Administration — Longhurst Engineering, PLC and Vanderbilt University propose the innovation of torque control of friction stir welding (FSW) as a replacement to force control of...

  15. Laser welding closed-loop power control

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove


    A closed-loop control system is developed to maintain an even seam width on the root side of a laser weld by continually controlling the output laser power of a 1500 W CO2 laser.......A closed-loop control system is developed to maintain an even seam width on the root side of a laser weld by continually controlling the output laser power of a 1500 W CO2 laser....

  16. Monitoring the quality of welding based on welding current and ste analysis (United States)

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


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

  17. Computerized adaptive control weld skate with CCTV weld guidance project (United States)

    Wall, W. A.


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

  18. Multi-mode ultrasonic welding control and optimization (United States)

    Tang, Jason C.H.; Cai, Wayne W


    A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

  19. Control of two Wheeled Welding Mobile Manipulator

    Directory of Open Access Journals (Sweden)

    M. D. Ngo


    Full Text Available A three-linked manipulator mounted on a two-wheeled mobile platform is used to weld a long curved welding path. A welding torch mounted at the end of a manipulator of the welding mobile manipulator (WMM must be controlled for tracking a welding path with constant velocity and constant welding angle of torch. In this paper, a decentralized control method is applied to control the WMM considered as two separate subsystems such as a mobile platform and a manipulator. Two decentralized motion controllers are designed to control two subsystems of WMM, respectively. Firstly, based on a tracking error vector of the manipulator and a feedback motion of the mobile platform, a kinematic controller is designed for manipulator. Secondly, based on an another tracking error vector of the mobile platform and a feedback angular velocities of revolution joints of three-link, a sliding mode controller is designed for the mobile platform. These controllers are obtained based on the Lyapunov's function and its stability condition to ensure for the tracking error vectors to be asymptotically stable. Furthermore, simulation and experimental results are presented to illustrate the effectiveness of the proposed algorithm.

  20. Control of two Wheeled Welding Mobile Manipulator

    Directory of Open Access Journals (Sweden)

    M. D. Ngo


    Full Text Available A three-linked manipulator mounted on a two-wheeled mobile platform is used to weld a long curved welding path. A welding torch mounted at the end of a manipulator of the welding mobile manipulator (WMM must be controlled for tracking a welding path with constant velocity and constant welding angle of torch. In this paper, a decentralized control method is applied to control the WMM considered as two separate subsystems such as a mobile platform and a manipulator. Two decentralized motion controllers are designed to control two subsystems of WMM, respectively. Firstly, based on a tracking error vector of the manipulator and a feedback motion of the mobile platform, a kinematic controller is designed for manipulator. Secondly, based on an another tracking error vector of the mobile platform and a feedback angular velocities of revolution joints of three-link, a sliding mode controller is designed for the mobile platform. These controllers are obtained based on the Lyapunov's function and its stability condition to ensure for the tracking error vectors to be asymptotically stable. Furthermore, simulation and experimental results are presented to illustrate the effectiveness of the proposed algorithm.

  1. Probing weld quality monitoring in friction stir welding through characterization of signals by fractal theory

    Energy Technology Data Exchange (ETDEWEB)

    Das, Bipul; Bag, Swarup; Pal, Sukhomay [Indian Institute of Technology Guwahati, Assam (India)


    Providing solutions towards the improvisation of welding technologies is the recent trend in the Friction stir welding (FSW) process. We present a monitoring approach for ultimate tensile strength of the friction stir welded joints based on information extracted from process signals through implementing fractal theory. Higuchi and Katz algorithms were executed on current and tool rotational speed signals acquired during friction stir welding to estimate fractal dimensions. Estimated fractal dimensions when correlated with the ultimate tensile strength of the joints deliver an increasing trend with the increase in joint strength. It is observed that dynamicity of the system strengthens the weld joint, i.e., the greater the fractal dimension, the better will be the quality of the weld. Characterization of signals by fractal theory indicates that the single-valued indicator can be an alternative for effective monitoring of the friction stir welding process.

  2. Automatic weld torch guidance control system (United States)

    Smaith, H. E.; Wall, W. A.; Burns, M. R., Jr.


    A highly reliable, fully digital, closed circuit television optical, type automatic weld seam tracking control system was developed. This automatic tracking equipment is used to reduce weld tooling costs and increase overall automatic welding reliability. The system utilizes a charge injection device digital camera which as 60,512 inidividual pixels as the light sensing elements. Through conventional scanning means, each pixel in the focal plane is sequentially scanned, the light level signal digitized, and an 8-bit word transmitted to scratch pad memory. From memory, the microprocessor performs an analysis of the digital signal and computes the tracking error. Lastly, the corrective signal is transmitted to a cross seam actuator digital drive motor controller to complete the closed loop, feedback, tracking system. This weld seam tracking control system is capable of a tracking accuracy of + or - 0.2 mm, or better. As configured, the system is applicable to square butt, V-groove, and lap joint weldments.

  3. Stainless steel welding and semen quality

    DEFF Research Database (Denmark)

    Jelnes, J E; Knudsen, Lisbeth E.


    Questionnaire studies of patients from fertility clinics suggest that welders may have an increased risk of reduced semen quality. In this study, welders and nonwelders from the same plants were asked to provide blood, urine, and semen samples. Urine was analyzed for chromium and nickel, and for ...... and nonwelders. Because the metal dust exposure of nonwelders in the plant may be higher than that in the general population, welders were also compared to referents not working in the metal industry. Again, no decrease in semen quality associated with welding was demonstrated....

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

    Energy Technology Data Exchange (ETDEWEB)

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


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

  5. Theory research of seam recognition and welding torch pose control based on machine vision (United States)

    Long, Qiang; Zhai, Peng; Liu, Miao; He, Kai; Wang, Chunyang


    At present, the automation requirement of the welding become higher, so a method of the welding information extraction by vision sensor is proposed in this paper, and the simulation with the MATLAB has been conducted. Besides, in order to improve the quality of robot automatic welding, an information retrieval method for welding torch pose control by visual sensor is attempted. Considering the demands of welding technology and engineering habits, the relative coordinate systems and variables are strictly defined, and established the mathematical model of the welding pose, and verified its feasibility by using the MATLAB simulation in the paper, these works lay a foundation for the development of welding off-line programming system with high precision and quality.

  6. Intelligent Control of Modular Robotic Welding Cell

    Energy Technology Data Exchange (ETDEWEB)

    Smartt, Herschel Bernard; Kenney, Kevin Louis; Tolle, Charles Robert


    Although robotic machines are routinely used for welding, such machines do not normally incorporate intelligent capabilities. We are studying the general problem of formulating usable levels of intelligence into welding machines. From our perspective, an intelligent machine should: incorporate knowledge of the welding process, know if the process is operating correctly, know if the weld it is making is good or bad, have the ability to learn from its experience to perform welds, and be able to optimize its own performance. To this end, we are researching machine architecture, methods of knowledge representation, decision making and conflict resolution algorithms, methods of learning and optimization, human/machine interfaces, and various sensors. This paper presents work on the machine architecture and the human/machine interface specifically for a robotic, gas metal arc welding cell. Although the machine control problem is normally approached from the perspective of having a central body of control in the machine, we present a design using distributed agents. A prime goal of this work is to develop an architecture for an intelligent machine that will support a modular, plug and play standard. A secondary goal of this work is to formulate a human/machine interface that treats the human as an active agent in the modular structure.

  7. Control of welding distortion during gas metal arc welding of AH36 plates by stress engineering

    NARCIS (Netherlands)

    Pazooki, A.M.A.; Hermans, M.J.M.; Richardson, I.M.


    Welding residual stress and distortion are strongly linked together. One of the ways to control or reduce the welding distortions is the manipulation of the generated stresses during welding, and final residual stresses exist in the workpiece (stress engineering). In this paper, the control of gas

  8. Stainless steel welding and semen quality

    Energy Technology Data Exchange (ETDEWEB)

    Jelnes, J.E.; Knudsen, L.E. (Department of Biology and Toxicology, Danish National Institute of Occupational Health, Copenhagen (Denmark))


    Questionnaire studies of patients from fertility clinics suggest that welders may have an increased risk of reduced semen quality. In this study, welders and nonwelders from the same plants were asked to provide blood, urine, and semen samples. Urine was analyzed for chromium and nickel, and for mutagenic activity and metal concentration; blood for metal concentrations, immunoglobulin G, total protein, and measures of genotoxicity in lymphocytes; and semen was evaluated by standard semen analysis. Results of the semen evaluation, presented here, showed no difference in semen quality between welders and nonwelders. Because the metal dust exposure of nonwelders in the plant may be higher than that in the general population, welders were also compared to referents not working in the metal industry. Again, no decrease in semen quality associated with welding was demonstrated.

  9. Actively controlled vibration welding system and method (United States)

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


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

  10. The Investigation of Mechanical Properties of Welding Quality of R65 Type Rail


    Mindaugas Rauduvė; Vitalijus Rudzinskas


    This article is about the aluminothermic welding quality ofrail joints, using different parameters. The thermit portion andpreheat time estimated for quality of welded joints as well asthe mechanical characteristics of aluminothermic welds in railshave been examined.

  11. The Investigation of Mechanical Properties of Welding Quality of R65 Type Rail

    Directory of Open Access Journals (Sweden)

    Mindaugas Rauduvė


    Full Text Available This article is about the aluminothermic welding quality ofrail joints, using different parameters. The thermit portion andpreheat time estimated for quality of welded joints as well asthe mechanical characteristics of aluminothermic welds in railshave been examined.

  12. IIW Commission V - NDT and quality assurance of welded products

    Energy Technology Data Exchange (ETDEWEB)

    Sjerve, E., E-mail: [IRISNDT Corp., Edmonton, Alberta (Canada)


    The IIW (International Institute of Welding) is an active international organization in the area of weld based topics. Within a structure of 16 independent Commissions and other working committees, the IIW gathers together leading people from the perspectives of fabrication, maintenance and inspection to discuss and forward the state of the art in welding. Within this framework, Commission V is dedicated to NDT and Quality Assurance of Welded Products. This paper describes Commission V activities from the 2012 IIW Annual Assembly in Denver, USA. (author)

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

    NARCIS (Netherlands)

    Beyer, Eckhard; Sibillano, Teresa; Ancona, Antonio; Morris, Timothy; Rizzi, Domenico; Mezzapesa, Francesco; Konuk, A.R.; Aarts, Ronald G.K.M.; Huis in 't Veld, Bert; Lugara, Pietro Mario


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

  14. A comparison of two types of neural network for weld quality prediction in small scale resistance spot welding (United States)

    Wan, Xiaodong; Wang, Yuanxun; Zhao, Dawei; Huang, YongAn


    Our study aims at developing an effective quality monitoring system in small scale resistance spot welding of titanium alloy. The measured electrical signals were interpreted in combination with the nugget development. Features were extracted from the dynamic resistance and electrode voltage curve. A higher welding current generally indicated a lower overall dynamic resistance level. A larger electrode voltage peak and higher change rate of electrode voltage could be detected under a smaller electrode force or higher welding current condition. Variation of the extracted features and weld quality was found more sensitive to the change of welding current than electrode force. Different neural network model were proposed for weld quality prediction. The back propagation neural network was more proper in failure load estimation. The probabilistic neural network model was more appropriate to be applied in quality level classification. A real-time and on-line weld quality monitoring system may be developed by taking advantages of both methods.

  15. Synthetic Reference Materials Based on Polymer Films for the Control of Welding Fumes Composition (United States)

    Kuznetsova, O. V.; Kuznetsova, A. N.; Begunova, L. A.


    Analysis of the current hygienic situation in the welding production showed that the intensification of welding processes involves the deterioration of air quality, which negatively affects the welders health. Welders are exposed to a variety of metal fumes, including manganese that may elevate the risk for neurological diseases. The control of metals concentration in the air of the working area is difficult due to the lack of reference materials. The creation of reference materials of welding fumes composition is a challenge due to chemical characteristics of their physical properties. Synthetic samples in a form of the polymer film containing powder particles of welding fumes were create. Studies on the selection of the polymer were done. Experiments proved that the qualitative materials of synthetic welding fumes are obtained by using polyvinyl alcohol. The metals concentration in the samples was determined by X-ray fluorescence analysis. The obtained data demonstrates indirectly the uniform distribution of welding fumes powder particles on the polymer film.

  16. Plasma arc welding, equipment, installation and process control (United States)

    Fuershbach, P. W.


    The plasma arc welding (PAW) process can achieve the highest power density of all the conventional arc welding processes and has advantages over laser beam welding (LBW) and electron beam welding (EBW). Power density is an independent variable which can be precisely controlled. The combination of high orifice gas flowrates and arc current pulsation increases weld penetration for thin section partial penetration PAW welds. Contaminants (i.e., oxygen, water vapor) in the orifice gas system are important for stable operation of the pilot arc as is the concentric alignment of the electrode within the nozzle bore. Due to a refractory oxide skin, high heat input is necessary to weld aluminum with conventional arc processes. LBW has not proven practical. Low current ac PAW with 0.035 in. thick aluminum produced small welds with a good depth-to-width ratio.

  17. ARC length control for plasma welding (United States)

    Iceland, William F. (Inventor)


    A control system to be used with a plasma arc welding apparatus is disclosed. The plasma arc welding apparatus includes a plasma arc power supply, a contactor, and an electrode assembly for moving the electrode relative to a work piece. The electrode assembly is raised or lowered by a drive motor. The present apparatus includes a plasma arc adapter connected across the power supply to measure the voltage across the plasma arc. The plasma arc adapter forms a dc output signal input to a differential amplifier. A second input is defined by an adjustable resistor connected to a dc voltage supply to permit operator control. The differential amplifier forms an output difference signal provided to an adder circuit. The adder circuit then connects with a power amplifier which forms the driving signal for the motor. In addition, the motor connects to a tachometor which forms a feedback signal delivered to the adder to provide damping, therby avoiding servo loop overshoot.

  18. Welding. (United States)

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

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

  19. Quality improvement of steel cast-welded constructions

    Directory of Open Access Journals (Sweden)

    Аркадій Васильович Лоза


    Full Text Available Among the various types of metallurgical equipment there are structures which are welded compounds of a cast base and additional elements produced by casting or any other means. Such structures are called cast-welded constructions. Besides new working properties such constructions appear to be more efficient and provide better durability as compared to the similar structures produced by other industrial means. Meanwhile the advantages of the technology are not used in full. One reason is low quality of the compound products caused by lack of proper preparation of the elements to be welded and poor quality of the welds themselves. In the article the methods of quality production and the maintenance of steel cast-welded constructions have been considered. A ladle of a blast-furnace slag car is used as the subject of investigation and further testing of the mentioned above technologies. The ladle is a cast product. Under operating conditions, the ladle undergoes mechanical and thermal load, which results in deformation of its sides that deflect inside. To prevent the deflection stiffening ribs are welded onto the outer surface of the ladle. However, there may be casting defects in the base metal that could reduce the durability of the welds. It has been proved that welds on the unprepared cast base of the steel product cannot guarantee the combination’s durability and reliability. To prevent the influence of the casting defects it has been recommended to cover the base metal with one more metal layer before welding the elements on. Two-layer surfacing provides best result as the first layer serves for the weld penetration of the casting defects since this layer has a significant share of base metal therefore it is less malleable; the second layer is necessary for making the layer viscous enough. The viscous layer ensures the absence of sharp transition from the deposited metal to the base metal and increases the crack resistance of the weld. In

  20. Heat Control via Torque Control in Friction Stir Welding (United States)

    Venable, Richard; Colligan, Kevin; Knapp, Alan


    In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

  1. Flexible Vision Control System For Precision Robotic Arc Welding (United States)

    Richardson, Richard W.


    A system is described which is based on a unique weld image sensor design which integrates the optical system into the weld end effector to produce the so-called "coaxial view" of the weld zone. The resulting weld image is processed by a flexible, table driven vision processing system which can be adapted to detect a variety of features and feature relationships. Provision is made for interactive "teaching" of image features for generation of table parameters from test welds. A table driven control program allows various vision control strategies to be invoked. The main result of the system is a level of emulation of the capability of the expert welder or welding operator, essential to successful precision welding robotization.

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

    Sifa, A.; Endramawan, T.; Badruzzaman


    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.

  3. Control of GMA Butt Joint Welding Based on Neural Networks

    DEFF Research Database (Denmark)

    Christensen, Kim Hardam; Sørensen, Torben


    in the challenging field of butt joint welding with full penetration under stochastically changing boundary conditions, e.g. major gap width variations. GMAW experiments performed on mild-steel plates (3 mm of thickness), show that high quality welds with uniform back-bead geometry are achievable for gap width...

  4. Low Speed Control for Automatic Welding (United States)

    Iceland, W. E.


    Amplifier module allows rotating positioner of automatic welding machine to operate at speeds below normal range. Low speeds are precisely regulated by a servomechanism as are normal-range speeds. Addition of module to standard welding machine makes it unnecessary to purchase new equipment for low-speed welding.

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

    Directory of Open Access Journals (Sweden)

    Valeriy Shchavlev


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

  6. Plasma charge current for controlling and monitoring electron beam welding with beam oscillation. (United States)

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


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

  7. Intelligent Control of Welding Gun Pose for Pipeline Welding Robot Based on Improved Radial Basis Function Network and Expert System


    Jingwen Tian; Meijuan Gao; Yonggang He


    Since the control system of the welding gun pose in whole‐position welding is complicated and nonlinear, an intelligent control system of welding gun pose for a pipeline welding robot based on an improved radial basis function neural network (IRBFNN) and expert system (ES) is presented in this paper. The structure of the IRBFNN is constructed and the improved genetic algorithm is adopted to optimize the network structure. This control system makes full use of the characteristics of the IRBFNN...

  8. Non-destructive Magnetic Evaluation of Laser Weld Quality in Hot Rolled Coils (United States)

    Mohapatra, J. N.; Chakradhar, I.; Rao, K. R. C.; Rao, V. V. L.; Kaza, Marutiram


    Weld quality evaluation was conducted on laser welded thin sectsions (2 mm) of hot-rolled (HR) low-carbon steel coils during cold rolling process. The analysis revealed that the poor welds consisting of the weld defects like incomplete fusion, cluster of porosity, and large difference in hardness between the weld zone and base metal were responsible for the weld failures. Experiments were conducted by varying the welding parameters; laser power and welding speed to optimize the parameters for minimizing the weld defects. The optimized weld process parameters have helped elimination of weld defects and the results are verified with microscopy and microhardness measurements. As destructive evaluation techniques are time consuming and not always permitted in industrial applications, attempts have been made in the present investigation for the utilization of suitable non-destructive techniques for the evaluation of weld quality. Non-destructive magnetic techniques of magnetic hysteresis loop and magnetic Barkhausen emissions were used in the present investigation to establish possible correlations of magnetic properties across the weld seam with the mechanical property (microhardness) for evaluation of weld quality. It is inferred that the magnetic properties of coercivity and inverse of root mean square voltage can be effectively utilized to determine weld quality in HR steel coils.

  9. Gas tungsten arc welding of vanadium alloys with impurity control (United States)

    Grossbeck, M. L.; King, J. F.; Nagasaka, T.; David, S. A.


    Gas tungsten arc welding in vanadium alloys is controlled by interstitial impurities. Techniques have been developed to weld V-4Cr-4Ti in a high-purity argon atmosphere resulting in a DBTT of -20 °C. The atmosphere was controlled by a Zr-Al getter which is activated at high temperature to obtain a clean surface then cooled and allowed to absorb hydrogen and oxygen impurities. Through the use of low-oxygen base metal and high-purity weld filler wire, a DBTT of -145 °C was obtained. Experiments using electron beam welding have shown that grain size also has an important effect on weld ductility. Introduction of nitrogen and yttrium has been used to study their effect on grain size. Using a combination of atmosphere control, alloy purity control, and grain size control, it is anticipated that V-Cr-Ti alloys will be weldable in field conditions.

  10. The Effects of Laser Welding Direction on Joint Quality for Non-Uniform Part-to-Part Gaps

    Directory of Open Access Journals (Sweden)

    Rocku Oh


    Full Text Available Controlling part-to-part gaps is a crucial task in the laser welding of galvanized steel sheets for ensuring the quality of the assembly joint. However, part-to-part gaps are frequently non-uniform. Hence, elevations and depressions from the perspective of the heading direction of the laser beam always exist throughout the gap, creating ascending, descending, and flat travelling paths for laser welding. In this study, assuming non-uniform part-to-part gaps, the effects of welding direction on the quality of the joint of galvanized steel sheets—SGARC440 (lower part and SGAFC590DP (upper part—were examined using 2-kW fiber and 6.6-kW disk laser welding systems. The experimental analysis of coupon tests confirmed that there is no statistically significant correlation between the direction of welding and weld pool quality if the gap exceeds the tolerable range. However, when the gap is controlled within the tolerable range, the welding direction can be considered as an important process control variable to enhance the quality of the joint.

  11. Closed loop control of laser welding using an optical spectroscopic sensor for Nd:YAG and CO2 lasers

    NARCIS (Netherlands)

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


    Recent developments in laser joining show the applicability of spectral analysis of the plasma plume emission to monitor and control the quality of weld. The analysis of the complete spectra makes it possible to measure specific emission lines which reveal information about the welding process. The

  12. Exemplification of Tomographic Method to Evaluate the Quality of Welded Joints Made from EN 5754-H22 Alloy

    Directory of Open Access Journals (Sweden)

    Błachnio Józef


    Full Text Available The quality of welded joints depends on many factors. The relevant standards stipulate technical conditions of welds quality assessment, which provides the basis for stating whether the given joint is compatible with the requirements or whether it is defective. In practice, making welded joints that are totally devoid of defects is extremely difficult. To conduct the control of inner structure of the given joint a non-destructive method with the application of industrial CT scanner might be applied. This modern diagnosing method combines the x-ray examination with advanced computer technology. The basic advantage of computer-assisted tomography consists in examining objects in three dimensions and the possibility to carry out three-dimensional reconstructions. The aim of this article is to discuss the use of this method to evaluate the quality of welded joints made of aluminium alloys. Capabilities of computer-assisted tomography were depicted by the case of weld probes constructed with TIG (ang. Tungsten Inert Gas welding by different process variables. One has made the analysis of the quality of probes showing the smallest and the biggest internal and external welding defects.

  13. Bond and electron beam welding quality control of the aluminum stabilized and reinforced CMS conductor by means of ultrasonic phased-array technology

    CERN Document Server

    Neuenschwander, J; Horváth, I L; Luthi, T; Marti, H


    The Compact Muon Solenoid (CMS) is one of the general-purpose detectors to be provided for the LHC project at CERN. The design field of the CMS superconducting magnet is 4 T, the magnetic length is 12.5 m and the free bore is 6 m. The coils for CNIS are wound of aluminum-stabilized Rutherford type superconductors reinforced with high-strength aluminum alloy. For optimum performance of the conductor a void-free metallic bonding between the high-purity aluminum and the Rutherford type cable as well as between the electron beam welded reinforcement and the high-purity aluminum must be guaranteed. It is the main task of this development work to assess continuously the bond quality over the whole width and the total length of the conductors during manufacture. To achieve this goal we use the ultrasonic phased-array technology. The application of multi- element transducers allows an electronic scanning perpendicular to the direction of production. Such a testing is sufficiently fast in order to allow a continuous a...


    Directory of Open Access Journals (Sweden)

    Hakan ATEŞ


    Full Text Available In this work, automatic controllability of a laboratory-sized friction-welding machine has been investigated. The laboratory-sized friction-welding machine was composed of motor, brake, rotary and constant samples late pliers, and hydraulic unit. In automatic method, welding parameters such as friction time, friction pressure, forge time and forge pressure can be applied sensitively using time relays and contactors. At the end of the experimental study it's observed that automatic control system has been worked successfully.

  15. Health monitoring of welded structures using statistical process control (United States)

    Srinivasa Rao, Putti; Ratnam, Ch.


    This paper presents health monitoring of welded structures using acceleration time response data. Residual errors are extracted from the measured acceleration time response data using an auto-regressive model. Damage identification is done by monitoring the residual errors using Shewhart and exponentially weighted moving average control charts. The applicability of the proposed method is tested with the welded structure model. Five damage levels are investigated and the damage is introduced by cutting a slot in the weld using an electrical discharge machine. Acceleration time response data are collected using piezoelectric sensors for all damage levels. The results show that both Shewhart and exponentially weighted moving average control charts are capable of identifying the presence of damage in the welded structure model under consideration. Exponentially weighted moving average control charts are more sensitive in damage identification than Shewhart control charts.

  16. Multivariable Intelligent Control for M.A.G. Welding Process

    Directory of Open Access Journals (Sweden)

    Constantin MIHOLCA


    Full Text Available A neural control technique, applied to the MAG (Metal-Active Gas welding process, is presented in the paper. The static nonlinear model of welding process is based on experimental determinations. The geometric parameters of the welding beam are considered as output parameters of the MAG process (Bs, a, p, and they are measured for different step-variations of the input parameters (Ve, Vs, Ua. The analysis of the output dynamics was further used to model the MAG welding process using a 3- layer neural network with 6 hidden-layer neurons. In order to reject perturbations and cancel the stationary error, an error compensator was used, which consists of the reversedynamic model connected to a proportional integrator controller. imulation results for the multivariable neural controller are presented.

  17. Testing of the shopprimer’s influence on the quality of welded joint

    Directory of Open Access Journals (Sweden)

    T. Šolić


    Full Text Available This paper presents the process of preparing the surface of construction material and applying the temporary protection that refers to the two-component epoxy workshop primer (shopprimer in order to perform testing of its influence on mechanical properties of the weld. Testing of mechanical properties of welds after welding proved that there were no negative influences of the protective coating on the quality of welded joint.

  18. The application of fuzzy theory for the control of weld line positions in injection-molded part. (United States)

    Chen, Mei-Yung; Tzeng, Huan-Wen; Chen, Yi-Cheng; Chen, Shia-Chung


    This research proposes the fuzzy theory for the control of weld lines in plastic injection molding. The weld line occurs as a result of geometrical changes in molded parts in the injection molding process. The weld line is one of the defects present in plastic injection-molded parts; the line affects the quality of parts as well as the strength of the products. In the present study, fuzzy theory was applied in the design of injection molding. First, expert experiences were transformed into IF approximately THEN approximately rules to establish the knowledge base for developing fuzzy inference rules. The rules were then used to adjust the molding parameters, which in turn were applied to control the weld line position in the injection molding process. The results indicate that fuzzy theory exhibited favorable applicability in the control of the weld line as well as decreased the simulation time, thereby accelerating the design process of injection molding.

  19. 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


    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)

  20. Robust Control of Welding Robot for Tracking a Rectangular Welding Line

    Directory of Open Access Journals (Sweden)

    Manh Dung Ngo


    Full Text Available This paper highlights a welding robot (WR for its end effector to track a rectangular welding line (RWL. The WR includes five actuators which use a DC motor as a power source. Two controllers are proposed to control the WR's end effector: a main controller and a servo controller. Firstly, based on WR's kinematic equations and its feedback errors using backstepping method the main controller is proposed to design the reference-inputs for the WR's actuators in order that the WR's end effector tracks the RWL. Secondly, based on the dynamic equation of WR's actuator, the servo controller is designed using an active disturbance rejection control method. Finally, a control system incorporated with the main controller and the servo controllers make the WR's end effector robustly track a RWL in the presence of the modeling uncertainty and disturbances during the welding process. In experiment, the main controller which has a function as a master of the control system links to the five servo controllers which have a function as a slave via I2C communication. The effectiveness of the proposed control system is proven through the simulation and experimental results.

  1. Robust Control of Welding Robot for Tracking a Rectangular Welding Line

    Directory of Open Access Journals (Sweden)

    Manh Dung Ngo


    Full Text Available This paper highlights a welding robot (WR for its end effector to track a rectangular welding line (RWL. The WR includes five actuators which use a DC motor as a power source. Two controllers are proposed to control the WR's end effector: a main controller and a servo controller. Firstly, based on WR's kinematic equations and its feedback errors using backstepping method the main controller is proposed to design the reference-inputs for the WR's actuators in order that the WR's end effector tracks the RWL. Secondly, based on the dynamic equation of WR's actuator, the servo controller is designed using an active disturbance rejection control method. Finally, a control system incorporated with the main controller and the servo controllers make the WR's end effector robustly track a RWL in the presence of the modeling uncertainty and disturbances during the welding process. In experiment, the main controller which has a function as a master of the control system links to the five servo controllers which have a function as a slave via I2C communication. The effectiveness of the proposed control system is proven through the simulation and experimental results.

  2. Integrity and quality assessment applied on laser welded titanium components

    Directory of Open Access Journals (Sweden)

    Wirdelius Håkan


    Full Text Available Laser welding of thin titanium components, a critical component of many gas turbine engines, has demonstrated a tendency of generating pores in clusters with a prescribed orientation. These pores, also known as chain porosities, are often of harmless sizes (of 50–100 micrometer as individuals. Though the cluster as such, depending on the distances and orientations in between the pores, may have an impact on the structural integrity. A recently developed algorithm for 3-D positioning of small pore defects in planar geometries using digital X-ray inspection aims at providing 3-D positions of the defects. This could then be used in-line to assess the welding quality in the manufacturing process. This presentation describes the development of a methodology that aims to incorporate non-destructive evaluation with, in this case, structural integrity.

  3. Effect of the rotational speed of on the surface quality of 6061 Al-alloy welded joint using friction stir welding (United States)

    Feng, T. T.; Zhang, X. H.; Fan, G. J.; Xu, L. F.


    The rotational speed of the stir-welding head is an important technological parameter in friction stir welding (FSW) process. For investigating the effect of the rotational speed of the stir-welding head on the surface quality of the welded joint, in this study, the weld tests were conducted under different rotational speeds (in which the welding speed was fixed), and then the effects were analyzed using the heat-fluid analysis model established. The test results revealed that cracks or grooves could be observed on the welded joint at small rotational speeds; with the increase of rotational speed, the weld surface became bright and clean; as the rotational speed further increased, the surface of the welded joint may be over burnt. Through analysis, it can be observed that appropriate increasing the rotational speed of the stir-welding joint increased the heat input in welding; meanwhile, fewer materials participated in the formation of weld, the material’s flowability was improved, and the resistance that impeded the advance of the stir-welding needle was reduced, thereby improving the quality of the welded joint.

  4. Weld overlay coatings for erosion control

    Energy Technology Data Exchange (ETDEWEB)

    Levin, B.; DuPont, J.N.; Marder, A.R.


    A literature review was made. In spite of similarities between abrasive wear and solid particle erosion, weld overlay hardfacing alloys that exhibit high abrasion resistance may not necessarily have good erosion resistance. The performance of weld overlay hardfacing alloys in erosive environments has not been studied in detail. It is believed that primary-solidified hard phases such as carbides and intermetallic compounds have a strong influence on erosion resistance of weld overlay hardfacing alloys. However, relationships between size, shape, and volume fraction of hard phases in a hardfacing alloys and erosion resistance were not established. Almost all hardfacing alloys can be separated into two major groups based upon chemical compositions of the primary solidified hard phases: (a) carbide hardening alloys (Co-base/carbide, WC-Co and some Fe base superalloys); and (b) intermetallic hardening alloys (Ni-base alloys, austenitic steels, iron-aluminides).

  5. Concrete and steel construction quality control and assurance

    CERN Document Server

    El-Reedy, Mohamed A


    Starting with the receipt of materials and continuing all the way through to the final completion of the construction phase, Concrete and Steel Construction: Quality Control and Assurance examines all the quality control and assurance methods involving reinforced concrete and steel structures. This book explores the proper ways to achieve high-quality construction projects, and also provides a strong theoretical and practical background. It introduces information on quality techniques and quality management, and covers the principles of quality control. The book presents all of the quality control and assurance protocols and non-destructive test methods necessary for concrete and steel construction projects, including steel materials, welding and mixing, and testing. It covers welding terminology and procedures, and discusses welding standards and procedures during the fabrication process, as well as the welding codes. It also considers the total quality management system based on ISO 9001, and utilizes numer...

  6. Controlling Force and Depth in Friction Stir Welding (United States)

    Adams, Glynn; Loftus, Zachary; McCormac, Nathan; Venable, Richard


    Feedback control of the penetration force applied to a pin tool in friction stir welding has been found to be a robust and reliable means for controlling the depth of penetration of the tool. This discovery has made it possible to simplify depth control and to weld with greater repeatability, even on workpieces with long weld joints. Prior to this discovery, depths of penetration in friction stir welding were controlled by hard-tooled roller assemblies or by depth actuators controlled by feedback from such external sensors as linear variable-differential transformers or laser-based devices. These means of control are limited: A hard-tooled roller assembly confines a pin tool to a preset depth that cannot be changed easily during the welding process. A measurement by an external sensor is only an indirect indicative of the depth of penetration, and computations to correlate such a measurement with a depth of penetration are vulnerable to error. The present force-feedback approach exploits the proportionality between the depth and the force of penetration Unlike a depth measurement taken by an external sensor, a force measurement can be direct because it can be taken by a sensor coupled directly to the pin tool. The reading can be processed through a modern electronic servo control system to control an actuator to keep the applied penetration force at the desired level. In comparison with the older depth-control methods described above, this method offers greater sensitivity to plasticizing of the workpiece metal and is less sensitive to process noise, resulting in a more consistent process. In an experiment, a tapered panel was friction stir welded while controlling the force of penetration according to this method. The figure is a plot of measurements taken during the experiment, showing that force was controlled with a variation of 200 lb (890 N), resulting in control of the depth of penetration with a variation of 0.004 in. (0.1 mm).

  7. Spectroscopic closed loop control of penetration depth in laser beam welding process (United States)

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


    In-process monitoring and feedback control are fundamental actions for stable and good quality laser welding process. In particular, penetration depth is one of the most critical features to be monitored. In this research, overlap welding of stainless steel is investigated to stably reproduce a fixed penetration depth using both CO2 and Nd:YAG lasers. Plasma electron temperatures of Fe(I) and Cr(I) are evaluated as in process monitoring using the measurement of intensities of emission lines with fast spectrometers. The sensor system is calibrated using a quantitative relationship between electron temperature and penetration depth in different welding conditions. Finally closed loop control of the weld penetration depth is implemented by acquiring the electron temperature value and by adjusting the laser power to maintain a pre-set penetration depth. A PI controller is successfully used to stabilize the electron temperature around the set point corresponding to the right penetration depth starting from a wrong value of any initial laser power different than the set point. Optical inspection of the weld surface and macroscopic analyses of cross sections verify the results obtained with the proposed closed-loop system based on a spectroscopic controller and confirms the reliability of our system.

  8. 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 (United States)

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


    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.

  9. Application of infrared imaging for quality inspection in resistance spot welds (United States)

    Woo, Wanchuck; Chin, Charles W.; Feng, Zhili; Wang, Hsin; Zhang, Wei; Xu, Hanbing; Sklad, Philip S.


    Infrared thermal imaging method was applied for the development of a non-destructive inspection technique to determine the quality of resistance spot welds. The current work is an initial feasibility study based on post-mortem inspection. First, resistance spot welds were fabricated on dual phase steel sheets (DP 590 steel) with carefullycontrolled welding parameters. It created welds with desirable and undesirable qualities in terms of nugget size, indentation depth, and voids and cracks. Second, five different heating and cooling methods were evaluated. The heating or cooling source was applied on one side of the weld stack while the surface temperature change on the other side of the weld was recorded using an infrared camera. Correlation between the weld quality and the "thermal signature" of each weld was established. Finally, a simplified thermal finite element analysis was developed to simulate the heat flow during inspection. The thermal model provided insight into the effect of the nugget size and indentation depth on the peak temperature and heating rate. The results reported in this work indicate that the IR thermography technique is feasible for weld quality inspection due to the distinguish temperature profiles for different welds and the repeatability and consistency in measurement.

  10. 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)


    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.

  11. A CMOS Visual Sensing System for Welding Control and Information Acquirement in SMAW Process (United States)

    Anren, Yao; Zhen, Luo; Sansan, Ao

    A sequential research work on visual information of manual arc welding pool dynamics are presented in this paper. An optical inspection system, for monitoring the shielded manual arc welding (SMAW) process is described. The system consisted of a vision sensor that consisted of a Complementary Metal Oxide Semiconductor (CMOS) camera and lenses, image processing algorithms, and a computer controller. During welding, an image of the weld pool and its vicinity was captured when basic current of welding power. Experimental results showed that the temperature signal varies greatly in the case of instabilities of the weld pool that cause weld defects. The visual information acquirement methods are focused in computer vision sensing, image processing and characteristic extraction of the weld pool surface from the single-item pool images by particular algorithms control strategies are developed to control welding pool dynamics during SMAW.

  12. Hexavalent chromium exposure and control in welding tasks. (United States)

    Meeker, John D; Susi, Pam; Flynn, Michael R


    Studies of exposure to the lung carcinogen hexavalent chromium (CrVI) from welding tasks are limited, especially within the construction industry where overexposure may be common. In addition, despite the OSHA requirement that the use of engineering controls such as local exhaust ventilation (LEV) first be considered before relying on other strategies to reduce worker exposure to CrVI, data on the effectiveness of LEV to reduce CrVI exposures from welding are lacking. The goal of the present study was to characterize breathing zone air concentrations of CrVI during welding tasks and primary contributing factors in four datasets: (1) OSHA compliance data; (2) a publicly available database from The Welding Institute (TWI); (3) field survey data of construction welders collected by the Center for Construction Research and Training (CPWR); and (4) controlled welding trials conducted by CPWR to assess the effectiveness of a portable LEV unit to reduce CrVI exposure. In the OSHA (n = 181) and TWI (n = 124) datasets, which included very few samples from the construction industry, the OSHA permissible exposure level (PEL) for CrVI (5 μg/m(3)) was exceeded in 9% and 13% of samples, respectively. CrVI concentrations measured in the CPWR field surveys (n = 43) were considerably higher, and 25% of samples exceeded the PEL. In the TWI and CPWR datasets, base metal, welding process, and LEV use were important predictors of CrVI concentrations. Only weak-to-moderate correlations were found between total particulate matter and CrVI, suggesting that total particulate matter concentrations are not a good surrogate for CrVI exposure in retrospective studies. Finally, in the controlled welding trials, LEV reduced median CrVI concentrations by 68% (p = 0.02). In conclusion, overexposure to CrVI in stainless steel welding is likely widespread, especially in certain operations such as shielded metal arc welding, which is commonly used in construction. However, exposure could be

  13. Manganese and welding fume exposure and control in construction. (United States)

    Meeker, John D; Susi, Pam; Flynn, Michael R


    Overexposure to welding fume constituents, particularly manganese, is of concern in the construction industry due to the prevalence of welding and the scarcity of engineering controls. The control effectiveness of a commercially available portable local exhaust ventilation (LEV) unit was assessed. It consisted of a portable vacuum and a small bell-shaped hood connected by a flexible 2 inch (50.8 mm) diameter hose, in both experimental and field settings. The experimental testing was done in a semienclosed booth at a pipefitter training facility. Five paired trials of LEV control vs. no control, each approximately 1 hr in duration and conducted during two successive welds of 6 inch (152.4 mm) diameter carbon steel pipe were run in random order. Breathing zone samples were collected outside the welding hood during each trial. In the field scenario, full-shift breathing zone samples were collected from two pipefitters welding carbon steel pipe for a chiller installation on a commercial construction project. Eight days of full-shift sampling were conducted on both workers (n = 16), and the LEV was used by one of the two workers on an alternating basis for 7 of the days. All samples were collected with personal sample pumps calibrated at 2 L/min. Filter cassettes were analyzed for total particulate and manganese concentration by a certified laboratory. In the experimental setting, use of the portable LEV resulted in a 75% reduction in manganese exposure (mean 13 microg/m(3) vs. 51 microg/m(3); p 0.05). These results demonstrate that LEV use can reduce manganese exposure associated with welding tasks in construction.

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

    Energy Technology Data Exchange (ETDEWEB)

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


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

  15. Welding. (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…

  16. Stress-induced birefringence control in femtosecond laser glass welding (United States)

    Gstalter, M.; Chabrol, G.; Bahouka, A.; Serreau, L.; Heitz, J.-L.; Taupier, G.; Dorkenoo, K.-D.; Rehspringer, J.-L.; Lecler, S.


    Glass welding by femtosecond laser pulses causes microscopic structural modifications, affecting the refractive index due to residual stress. Locally induced birefringence is studied by photoelasticimetry using a polarized light microscope. The study is performed on borosilicate thin glass plates using an industrial femtosecond laser generating 300 fs pulses at 500 kHz, with a 100 mm focusing length F-theta lens allowing fast welding. For low-energy deposition, the principal birefringence axes are determined to be homogenous along the seam and perpendicular and parallel to the laser scanning direction. Tensile stress is induced in the laser scanning direction by the welding seams. The induced birefringence is determined to be equivalent for in-volume irradiated track and welding seams. An inhomogeneity of the birefringence within the seam is observed for the first time at high-energy deposition. The distribution of the birefringence can be controlled with the laser scanning patterns. The amount of residual stress is measured by compensating the local birefringence. The birefringence Δ n is estimated at 2.4 × 10^{-4}, corresponding to a residual stress amount around 59 MPa. The influence of the welding geometry is also illustrated.

  17. Electron Gun for Computer-controlled Welding of Small Components

    Czech Academy of Sciences Publication Activity Database

    Dupák, Jan; Vlček, Ivan; Zobač, Martin


    Roč. 62, 2-3 (2001), s. 159-164 ISSN 0042-207X R&D Projects: GA AV ČR IBS2065015 Institutional research plan: CEZ:AV0Z2065902 Keywords : Electron beam-welding machine * Electron gun * Computer- control led beam Subject RIV: BM - Solid Matter Physics ; Magnetism Impact factor: 0.541, year: 2001

  18. Development of the new physical method for real time spot weld quality evaluation using ultrasound (United States)

    Chertov, Andriy M.

    Since the invention of resistance spot welding, the manufacturers have been concerned about the quality assurance of the joints. One of the most promising directions in quality inspection is the real time ultrasonic nondestructive evaluation. In such a system, the acoustic signals are sent through the spot weld during welding and then analyzed to characterize the quality of the joint. Many research groups are currently working to develop a reliable inspection method. In this dissertation the new physical method of resistance spot weld quality monitoring is presented. It differs from all other ultrasonic methods by the physical principles of inspection. The multilayered structure of the spot weld with varying physical properties is investigated with short pulses of longitudinal ultrasonic waves. Unlike other methods, the developed technology works in reflection mode. The waves bring back the information which, after careful analysis, can be used to evaluate the weld quality. The complex structure of the weldment modifies the waves in different ways which, makes it hard to accurately measure the physical properties of the weldment. The frequency-dependent attenuation of the sound, diffraction, and beam divergence - all contribute to the signal distraction. These factors are fully studied, and ways to minimize them are presented. After application of pattern recognition routines, the weld characteristics are submitted to fuzzy logic algorithm, and the weld is characterized. The current level of the system development allowed the installation of two prototype machines at one assembly plant. The technology is now under thorough evaluation for robustness and accuracy in an industrial environment.

  19. Hybrid Control and Verification of a Pulsed Welding Process

    DEFF Research Database (Denmark)

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

    Currently systems, which are desired to control, are becoming more and more complex and classical control theory objectives, such as stability or sensitivity, are often not sufficient to cover the control objectives of the systems. In this paper it is shown how the dynamics of a pulsed welding...... process can be reformulated into a timed automaton hybrid setting and subsequently properties such as reachability and deadlock absence is verified by the simulation and verification tool UPPAAL....

  20. 77 FR 37711 - Circular Welded Carbon-Quality Steel Pipe From India, Oman, the United Arab Emirates, and Vietnam... (United States)


    ... COMMISSION Circular Welded Carbon-Quality Steel Pipe From India, Oman, the United Arab Emirates, and Vietnam...-fair-value imports from India, Oman, the United Arab Emirates, and Vietnam of circular welded carbon... respect to circular welded carbon-quality steel pipe from Oman and the United Arab Emirates being sold in...

  1. Design, implementation and testing of a fuzzy control scheme for laser welding

    NARCIS (Netherlands)

    Jauregui Becker, Juan Manuel; Aalderink, B.J.; Aalderink, Benno; Aarts, Ronald G.K.M.; Olde Benneker, Jeroen; Meijer, J.


    A fuzzy logic controller (FLC) scheme has been developed for laser welding. Process light emissions are measured and combined to determine the current status of the welding process. If the process is not in a desired welding state, the FLC will adapt the laser power. The FLC has been demonstrated

  2. Welding arc plasma physics (United States)

    Cain, Bruce L.


    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.

  3. Study on Intelligent Control of Metal Filling System by Welding Robots in the Open Environment

    Directory of Open Access Journals (Sweden)

    Wei Fu


    Full Text Available robot model of three-arm and five-degree freedom plus large scope of traversing welding was established, and decoupling of models of “large scope of traversing”, “triangle movement of two arms” and “spherical movement of one arm” was realized. The model of “triangle movement of two arms ”is able to use geometrical calculation to solve the kinematics inverse problem , avoid the multiplicity, improve the calculation speed, eliminate the blind spots of the motions of welding gun of welding robot, and simplify the kinematic pair of kinematic mechanism for the arc filling strategy during welding travelling of robot. Binocular stereo vision camera was used to detect the edges of welds, and laser array sensor was used to detect the amount of metal filling of welds. In completely open conditions, feedback was fused based on sensor data to realize the welding tracking control by welding robot.

  4. Process control in continuous high-power CO2 laser beam welding (United States)

    Seidel, Bernd; Beersiek, Jorg; Beyer, Eckhard


    The use of high power CO2 lasers in welding enables processing with high laser intensities at the workpiece which is connected with the formation of a laser induced plasma at the surface of the workpiece. Therefore the effect of deep penetration welding by formation of a plasma filled keyhole and plasma plume above the workpiece is possible, including the risk of plasma shielding, which means strong absorption of the incident laser beam above the workpiece and thus interruption of the welding process. The conditions for ignition of plasma shielding, which is determined by electron density, are mainly influenced by laser intensity, process gas and material. Variations of these parameters have been conducted in order to find limits for the appearance of plasma shielding. Experimental data are used to verify a model concerning the absorption mechanism of a stationary shielding plasma state. The dynamic behavior is treated by time resolved spectroscopic analysis of the light emitted by the plasma above the workpiece yielding monitoring signals that have a strong correlation with the formation of plasma shielding. Based on these investigations a closed-loop process control in continuous high power laser welding has been developed. Using the intensity of a spectral line of laser induced plasma as monitoring signal and the regulation of laser intensity via laser power, plasma shielding can be suppressed. From the industrial point of view increase in economy and reliability of the laser welding process combined with quality improvements which are induced by the application of the plasma shielding controller (PSC) are of great importance. For this reason three examples of PSC application are presented.

  5. In-line process control for laser welding of titanium by high dynamic range ratio pyrometry and plasma spectroscopy (United States)

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


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

  6. Design of controller for mobile robot in welding process of shipbuilding engineering

    Directory of Open Access Journals (Sweden)

    Namkug Ku


    Full Text Available The present study describes the development of control hardware and software for a mobile welding robot. This robot is able to move and perform welding tasks in a double hull structure. The control hardware consists of a main controller and a welding machine controller. Control software consists of four layers. Each layer consists of modules. Suitable combinations of modules enable the control software to perform the required tasks. Control software is developed using C programming under QNX operating system. For the modularizing architecture of control software, we designed control software with four layers: Task Manager, Task Planner, Actions for Task, and Task Executer. The embedded controller and control software was applied to the mobile welding robot for successful execution of the required tasks. For evaluate this imbedded controller and control software, the field tests are conducted, it is confirmed that the developed imbedded controller of mobile welding robot for shipyard is well designed and implemented.

  7. Weld quality inspection using laser-EMAT ultrasonic system and C-scan method (United States)

    Yang, Lei; Ume, I. Charles


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

  8. Residual stress reduction and fatigue strength improvement by controlling welding pass sequences

    Energy Technology Data Exchange (ETDEWEB)

    Mochizuki, Masahito; Hattori, Toshio; Nakakado, Kimiaki


    The effects of residual stress on fatigue strength at a weld toe in a multi-pass fillet weld joint were evaluated. The residual stresses in the weld joints were varied by controlling the sequence of welding passes. The residual stress at the weld toe was 80 MPa in the specimen whose last welding pass was on the main plate side, but it was 170 MPa in the specimen whose last pass was on the attachment side. The fatigue strength was nearly the same at high stress amplitude for both specimens, but the fatigue strength of the specimen whose last weld pass on the main plate was higher than that of the other specimen at low stress amplitude. This difference is due to the magnitude of the initial residual stress and the relaxation of the residual stress under fatigue cycling. The effects of the residual stress were shown in a modified Goodman diagram, in which residual stress is treated as a mean stress.

  9. System for evaluating weld quality using eddy currents

    Energy Technology Data Exchange (ETDEWEB)

    Todorov, Evgueni I.; Hay, Jacob


    Electromagnetic and eddy current techniques for fast automated real-time and near real-time inspection and monitoring systems for high production rate joining processes. An eddy current system, array and method for the fast examination of welds to detect anomalies such as missed seam (MS) and lack of penetration (LOP) the system, array and methods capable of detecting and sizing surface and slightly subsurface flaws at various orientations in connection with at least the first and second weld pass.

  10. Robot welding process control development task (United States)

    Romine, Peter L.


    The completion of, and improvements made to, the software developed during 1990 for program maintenance on the PC and HEURIKON and transfer to the CYRO, and integration of the Rocketdyne vision software with the CYRO is documented. The new programs were used successfully by NASA, Rocketdyne, and UAH technicians and engineers to create, modify, upload, download, and control CYRO NC programs.

  11. 77 FR 73674 - Circular Welded Carbon-Quality Steel Pipe From India, Oman, The United Arab Emirates, and Vietnam (United States)


    ...-1191-1194 (Final)] Circular Welded Carbon-Quality Steel Pipe From India, Oman, The United Arab Emirates... of circular welded carbon-quality steel pipe from India, Oman, the United Arab Emirates, and Vietnam...- quality steel pipe from India, Oman, the United Arab Emirates, and Vietnam were subsidized and/or dumped...

  12. Improved electron beam weld design and control with beam current profile measurements (United States)

    Giedt, Warren H.

    The determination of machine settings for making an electron beam weld still involves trial and error tests. Also, even after settings are selected, serious variations in penetration may occur. Results are presented to demonstrate that improved weld consistency and quality can be obtained with measurement of the beam size and intensity distribution.

  13. Investigation and control of factors influencing resistance upset butt welding.

    NARCIS (Netherlands)

    Kerstens, N.F.H.


    The purpose of this work is to investigate the factors influencing the resistance upset butt welding process to obtain an understanding of the metal behaviour and welding process characteristics, so that new automotive steels can be welded with reduced development time and fewer failures in

  14. Upgrading weld quality of a friction stir welded aluminum alloys AMG6 (United States)

    Chernykh, I. K.; Vasil’ev, E. V.; Matuzko, E. N.; Krivonos, E. V.


    In the course of introduction of FSW technology into the industry there is a keen interest in this process; there are issues such as how does joining take place, what is the structure of the joint, and where there are dangerous zones. The objective of this research is to obtain information about the structure of the joint, what are the temperatures that arise during the joining, what strength is apply to the tool when joining the material, what tensile strength of joint, and where fracture tended to occur. Specimens were produced at different modes of welding at a tool rotation speed of 315 to 625 rpm and tool travel speed of 40 to 125 mm/min. During the experiment, the strength applied to the tool was measured, which reached 800016000 N (Fz) and 400-1400 N (Fx) and the temperature on the surface of the tool, which is in the range 250-400°C. Before the welding process the tool was heated to a temperature in the range of 100-250 degrees, but the tensile strength is not had a tangible impact. The tensile strength is about 80 % of that of the aluminum alloy base metal tensile strength, and fracture tended is occur not at the line of joint but follow the shape of the tool. In the transverse cross section of a FSW material there is a microstructural regions such as weld nugget, thermomechanically affected zone and heat-affected zone with parent material.

  15. Control of Hydrogen Embrittlement in High Strength Steel Using Special Designed Welding Wire (United States)


    microstructure 4. A low near ambient temperature is reached. • All four factor must be simultaneously present 3 Mitigating HIC and Improving Weld Fatigue...Performance Through Weld Residual Stress Control UNCLASIFIED:DISTRIBUTION A. Approved for public release: distribution unlimited. Click to edit Master...title style 4 • Welding of Armor Steels favors all these conditions for HIC • Hydrogen Present in Sufficient Degree – Derived from moisture in the

  16. 78 FR 63517 - Control of Ferrite Content in Stainless Steel Weld Metal (United States)


    ... to remove an appendix that has been incorporated into relevant specifications. ADDRESSES: Please... procedure for the control of ferrite content in stainless steel weld metal. This guide provides methods that..., Safety Guide 31, ``Control of Stainless Steel Welding,'' issued August 1972, provided guidance to test...

  17. Feasibility study of imaging spectroscopy to monitor the quality of online welding. (United States)

    Mirapeix, Jesús; García-Allende, P Beatriz; Cobo, Adolfo; Conde, Olga M; López-Higuera, José M


    An online welding quality system based on the use of imaging spectroscopy is proposed and discussed. Plasma optical spectroscopy has already been successfully applied in this context by establishing a direct correlation between some spectroscopic parameters, e.g., the plasma electronic temperature and the resulting seam quality. Given that the use of the so-called hyperspectral devices provides both spatial and spectral information, we propose their use for the particular case of arc welding quality monitoring in an attempt to determine whether this technique would be suitable for this industrial situation. Experimental welding tests are presented, and the ability of the proposed solution to identify simulated defects is proved. Detailed spatial analyses suggest that this additional dimension can be used to improve the performance of the entire system.

  18. Significance of the Resonance Condition for Controlling the Seam Position in Laser-assisted TIG Welding (United States)

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

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

  19. A Neural Network Approach for GMA Butt Joint Welding

    DEFF Research Database (Denmark)

    Christensen, Kim Hardam; Sørensen, Torben


    This paper describes the application of the neural network technology for gas metal arc welding (GMAW) control. A system has been developed for modeling and online adjustment of welding parameters, appropriate to guarantee a certain degree of quality in the field of butt joint welding with full...... penetration, when the gap width is varying during the welding process. The process modeling to facilitate the mapping from joint geometry and reference weld quality to significant welding parameters has been based on a multi-layer feed-forward network. The Levenberg-Marquardt algorithm for non-linear least...

  20. The Design of Intelligent Repair Welding Mechanism and Relative Control System of Big Gear

    Directory of Open Access Journals (Sweden)

    Hong-Yu LIU


    Full Text Available Effective repair of worn big gear has large influence on ensuring safety production and enhancing economic benefits. A kind of intelligent repair welding method was put forward mainly aimed at the big gear restriction conditions of high production cost, long production cycle and high- intensity artificial repair welding work. Big gear repair welding mechanism was designed in this paper. The work principle and part selection of big gear repair welding mechanism was introduced. The three dimensional mode of big gear repair welding mechanism was constructed by Pro/E three dimensional design software. Three dimensional motions can be realized by motor controlling ball screw. According to involute gear feature, the complicated curve motion on curved gear surface can be transformed to linear motion by orientation. By this way, the repair welding on worn gear area can be realized. In the design of big gear repair welding mechanism control system, Siemens S7-200 series hardware was chosen. Siemens STEP7 programming software was chosen as system design tool. The entire repair welding process was simulated by experiment simulation. It provides a kind of practical and feasible method for the intelligent repair welding of big worn gear.

  1. 77 FR 60478 - Control of Ferrite Content in Stainless Steel Weld Metal (United States)


    ... Ferrite Content in Stainless Steel Weld Metal.'' This guide describes a method that the NRC staff... guide describes a method that the staff of the U.S. Nuclear Regulatory Commission (NRC) considers... COMMISSION Control of Ferrite Content in Stainless Steel Weld Metal AGENCY: Nuclear Regulatory Commission...

  2. Pulse current gas metal arc welding characteristics, control and applications

    CERN Document Server

    Ghosh, Prakriti Kumar


    This monograph is a first-of-its-kind compilation on high deposition pulse current GMAW process. The nine chapters of this monograph may serve as a comprehensive knowledge tool to use advanced welding engineering in prospective applications. The contents of this book will prove useful to the shop floor welding engineer in handling this otherwise critical welding process with confidence. It will also serve to inspire researchers to think critically on more versatile applications of the unique nature of pulse current in GMAW process to develop cutting edge welding technology.

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

    DEFF Research Database (Denmark)

    Juhl, Thomas Winther; Olsen, Flemming Ove


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

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

    Directory of Open Access Journals (Sweden)

    Eber Huanca Cayo


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

  5. Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties (United States)

    Pan, Yi; Lados, Diana A.


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

  6. Development of the manufacture and process for DUPIC fuel elements; development of the quality evaluation techniques for end cap welds of DUPIC fuel elements

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Sang Tae; Choi, Myong Seon; Yang, Hyun Tae; Kim, Dong Gyun; Park, Jin Seok; Kim, Jin Ho [Yeungnam University, Kyongsan (Korea)


    The objective of this research is to set up the quality evaluation techniques for end cap welds of DUPIC fuel element. High temperature corrosion test and the SCC test for Zircaloy-4 were performed, and also the possibility of the ultrasonic test technique was verified for the quality evaluation and control of the laser welds in the DUPIC fuel rod end cap. From the evaluation of corrosion properties with measuring the weight gain and observing oxide film of the specimen that had been in the circumstance of steam(400 .deg. C, 1,500 psi) by max. 70 days later, the weight gain of the welded specimens was larger than original tube and the weight increasing rate increased with the exposed days. For the Development of techniques for ultrasonic test, semi-auto ultrasonic test system has been made based on immersion pulse-echo technique using spherically concentrated ultrasonic beam. Subsequently, developed ultrasonic test technique is quite sensible to shape of welds in the inside and outside of tube as well as crack, undercut and expulsion, and also this ultrasonic test, together with metallurgical fracture test, has good reliance as enough to be used for control method of welding process. 43 refs., 47 figs., 8 tabs. (Author)

  7. 77 FR 65712 - Circular Welded Carbon-Quality Steel Pipe From Vietnam; Termination of Investigation (United States)


    ... COMMISSION Circular Welded Carbon-Quality Steel Pipe From Vietnam; Termination of Investigation AGENCY... subsidies in connection with the subject investigation (77 FR 64471). Accordingly, pursuant to section 207.40(a) of the Commission's Rules of Practice and Procedure (19 CFR 207.40(a)), the countervailing duty...

  8. Programmable Automated Welding System (PAWS): Control of welding through software and hardware (United States)

    Kline, Martin D.; Doyle, Thomas E.


    The ATD phase of the PAWS program ended in November 1992 and the follow-on ManTech program was started in September 1993. The system will be industrially hardened during the first year of this program. Follow-on years will focus upon the transition into specific end-user sites. These implementations will also expand the system into other welding processes (e.g. FCAW, GTAW, PAW). In addition, the architecture is being developed for application to other non-welding robotic processes (e.g. inspection, surface finishing). Future development is anticipated to encompass hardening for extreme environments, expanded exception handling techniques, and application to a range of manipulators.

  9. A Neural Network Approach for GMA Butt Joint Welding

    DEFF Research Database (Denmark)

    Christensen, Kim Hardam; Sørensen, Torben


    This paper describes the application of the neural network technology for gas metal arc welding (GMAW) control. A system has been developed for modeling and online adjustment of welding parameters, appropriate to guarantee a certain degree of quality in the field of butt joint welding with full...

  10. 77 FR 19211 - Circular Welded Carbon-Quality Steel Pipe From the Socialist Republic of Vietnam: Preliminary... (United States)


    ... circular welded pipe. Specifically, SeAH VINA claims that the Brazilian, Korean, and Mexican orders on...: Circular Welded Carbon Quality Steel Pipe From the People's Republic of China, 73 FR 31970 (June 5, 2008... Certain Oil Country Tubular Goods From the People's Republic of China: ] Amended Final Affirmative...

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

    DEFF Research Database (Denmark)

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


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

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


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


    Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which sub...

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

    Directory of Open Access Journals (Sweden)

    Faheem Yousaf


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

  14. The use of electromagnetic body forces to enhance the quality of laser welds (United States)

    Ambrosy, Guenter; Berger, P.; Huegel, H.; Lindenau, D.


    The use of electromagnetic body forces in laser beam welding of aluminum alloys is a new method to shape the geometry and to enhance the quality of the weld seams. In this new approach, electromagnetic volume forces are utilized by applying magnetic fields and electric currents of various origins. Acting in the liquid metal, they directly affect the flow field and can lead to favourable conditions for the melt dynamics and energy coupling. Numerous welds with full and partial penetration using both CO2 and Nd:YAG lasers demonstrate that this method directly influences the seam geometry and top-bead topography as well as the penetration depth and the evolution of pores and cracks. In the case of full penetration, it is also possible to lift or to lower the weld pool. The method, therefore, can be used to shape the geometry and to enhance the quality of the weld seam. Depending on the orientation of an external magnetic field, significant impacts are achieved in CO2 welding, even without an external current: the shape of the cross-sectional area can be increased of up to 50% and also the seam width is changed. Whereas for such conditions with Nd:YAG lasers no significant effect could be observed, it turned out that, when an external electric current is applied, similar effects are present with both wavelengths. In further investigations, the effect of electromagnetic body forces resulting from the interaction of an external current and its self-induced magnetic field was studied. Hereby, the current was fed into the workpiece via a tungsten electrode or a filler wire. The resulting phenomena are the same independent from wavelength and means of current feed.

  15. The risk of male subfecundity attributable to welding of metals. Studies of semen quality, infertility, fertility, adverse pregnancy outcome and childhood malignancy. (United States)

    Bonde, J P


    congenital malformation and cancer in offspring from stainless steel welding are not indicated by the studies. Weak indications of an increased risk of spontaneous abortion among partners to stainless steel welders (OR 1.9, 95% CI 1.1-3.2) need to be refuted or corroborated in future studies. Suggested effects of mild steel welding on male fecundity should be corroborated by longitudinal controlled studies of semen quality examined before and during exposure and by prospective studies of fecundability in couples trying to conceive a child. On account of the present knowledge it is not possible to recommend rational preventative measures with the exception of elimination of radiant heat exposure in cases of infertility.(ABSTRACT TRUNCATED AT 400 WORDS)

  16. Development of precision numerical controlled high vacuum electron beam welding machine

    CERN Document Server

    Li Shao Lin


    The structure, main technical parameters and characteristics of the precision numerical controlled high vacuum electron beam welding machine are introduced. The design principle, some features and solutions to some key technique problems of this new type machine are described


    Directory of Open Access Journals (Sweden)

    O. A. Haivoronskyi


    the martensite share does not exceed the number of lower bainite (ratio of M/Bn < 1. It is proved that exposure of wheels within 3.5-4.5 hours at 100°C after welding, during their slow cooling improves resistance to brittle fracture of metal heat-affected zone by 1.8-2.3 times. This is due to the removal of diffusion hydrogen from the metal and reduction of the ІІ type stress in the lath volume of bainite and martensite by 1.5. Originality. The author has developed the idea of the structural-phase changes that occur in the metal of railway wheels during arc welding. The relation between the carbon content in steel, cooling rate during welding and resistance to cracking and brittle fracture was found. The authors determined the influence of after-welding wheel cooling conditions on the metal properties. Practical value. Technological recommendations for railway freight wheel building up by welding were developed. Their application will improve quality of the railway wheels built up by welding, reliability and safety of traffic in conditions of growing operating loads.

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

    Energy Technology Data Exchange (ETDEWEB)

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


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

  19. Design of Boiler Welding for Improvement of Lifetime and Cost Control. (United States)

    Thong-On, Atcharawadi; Boonruang, Chatdanai


    Fe-2.25Cr-1Mo a widely used material for headers and steam tubes of boilers. Welding of steam tube to header is required for production of boiler. Heat affected zone of the weld can have poor mechanical properties and poor corrosion behavior leading to weld failure. The cost of material used for steam tube and header of boiler should be controlled. This study propose a new materials design for boiler welding to improve the lifetime and cost control, using tungsten inert gas (TIG) welding of Fe-2.25Cr-1Mo tube to carbon steel pipe with chromium-containing filler. The cost of production could be reduced by the use of low cost material such as carbon steel pipe for boiler header. The effect of chromium content on corrosion behavior of the weld was greater than that of the microstructure. The lifetime of the welded boiler can be increased by improvement of mechanical properties and corrosion behavior of the heat affected zone.

  20. Design of Boiler Welding for Improvement of Lifetime and Cost Control

    Directory of Open Access Journals (Sweden)

    Atcharawadi Thong-On


    Full Text Available Fe-2.25Cr-1Mo a widely used material for headers and steam tubes of boilers. Welding of steam tube to header is required for production of boiler. Heat affected zone of the weld can have poor mechanical properties and poor corrosion behavior leading to weld failure. The cost of material used for steam tube and header of boiler should be controlled. This study propose a new materials design for boiler welding to improve the lifetime and cost control, using tungsten inert gas (TIG welding of Fe-2.25Cr-1Mo tube to carbon steel pipe with chromium-containing filler. The cost of production could be reduced by the use of low cost material such as carbon steel pipe for boiler header. The effect of chromium content on corrosion behavior of the weld was greater than that of the microstructure. The lifetime of the welded boiler can be increased by improvement of mechanical properties and corrosion behavior of the heat affected zone.

  1. Design of Boiler Welding for Improvement of Lifetime and Cost Control (United States)

    Thong-On, Atcharawadi; Boonruang, Chatdanai


    Fe-2.25Cr-1Mo a widely used material for headers and steam tubes of boilers. Welding of steam tube to header is required for production of boiler. Heat affected zone of the weld can have poor mechanical properties and poor corrosion behavior leading to weld failure. The cost of material used for steam tube and header of boiler should be controlled. This study propose a new materials design for boiler welding to improve the lifetime and cost control, using tungsten inert gas (TIG) welding of Fe-2.25Cr-1Mo tube to carbon steel pipe with chromium-containing filler. The cost of production could be reduced by the use of low cost material such as carbon steel pipe for boiler header. The effect of chromium content on corrosion behavior of the weld was greater than that of the microstructure. The lifetime of the welded boiler can be increased by improvement of mechanical properties and corrosion behavior of the heat affected zone. PMID:28774014

  2. Prediction of weld data using process control based on surface temperature measurement for high-power energy flow processes (United States)

    Brueggemann, Gunnar; Benziger, Thomas


    The main aim of this article is to obtain the correlation between the thermal cycle and the mechanical properties in the weld seam and the heat-affected zone of mild and stainless steels. Key targeted process is welding using electron beam, laser and plasma. Since these processes are characterized by high heating and cooling rates, wide temperature range, small heat affected zones, they are difficult to control and automize. As a consequence, the quality of the product varies over a large range. Because either temperature measurement on one spot or quasi steady- state surface temperature distribution in a large area are generally unsuitable, temperature gradients need to be controlled directly on-line with a high accuracy. This requires the use of a two dimensional temperature control. An infrared camera systems can be used in order to investigate the cooling process in the weld seam area as well as in the heat affected zone. On the one hand the aim of the experiments is the estimation of the microstructure, especially of the hardness distribution using welding-time- temperature-conversion-diagrams and equations of regression. On the other hand the observation of the cooling cycle allows trends of mechanical diagrams and equations of regression. On the other hand the observation of the cooing cycle allows trends of mechanical properties like stretch limit, tensile strength, breaking elongation to be predicted. Simultaneously it is possible to recognize and to localize pores, voids and bonding defects, losses in penetration, problems with gap and height, appearing during the cooling of the weld.

  3. Quality Control Applications

    CERN Document Server

    Chorafas, Dimitris N


    Quality control is a constant priority in electrical, mechanical, aeronautical, and nuclear engineering – as well as in the vast domain of electronics, from home appliances to computers and telecommunications. Quality Control Applications provides guidance and valuable insight into quality control policies; their methods, their implementation, constant observation and associated technical audits. What has previously been a mostly mathematical topic is translated here for engineers concerned with the practical implementation of quality control. Once the fundamentals of quality control are established, Quality Control Applications goes on to develop this knowledge and explain how to apply it in the most effective way. Techniques are described and supported using relevant, real-life, case studies to provide detail and clarity for those without a mathematical background. Among the many practical examples, two case studies dramatize the importance of quality assurance: A shot-by-shot analysis of the errors made ...

  4. Remotely controlled semi-automatic welding of two revolution symmetrical pieces. Procede de soudage semi-automatique commande a distance de deux pieces symetriques de revolution

    Energy Technology Data Exchange (ETDEWEB)

    Gaudin, J.P.


    The welding is controlled from a control station situated at some distance from the welding zone. The welding parameters are fixed before the welding pass by an operator from values furnished by a memory in which the appropriate parameters are stored. After control of these parameters the welding operation is initiated. The welding operation is constantly observed on a remotely placed screen. The welding parameters may be adjusted by the operator in accordance with the image observed. These modifications are controlled by comparison with the memory content.

  5. Assisting Gas Optimization in CO2 Laser Welding

    DEFF Research Database (Denmark)

    Gong, Hui; Olsen, Flemming Ove


    High quality laser welding is achieved under the condition of optimizing all process parameters. Assisting gas plays an important role for sound welds. In the conventional welding process assisting gas is used as a shielding gas to prevent that the weld seam oxidates. In the laser welding process...... assisting gas is also needed to control the laser induced plasma.Assisting gas is one of the most important parameters in the laser welding process. It is responsible for obtaining a quality weld which is characterized by deep penetration, no interior imperfections, i.e. porosity, no crack, homogeneous seam...... surface, etc. In this work a specially designed flexible off-axis nozzle capable of adjusting the angle of the nozzle, the diameter of the nozzle, and the distance between the nozzle end and the welding zone is tested. In addition to the nozzle parameters three gases, Nitrogen, Argon, and Helium...

  6. 76 FR 72173 - Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman, the United Arab... (United States)


    ... From the Federal Register Online via the Government Publishing Office ] DEPARTMENT OF COMMERCE... domestic like product analysis in this case, see Countervailing Duty Investigation Initiation Checklist: Circular Welded Carbon-Quality Steel Pipe from India (``India CVD Checklist''), Countervailing Duty...

  7. Software product quality control

    CERN Document Server

    Wagner, Stefan


    Quality is not a fixed or universal property of software; it depends on the context and goals of its stakeholders. Hence, when you want to develop a high-quality software system, the first step must be a clear and precise specification of quality. Yet even if you get it right and complete, you can be sure that it will become invalid over time. So the only solution is continuous quality control: the steady and explicit evaluation of a product's properties with respect to its updated quality goals.This book guides you in setting up and running continuous quality control in your environment. Star


    Directory of Open Access Journals (Sweden)

    Janette Brezinová


    Full Text Available This contribution deals with the analysis of the renovation layer quality of continuous casting steel rolls, developed through the submerged arc surfacing method (SAW. The continuous casting roll was analysed via the degradation phenomena which act during the operation. Four kinds of filler materials were used for the renovation of the worn roll. Surfacing was carried out as a three-layer in order to eliminate the need for intermediate layer formation. The quality of weld deposits was evaluated in terms of the structure, hardness and wear resistance of weld deposits at 23°C and 400 °C using pin-on-disc wear test. The best properties showed newly developed filler material W8-WLDC8 from the point of view of the hardness, together with wear resistance of the deposited layers in room and elevated temperatures.

  9. Quality of weld clads applied by SAW method in adhesive wear conditions

    Directory of Open Access Journals (Sweden)

    Janette Brezinová


    Full Text Available This contribution deals with the analysis of the renovation layer quality of continuous casting steel rolls, developed through the submerged arc surfacing method (SAW. The continuous casting roll was analysed via the degradation phenomena which act during the operation. Four kinds of filler materials were used for the renovation of the worn roll. Surfacing was carried out as a three-layer in order to eliminate the need for intermediate layer formation. The quality of weld deposits was evaluated in terms of the structure, hardness and wear resistance of weld deposits at 23°C and 400 °C using pin-on-disc wear test. The best properties showed newly developed filler material W8-WLDC8 from the point of view of the hardness, together with wear resistance of the deposited layers in room and elevated temperatures.

  10. Welding processes handbook

    CERN Document Server

    Weman, Klas


    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...

  11. Development and actual application of new welding process for weld-type piston crown in LMC diesel engine

    Energy Technology Data Exchange (ETDEWEB)

    Hatano, H.; Shimizu, H.; Fujiwara, F.; Tokuoka, T.; Nishimoto, T.; Fujita, R.; Matsui, S.; Nakayama, S.


    In the improved LMC diesel engines for saving fuel oil, the piston crown becomes more rigid. Unibody casting cannot achieve sufficiently high quality for piston crowns, in the smoothness of the inner surface of the cooling hole, for example. A welded piston crown would solve this problem, in which various pieces could be machined smoothly and then welded together. Joint locations are selected to satisfy welding and design requirements. Welding sequence and welding restraint are analysed using the finite element method. Because pistons can be welded from outside only, narrow gap TIG welding is applied to obtain a smooth bead. Then, narrow gap MAG welding is applied to reduce welding time. TIG-MAG combined welding equipment including welding torchs manipulator, positioner and controller is designed, fabricated, and assembled. Utilizing this equipment, experiments such as welding condition test, restraint crack test, joint property test, operation tests, and mock-up tests are carried out. Then, the products are welded and welds are inspected by an optical fiber for the appearance of the bead and also by ultrasonic and magnetic tests for defects.

  12. Enhancing the Mechanical Properties of Electrospun Nanofiber Mats through Controllable Welding at the Cross Points. (United States)

    Li, Haoxuan; Zhu, Chunlei; Xue, Jiajia; Ke, Qinfei; Xia, Younan


    This communication describes a simple and effective method for welding electrospun nanofibers at the cross points to enhance the mechanical properties of their nonwoven mats. The welding is achieved by placing a nonwoven mat of the nanofibers in a capped vial with the vapor of a proper solvent. For polycaprolactone (PCL) nanofibers, the solvent is dichloromethane (DCM). The welding can be managed in a controllable fashion by simply varying the partial pressure of DCM and/or the exposure time. Relative to the pristine nanofiber mat, the mechanical strength of the welded PCL nanofiber mat can be increased by as much as 200%. Meanwhile, such a treatment does not cause any major structural changes, including morphology, fiber diameter, and pore size. This study provides a generic method for improving the mechanical properties of nonwoven nanofiber mats, holding great potential in various applications. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  13. Control of surface defects on plasma-MIG hybrid welds in cryogenic aluminum alloys (United States)

    Lee, Hee-Keun; Chun, Kwang-San; Park, Sang-Hyeon; Kang, Chung-Yun


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

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

    Directory of Open Access Journals (Sweden)

    Hee-Keun Lee


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

  15. Increase in oxidative stress levels following welding fume inhalation: a controlled human exposure study. (United States)

    Graczyk, Halshka; Lewinski, Nastassja; Zhao, Jiayuan; Sauvain, Jean-Jacques; Suarez, Guillaume; Wild, Pascal; Danuser, Brigitta; Riediker, Michael


    Tungsten inert gas (TIG) welding represents one of the most widely used metal joining processes in industry. It has been shown to generate a large majority of particles at the nanoscale and to have low mass emission rates when compared to other types of welding. Despite evidence that TIG fume particles may produce reactive oxygen species (ROS), limited data is available for the time course changes of particle-associated oxidative stress in exposed TIG welders. Twenty non-smoking male welding apprentices were exposed to TIG welding fumes for 60 min under controlled, well-ventilated settings. Exhaled breathe condensate (EBC), blood and urine were collected before exposure, immediately after exposure, 1 h and 3 h post exposure. Volunteers participated in a control day to account for oxidative stress fluctuations due to circadian rhythm. Biological liquids were assessed for total reducing capacity, hydrogen peroxide (H2O2), malondialdehyde (MDA), and 8-hydroxy-2'-deoxyguanosine (8-OHdG) concentrations at each time point. A linear mixed model was used to assess within day and between day differences. Significant increases in the measured biomarkers were found at 3 h post exposure. At 3 h post exposure, we found a 24 % increase in plasma-H2O2 concentrations ([95%CI: 4 % to 46 %], p = 0.01); a 91 % increase in urinary-H2O2 ([2 % to 258 %], p = 0.04); a 14 % increase in plasma-8-OHdG ([0 % to 31 %], p = 0.049); and a 45 % increase in urinary-8-OHdG ([3 % to 105 %], p = 0.03). Doubling particle number concentration (PNC) exposure was associated with a 22 % increase of plasma-8-OHdG at 3 h post exposure (p = 0.01). A 60-min exposure to TIG welding fume in a controlled, well-ventilated setting induced acute oxidative stress at 3 h post exposure in healthy, non-smoking apprentice welders not chronically exposed to welding fumes. As mass concentration of TIG welding fume particles is very low when compared to other types of welding, it is

  16. Automatic Optimization of Focal Point Position in CO2 Laser Welding with Neural Network in A Focus Control System

    DEFF Research Database (Denmark)

    Gong, Hui; Olsen, Flemming Ove

    acquisition card - DAQCard-700, and a self-learning mechanism - Neural Network. The optimization procedure starts with the welding process being carried out by continuously moving the focal point position from above a welding plate to below the plate, thus the process is ensured to be shifted from initially...... surface welding to deep/full penetration welding and back to surface welding again. A clear change on plasma brightness from the process is monitored by the photo diode on the front side of the plate with a viewing angle of 45o. The photo diode signal is acquired with the A/D converter card and installed......-learning mechanism - neural network as the essence of the control system is trained with the photo diode signals extracted from various welding processes with the changes on the laser power, translation speed, material and thickness of the plate, shielding gas type and flow rate, and welding configuration...

  17. Checking quality control?

    DEFF Research Database (Denmark)

    Brodersen, Lars


    How is quality control doing within the community of GIS, web-services based on geo-information, GI etc.?......How is quality control doing within the community of GIS, web-services based on geo-information, GI etc.?...

  18. Foreground marker controlled watershed on digital radiographic image for weld discontinuity detection (United States)

    Abd Halim, Suhaila; Zahid, Akhma; Abdul Razak, Nurul Syafinaz; Ibrahim, Arsmah; Manurung, Yupiter HP; Jayes, Mohd Idris


    Radiography is one of the most common and widely used non-destructive testing (NDT) technique in inspecting weld discontinuity in welded joints. Conventionally, radiography inspector is requires to do the inspection analysis manually on weld discontinuity based on visual characteristics such as location, shape, length and density. The results can be very subjective, time consuming and inconsistent. Hence, semi-automated inspection using digital image processing and segmentation technique can be applied for weld discontinuity detection. The goal of this work is to detect the weld discontinuity on digital radiographic image using Foreground Marker Controlled Watershed. It is usually implemented in image processing because it always generates closed contour for each region in the image. In this paper, image enhancement on radiographic image is aim to remove image noise and improve image contrast. Then, marker controlled watershed with foreground markers is applied on the image to detect the discontinuity. The accuracy of the technique is evaluated using Receiver Operating Characteristic (ROC) curve. The accuracy of the technique has been compared with the ground truth and the result shows that the accuracy is 67% and area under the curve is 0.7134. The application of image processing technique in detecting weld discontinuity is able to assist radiographer to improve the inconsistent results in evaluating the radiographic image.

  19. Influence of Mn contents in 0Cr18Ni10Ti thin wall stainless steel tube on TIG girth weld quality (United States)

    Liu, Bo


    Three kinds of cold worked 0Cr18Ni10Ti thin wall stainless steel tubes with the manganese contents of 1.27%, 1.35% and 1.44% and the cold worked 0Cr18Ni10Ti stainless steel end plug with manganese content of 1.35% were used for TIG girth welding in the present investigation. The effect of different manganese contents in stainless steel tube on weld quality was studied. The results showed that under the same welding conditions, the metallographic performance of the girth weld for the thin wall stainless steel tube with the manganese element content 1.44% welded with end plug was the best. Under the appropriate welding conditions, the quality of the girth weld increased with the increase of the manganese content till 1.44%. It was found that in the case of the Mn content of 1.44%, and under the proper welding condition the welding defects, such as welding cracks were effectively avoided, and the qualified weld penetration can be obtained.. It is concluded that the appropriate increase of the manganese content can significantly improve the TIG girth weld quality of the cold worked 0Cr18Ni10Ti stainless steel tube.

  20. Peptide identification quality control. (United States)

    Vaudel, Marc; Burkhart, Julia M; Sickmann, Albert; Martens, Lennart; Zahedi, René P


    Identification of large proteomics data sets is routinely performed using sophisticated software tools called search engines. Yet despite the importance of the identification process, its configuration and execution is often performed according to established lab habits, and is mostly unsupervised by detailed quality control. In order to establish easily obtainable quality control criteria that can be broadly applied to the identification process, we here introduce several simple quality control methods. An unbiased quality control of identification parameters will be conducted using target/decoy searches providing significant improvement over identification standards. MASCOT identifications were for instance increased by 13% at a constant level of confidence. The target/decoy approach can however not be universally applied. We therefore also quality control the application of this strategy itself, providing useful and intuitive metrics for evaluating the precision and robustness of the obtained false discovery rate. Copyright © 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  1. Friction Stir Welding (United States)

    Nunes, Arthur C., Jr.


    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.

  2. Friction Stir Spot Welding of 6061 Aluminum-to-Copper (United States)

    Heideman, Robert J.

    Friction stir spot welding (FSSW) between 1.5mm thick 6061 Al on top and 1.5mm thick Cu at bottom was conducted. First, weld parameters and the weld macrostructure that were necessary to form good quality welds, as determined using lap shear weld strength, were identified. Tool rotation speed and tool pin length are key variables that control weld strength. To obtain high quality strong welds, a Cu ring extruded upward from the lower Cu sheet into the upper 6061 Al-sheet, which promoted bonding and interlocking between the sheets, and an Al-rich stir zone between Cu ring and weld keyhole were both necessary. Second, a technique where the tool remained in the sample after FSSW helped determine the material flow that takes place during high quality weld formation and the functions of the welding tool features. The tool threads cause 6061 Al from the upper sheet to move downward into the region near the threads. The tool shoulder causes a counter flow movement of 6061 Al that results in the formation of the Al-rich stir zone and also causes the upward extrusion of the lower Cu sheet. This technique also identified that a Cu-rich material forms on the tool tip, that this material sheds and rebuilds during subsequent welds, and that this material can form large Cu-rich particles that can completely fill the tool threads, impede proper material flow and lead to a low strength, poor quality weld. Third, to further understand welding parameters, weld temperatures, torque, and vertical forces were measured. Temperature data was collected using a tool holder that permitted wireless thermocouple data collection. Through these measurements, rotational plunge weld energy was recognized as important in determining if a quality weld formed, and weld plunge rate was identified as the welding parameter that significantly impacted rotational weld plunge energy. The final phase of research was to improve weld quality consistency. Through repetitive trials with a single tool

  3. Optimized design on condensing tubes high-speed TIG welding technology magnetic control based on genetic algorithm (United States)

    Lu, Lin; Chang, Yunlong; Li, Yingmin; Lu, Ming


    An orthogonal experiment was conducted by the means of multivariate nonlinear regression equation to adjust the influence of external transverse magnetic field and Ar flow rate on welding quality in the process of welding condenser pipe by high-speed argon tungsten-arc welding (TIG for short). The magnetic induction and flow rate of Ar gas were used as optimum variables, and tensile strength of weld was set to objective function on the base of genetic algorithm theory, and then an optimal design was conducted. According to the request of physical production, the optimum variables were restrained. The genetic algorithm in the MATLAB was used for computing. A comparison between optimum results and experiment parameters was made. The results showed that the optimum technologic parameters could be chosen by the means of genetic algorithm with the conditions of excessive optimum variables in the process of high-speed welding. And optimum technologic parameters of welding coincided with experiment results.

  4. Fiber laser welding of dual-phase galvanized sheet steel (DP590): traditional analysis and new quality assessment techniques (United States)

    Miller, Stephanie; Pfeif, Erik; Kazakov, Andrei; Baumann, Esther; Dowell, Marla


    Laser welding has many advantages over traditional joining methods, yet remains underutilized. NIST has undertaken an ambitious initiative to improve predictions of weldability, reliability, and performance of laser welds. This study investigates butt welding of galvanized and ungalvanized dual-phase automotive sheet steels (DP 590) using a 10 kW commercial fiber laser system. Parameter development work, hardness profiles, microstructural characterization, and optical profilometry results are presented. Sound welding was accomplished in a laser power range of 2.0 kW to 4.5 kW and travel speed of 2000 mm/min to 5000 mm/min. Vickers hardness ranged from approximately 2 GPa to 4 GPa across the welds, with limited evidence of heat affected zone softening. Decreased hardness across the heat affected zone directly correlated to the appearance of ferrite. A technique was developed to non-destructively evaluate weld quality based on geometrical criteria. Weld face profilometry data were compared between light optical, metallographic sample, and frequency-modulated continuous-wave laser detection and ranging (FMCW LADAR) methods.

  5. The Quality of Welded Connections Elements from the Steel 30HGS and Titanium Alloy Ti6Al4V

    Directory of Open Access Journals (Sweden)

    Z. Łapiński


    Full Text Available The aim of that work was the evaluation of the quality of welded connections elements (welds from the 30HGS steel and titanium alloy Ti6Al4V. The metallographic, factographic tests were used, and measurements of microhardness with the Vickers method. In the head weld of the 30HGS steel there were non-metallic partial division and bubbles observed. The average microhardness in the head connection was 320 HV0.1. There was no significant increase/decrease observed of microhardness in the head influence zone of the weld. There was a good condition of head connections observed, in accordance with the standard EN12517 and EN25817. In the head weld of Ti6Al4V titanium alloy there were single, occasional non-metallic interjections and bubbles observed. There were no cracks both on the weld, and on the border of the heat influence zone. The value of microhardness in head connection was in the range 300÷445 HV0.1. Reveal a very good condition of the head connections in accordance with the standard EN12517 and EN25817. The factographic tests prove the correctness of welded connections done and then heat treatment in case of steel and titanium alloy.

  6. Welding and lung cancer in a pooled analysis of case-control studies. (United States)

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


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

  7. Closed loop control of penetration depth during CO2 laser lap welding processes

    NARCIS (Netherlands)

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


    In this paper we describe a novel spectroscopic closed loop control system capable of stabilizing the penetration depth during laser welding processes by controlling the laser power. Our novel approach is to analyze the optical emission from the laser generated plasma plume above the keyhole, to

  8. Weldability and toughness evaluation of pressure vessel quality steel using the shielded metal arc welding (SMAW) process (United States)

    Datta, R.; Mukerjee, D.; Mishra, S.


    The present study was carried out to assess the weldability properties of ASTM A 537 Cl. 1 pressure-vessel quality steel using the shielded metal arc welding (SMAW) process. Implant and elastic restraint cracking (ERC) tests were conducted under different welding conditions to determine the cold cracking susceptibility of the steel. The static fatigue limit values determined for the implant test indicate adequate resistance to cold cracking even with unbaked electrodes. The ERC test, however, established the necessity to rebake the electrodes before use. Lamellar tearing tests carried out using full-thickness plates under three welding conditions showed no incidence of lamellar tearing upon visual examination, ultrasonic inspection, and four-section macroexamination. Lamellar tearing tests were repeated using machined plates, such that the central segregated band located at the midthickness of the plate corresponded to the heat-affected zone (HAZ) of the weld. Only in one (no rebake, heat input: 14.2 kj cm-1, weld restraint load: 42 kg mm-2) of the eight samples tested was lamellar tearing observed. This was probably accentuated due to the combined effects of the presence of localized pockets of a hard phase (bainite) and a high hydrogen level (unbaked electrodes) in the weld joint. Optimal welding conditions were formulated based on the above tests. The weld joint was subjected to extensive tests and found to exhibit excellent strength (tensile strength: 56.8 kg mm-2, or 557 MPa), and low temperature impact toughness (7.4 and 4.5 kg-m at-20 °C for weld metal, WM, and HAZ) properties. Crack tip opening displacement tests carried out for the WM and HAZ resulted in δm values 0.36 and 0.27 mm, respectively, which indicates adequate resistance to brittle fracture.

  9. An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array (United States)

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


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

  10. Mathematical Modeling of Weld Bead Geometry, Quality, and Productivity for Stainless Steel Claddings Deposited by FCAW (United States)

    Gomes, J. H. F.; Costa, S. C.; Paiva, A. P.; Balestrassi, P. P.


    In recent years, industrial settings are seeing a rise in the use of stainless steel claddings. The anti-corrosive surfaces are made from low cost materials such as carbon steel or low alloy steels. To ensure the final quality of claddings, however, it is important to know how the welding parameters affect the process's outcome. Beads should be defect free and deposited with the desired geometry, with efficiency, and with a minimal waste of material. The objective of this study then is to analyze how the flux-cored arc welding (FCAW) parameters influence geometry, productivity, and the surface quality of the stainless steel claddings. It examines AISI 1020 carbon steel cladded with 316L stainless steel. Geometry was analyzed in terms of bead width, penetration, reinforcement, and dilution. Productivity was analyzed according to deposition rate and process yield, and surface quality according to surface appearance and slag formation. The FCAW parameters chosen included the wire feed rate, voltage, welding speed, and contact-tip-workpiece distance. To analyze the parameters' influences, mathematical models were developed based on response surface methodology. The results show that all parameters were significant. The degrees of importance among them varied according to the responses of interest. What also proved to be significant was the interaction between parameters. It was found that the combined effect of two parameters significantly affected a response; even when taken individually, the two might produce little effect. Finally, the development of Pareto frontiers confirmed the existence of conflicts of interest in this process, suggesting the application of multi-objective optimization techniques to the sequence of this study.

  11. Modern Methods of Rail Welding (United States)

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


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

  12. Gas metal arc welding of butt joint with varying gap width based on neural networks

    DEFF Research Database (Denmark)

    Christensen, Kim Hardam; Sørensen, Torben


    This paper describes the application of the neural network technology for gas metal arc welding (GMAW) control. A system has been developed for modeling and online adjustment of welding parameters, appropriate to guarantee a certain degree of quality in the field of butt joint welding with full...

  13. 76 FR 68208 - Circular Welded Carbon-Quality Steel Pipe From India, Oman, United Arab Emirates, and Vietnam... (United States)


    ...-1191-1194 (Preliminary)] Circular Welded Carbon-Quality Steel Pipe From India, Oman, United Arab... carbon-quality steel pipe from India, Oman, United Arab Emirates, and Vietnam, provided for in... Governments of India, Oman, United Arab Emirates, and Vietnam. Unless the Department of Commerce extends the...

  14. Signal Analysis of Gas Tungsten Arc Welds (United States)

    Eagar, T. W.


    Gas tungsten arc welding is a process in which the input parameters such as current, voltage and travel speed, can be easily controlled and/or monitored. However, weld quality is not solely a function of these parameters. An adaptive method of observing weld quality is desired to improve weld quality assurance. The use of dynamic electrical properties of the welding arc as a weld quality monitor was studied. The electrical properties of the arc are characterized by the current voltage transfer function. The hardware and software necessary to collect the data at a maximum rate of 45 kHz and to allow the off-line processing of this data are tested. The optimum input current waveform is determined. Bead-on-plate welds to observe such characteristics of the weld as the fundamental frequency of the puddle are studied. Future work is planned to observe changes of the arc response with changes in joint geometry, base metal chemistry, and shielding gas composition are discussed.

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

    DEFF Research Database (Denmark)

    Gong, Hui

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

  16. Quality Management, Quality Assurance and Quality Control in Blood Establishments


    Bolbate, N


    Quality terms and the roots of the matter are analyzed according to European Committee’s recommendations. Essence of process and product quality control as well as essence of quality assurance is described. Quality system’s structure including quality control, quality assurance and management is justified in the article.

  17. Real-time seam tracking for robotic laser welding using trajectory-based control

    NARCIS (Netherlands)

    de Graaf, M.W.; Aarts, Ronald G.K.M.; Jonker, Jan B.; Meijer, J.


    In this paper a real-time seam tracking algorithm is proposed that can cope with the accuracy demands of robotic laser welding. A trajectory-based control architecture is presented, which had to be developed for this seam tracking algorithm. Cartesian locations (position and orientation) are added

  18. High quality and efficiency arc welding for steel frames of high-rise buildings; Chokoso biru tekkotsumuke kohinshitsu koseino yosetsu gijutsu no kaihatsu

    Energy Technology Data Exchange (ETDEWEB)

    Kurehashi, T.; Taniyama, N.; Nakanishi, Y.; Katayama, N. [Ishikawajima-Harima Heavy Industries Co. Ltd., Tokyo (Japan)


    High current density narrow gap submerged arc welding method has been developed, high in quality and efficiency, for the preparation of steel frames for high-rise buildings. The conventional method is a heavy current, great heat input welding method using plural large-diameter wires. It demands huge facilities for power supply whose installation and management are quite complicated, and often gives rise to the anxiety that the produced weld may be defective, contain cracks, or reduced in toughness. In the method introduced here, the time-proved submerged arc welding method is applied to all the layers. In the newly developed high current density submerged arc welding technology, deep penetration and rich deposition protect toughness from deterioration, the quantity of input heat can be limited without lowering efficiency, and gaps can be made narrower for a reduction in the gap area. Penetration shapes are stable, welding heat input is appropriately specified for each welding pass, and fluctuation is reduced in the welding current and voltage. Thanks to heat input conditioned for each welding pass, welds are excellent in quality. The slag is easier to peel off, and incurs less defects, and the high melting speed results in excellent joint performance. 6 refs., 7 figs., 3 tabs.

  19. Assessment of the effect of welding fumes on welders' cognitive failure and health-related quality of life. (United States)

    Rahmani, Abdolrasoul; Golbabaei, Farideh; Dehghan, Somayeh Farhang; Mazlomi, Adel; Akbarzadeh, Arash


    This study examined whether cognitive symptoms and health-related quality of life can be affected by welding fume exposure. Participants consisted of welders (n = 40) and welder assistants (n = 25) from welding units as the exposed group, and office workers (n = 44) as the non-exposed group. All participants were studied using ambient air monitoring and two types of questionnaires: the Cognitive Failures Questionnaire (CFQ) and the 36-item Short Form Health Survey (SF-36). Welders and welder assistants were exposed to higher concentrations of all airborne metals than office employees, except for aluminum and chromium (p health-related quality of life were not related to the measures of welding fume exposure and further research should be performed to find other influencing factors.


    Directory of Open Access Journals (Sweden)

    Özlem KISAOĞLU


    Full Text Available Woven fabric quality depends on yarn properties at first, then weaving preparation and weaving processes. Defect control of grey and finished fabric is done manually on the lighted tables or automatically. Fabrics can be controlled by the help of the image analysis method. In image system the image of fabrics can be digitized by video camera and after storing controlled by the various processing. Recently neural networks, fuzzy logic, best wavelet packet model on automatic fabric inspection are developed. In this study the advantages and disadvantages of manual and automatic, on-line fabric inspection systems are given comparatively.


    Directory of Open Access Journals (Sweden)

    C. C. Fonte


    Full Text Available This paper presents a framework for considering quality control of volunteered geographic information (VGI. Different issues need to be considered during the conception, acquisition and post-acquisition phases of VGI creation. This includes items such as collecting metadata on the volunteer, providing suitable training, giving corrective feedback during the mapping process and use of control data, among others. Two examples of VGI data collection are then considered with respect to this quality control framework, i.e. VGI data collection by National Mapping Agencies and by the most recent Geo-Wiki tool, a game called Cropland Capture. Although good practices are beginning to emerge, there is still the need for the development and sharing of best practice, especially if VGI is to be integrated with authoritative map products or used for calibration and/or validation of land cover in the future.

  2. A Neural Network Approach for GMA Butt Joint Welding

    DEFF Research Database (Denmark)

    Christensen, Kim Hardam; Sørensen, Torben


    This paper describes the application of the neural network technology for gas metal arc welding (GMAW) control. A system has been developed for modeling and online adjustment of welding parameters, appropriate to guarantee a certain degree of quality in the field of butt joint welding with full...... penetration, when the gap width is varying during the welding process. The process modeling to facilitate the mapping from joint geometry and reference weld quality to significant welding parameters has been based on a multi-layer feed-forward network. The Levenberg-Marquardt algorithm for non-linear least...... squares has been used with the back-propagation algorithm for training the network, while a Bayesian regularization technique has been successfully applied for minimizing the risk of inexpedient over-training. Finally, a predictive closed-loop control strategy based on a so-called single-neuron self...

  3. Control of Saturation level in the magnetic core of a welding transformer by Hysteresis Controller (HC and Proportional Integral (PI Controller

    Directory of Open Access Journals (Sweden)

    Rama Subbanna.S


    Full Text Available The objective of this paper is to analyse the performances of two controllers such as Hysteresis control (HC and proportional integral (PI control to control saturation level in the magnetic core of a welding transformer in a middle-frequency direct current (MFDC resistance spot welding system(RSWS. It consists of an input converter, welding transformer, and a full-wave rectifier mounted at the transformer secondary. The unequal ohmic resistances of the two transformer’s secondary circuits and the different characteristics of the diodes of output rectifier certainly lead to the magnetic core saturation which, consequently, causes the unwanted spikes in the transformer’s primary current and over-current protection switch-off. The goal is to analyse the performance of both controllers in terms of transients, total harmonic distortion(THD and variations in primary current and flux in the magnetic core of a welding transformer of highly nonlinear system of RSWS. The simulation study has been done in Matlab/Simulink environment and presented performance analysis. The responses shows that from the aforementioned aspects, proportional integral Controller is the better choice for controlling the saturation level in magnetic core of a welding transformer which is widely used in automobile industry welding system.

  4. Development of remote-controlled circumferential TIG welding system. Enkaku sosashiki TIG enshu jido yosetsu koho no kaihatsu

    Energy Technology Data Exchange (ETDEWEB)

    Fujimoto, T.; Shiga, A. (Kawasaki Steel Corp., Tokyo (Japan))


    Development was made of remotely controlled circumferential tungsten inert gas (TIG) welding system. Outer surface of pipe is installed with a welding head truck, while remotely controlling post is done with a remotely controlling board, mounted with power source, control unit, display and speaker, torch cooling unit by water, etc. The operator commences the welding, only after presetting the standard welding condition in the program box, and minutely adjusts the welding condition, truck speed, etc. through monitoring the image and sound. All those items of operation are remotely controlled. The torch is equipped with a molten pool observation camera and microphone, to catch arc noise, therearound. If there is peripheral room, 200mm in radial space, circumferentially outside the pipe, the operation can be safely made even from a very narrow on-ground post. Liberation being made from skillfulness and heavy labor, inconvenience can be immediately confronted and corrected, and welding defect can be prevented from occurring. The present system, upon being applied to on-site welding of city water supply use stainless pipe and gas pipe, was confirmed to be good in practicability. 2 refs., 13 figs., 6 tabs.

  5. Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications (United States)

    Bjorkman, Gerry; Cantrell, Mark; Carter, Robert


    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

  6. 76 FR 78615 - Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman, the United Arab... (United States)


    ... International Trade Administration Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman... India, the Sultanate of Oman (``Oman''), The United Arab Emirates (``the UAE''), and the Socialist... of Oman, the United Arab Emirates, and the Socialist Republic of Vietnam: Initiation of...

  7. 77 FR 15718 - Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman, the United Arab... (United States)


    ... International Trade Administration Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman... and tube from India, the Sultanate of Oman (Oman), the United Arab Emirates (UAE), and the Socialist... Oman, the United Arab Emirates, and the Socialist Republic of Vietnam: Initiation of Antidumping Duty...

  8. 76 FR 78313 - Circular Welded Carbon-Quality Steel Pipe From India, Oman, the United Arab Emirates, and Vietnam (United States)


    ... COMMISSION Circular Welded Carbon-Quality Steel Pipe From India, Oman, the United Arab Emirates, and Vietnam... that an industry in the United States is materially injured by reason of imports from India, Oman, the... of India, Oman, the United Arab Emirates, and Vietnam.\\2\\ \\1\\ The record is defined in sec. 207.2(f...

  9. Plasma spectroscopy analysis technique based on optimization algorithms and spectral synthesis for arc-welding quality assurance. (United States)

    Mirapeix, J; Cobo, A; González, D A; López-Higuera, J M


    A new plasma spectroscopy analysis technique based on the generation of synthetic spectra by means of optimization processes is presented in this paper. The technique has been developed for its application in arc-welding quality assurance. The new approach has been checked through several experimental tests, yielding results in reasonably good agreement with the ones offered by the traditional spectroscopic analysis technique.

  10. 77 FR 36256 - Circular Welded Carbon-Quality Steel Pipe From India: Postponement of Final Determination of... (United States)


    ... International Trade Administration Circular Welded Carbon-Quality Steel Pipe From India: Postponement of Final..., 77 FR 32562 (June 1, 2012). (Preliminary Determination). Postponement of Final Determination and... determination if, in the event of an affirmative determination, a request for such postponement is made by...

  11. 76 FR 72164 - Circular Welded Carbon-Quality Steel Pipe From India, the Sultanate of Oman, the United Arab... (United States)


    ... From the Federal Register Online via the Government Publishing Office DEPARTMENT OF COMMERCE..., the United Arab Emirates, and Vietnam), or Angelica Mendoza (Oman), AD/CVD Operations, Office 7... Checklist: Circular Welded Carbon-Quality Steel Pipe from India (India AD Checklist), Antidumping Duty...

  12. Feedback Linearization Based Arc Length Control for Gas Metal Arc Welding

    DEFF Research Database (Denmark)

    Thomsen, Jesper Sandberg


    In this paper a feedback linearization based arc length controller for gas metal arc welding (GMAW) is described. A nonlinear model describing the dynamic arc length is transformed into a system where nonlinearities can be cancelled by a nonlinear state feedback control part, and thus, leaving only......, the cancellation of nonlinear terms might give rise to problems with respect to robustness. Robustness of the closed loop system is therefore nvestigated by simulation....

  13. Laser beam welding quality monitoring system based in high-speed (10 kHz) uncooled MWIR imaging sensors (United States)

    Linares, Rodrigo; Vergara, German; Gutiérrez, Raúl; Fernández, Carlos; Villamayor, Víctor; Gómez, Luis; González-Camino, Maria; Baldasano, Arturo; Castro, G.; Arias, R.; Lapido, Y.; Rodríguez, J.; Romero, Pablo


    The combination of flexibility, productivity, precision and zero-defect manufacturing in future laser-based equipment are a major challenge that faces this enabling technology. New sensors for online monitoring and real-time control of laserbased processes are necessary for improving products quality and increasing manufacture yields. New approaches to fully automate processes towards zero-defect manufacturing demand smarter heads where lasers, optics, actuators, sensors and electronics will be integrated in a unique compact and affordable device. Many defects arising in laser-based manufacturing processes come from instabilities in the dynamics of the laser process. Temperature and heat dynamics are key parameters to be monitored. Low cost infrared imagers with high-speed of response will constitute the next generation of sensors to be implemented in future monitoring and control systems for laser-based processes, capable to provide simultaneous information about heat dynamics and spatial distribution. This work describes the result of using an innovative low-cost high-speed infrared imager based on the first quantum infrared imager monolithically integrated with Si-CMOS ROIC of the market. The sensor is able to provide low resolution images at frame rates up to 10 KHz in uncooled operation at the same cost as traditional infrared spot detectors. In order to demonstrate the capabilities of the new sensor technology, a low-cost camera was assembled on a standard production laser welding head, allowing to register melting pool images at frame rates of 10 kHz. In addition, a specific software was developed for defect detection and classification. Multiple laser welding processes were recorded with the aim to study the performance of the system and its application to the real-time monitoring of laser welding processes. During the experiments, different types of defects were produced and monitored. The classifier was fed with the experimental images obtained. Self

  14. Experimental Investigation on Acoustic Control Droplet Transfer in Ultrasonic-Wave-Assisted Gas Metal Arc Welding (United States)

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


    Ultrasonic-wave-assisted gas metal arc welding (U-GMAW) is a new, advanced arc welding method that uses an ultrasonic wave emitted from an ultrasonic radiator above the arc. However, it remains unclear how the ultrasonic wave affects the metal droplet, hindering further application of U-GMAW. In this paper, an improved U-GMAW system was used and its superiority was experimentally demonstrated. Then a series of experiments were designed and performed to study how the ultrasonic wave affects droplet transfer, including droplet size, velocity, and motion trajectory. The behavior of droplet transfer was observed in high-speed images. The droplet transfer is closely related to the distribution of the acoustic field, determined by the ultrasonic current. Moreover, by analyzing the variably accelerated motion of the droplet, the acoustic control of the droplet transfer was intuitively demonstrated. Finally, U-GMAW was successfully used in vertical-up and overhead welding experiments, showing that U-GMAW is promising for use in welding in all positions.

  15. Relationship between image plates physical structure and quality of digital radiographic images in weld inspections

    Energy Technology Data Exchange (ETDEWEB)

    Oliveira, Davi F.; Silva, Aline S.S.; Machado, Alessandra S.; Gomes, Celio S.; Nascimento, Joseilson; Lopes, Ricardo T., E-mail:, E-mail:, E-mail:, E-mail:, E-mail:, E-mail: [Coordenacao dos Programas de Pos-Graduacao em Engenharia (COPPE/UFRJ), Rio de Janeiro, RJ (Brazil). Lab. de Instrumentacao Nuclear


    In the last decades a new type of detector which is based on photostimulable luminescence was developed. There are currently many kinds of image plates (IPs) available on the market, originating from different manufacturers. Each kind of plate distinguishes itself from the others by its peculiar physical structure and composition, two factors which have a direct influence upon the quality of the digital radiographic images obtained through them. For this study, several kinds of IPs were tested in order to determine in which way such influence takes place. For this purpose, each kind of IP has been characterized and correlated to its response in the final image. The aim of this work was to evaluate procedures for employing Computed Radiography (CR) to welding inspections in laboratory conditions using the Simple Wall Simple Image Technique (SWSI). Tests were performed in steel welded joins of thickness 5.33, 12.70 and 25.40 mm, using CR scanner and IPs available on the market. It was used an X-Ray equipment as radiation source. The image quality parameters Basic Spatial Resolution (BSR), Normalized Signal-to-Noise Ratio (SNR{sub N}), contrast and detectability were evaluated. In order to determine in which way the IPs' properties are correlated to its response in the final image, the thickness of the sensitive layer was determined and the grain size and the elemental composition of this layer were evaluated. Based on the results drawn from this study, it is possible to conclude that the physical characteristics of image plates are essential for determining the quality of the digital radiography images acquired with them. Regarding the chemical composition of the plates, it was possible to determine that, apart from the chemical elements that were expected to be found (Ba, I and Br), only two plates, with high resolution, do not have fluorine in their composition; the presence of Strontium was also detected in the chemical composition of the plates supplied by a

  16. Use of a Secondary Current Sensor in Plasma during Electron-Beam Welding with Focus Scanning for Process Control


    Dmitriy Trushnikov; Elena Krotova; Elena Koleva


    We consider questions of building a closed-loop focus control system for electron-beam welding. As a feedback signal, we use the secondary current in the plasma that forms above the welding zone. This article presents a model of a secondary current sensor in plasma during electron-beam welding with focus scanning. A comparison of modeled results with experimental data confirms the adequacy of the model. We show that the best results for focus control are obtained when using phase relationship...

  17. The full penetration hole as a stochastic process: controlling penetration depth in keyhole laser-welding processes (United States)

    Blug, A.; Abt, F.; Nicolosi, L.; Heider, A.; Weber, R.; Carl, D.; Höfler, H.; Tetzlaff, R.


    Although laser-welding processes are frequently used in industrial production the quality control of these processes is not satisfactory yet. Until recently, the "full penetration hole" was presumed as an image feature which appears when the keyhole opens at the bottom of the work piece. Therefore it was used as an indicator for full penetration only. We used a novel camera based on "cellular neural networks" which enables measurements at frame rates up to 14 kHz. The results show that the occurrence of the full penetration hole can be described as a stochastic process. The probability to observe it increases near the full penetration state. In overlap joints, a very similar image feature appears when the penetration depth reaches the gap between the sheets. This stochastic process is exploited by a closed-loop system which controls penetration depth near the bottom of the work piece ("full penetration") or near the gap in overlap joints ("partial penetration"). It guides the welding process at the minimum laser power necessary for the required penetration depth. As a result, defects like spatters are reduced considerably and the penetration depth becomes independent of process drifts such as feeding rate or pollution on protection glasses.

  18. Optimizing control of quality management

    Directory of Open Access Journals (Sweden)

    Fliginskih Tatyana Nikolayevna


    Full Text Available This paper describes the technology that permits controlling of business processes in industry. An example of the use of control charts as one of the most effective methods of statistical quality control of products. The author provides a definition that best reveals the understanding of quality and quality control.

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

    Villegas, Irene F.; Palardy, Genevieve


    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. PMID:26890931

  20. Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing. (United States)

    Villegas, Irene F; Palardy, Genevieve


    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.

  1. Radiographic quality control devices. (United States)


    In this study, we evaluate eight radiographic quality control (QC) devices, which noninvasively measure the output from a variety of diagnostic x-ray production systems. When used as part of a quality assurance (QA) program, radiographic QC devices help ensure that x-ray equipment is working within acceptable limits. This in turn helps ensure that high-quality images are achieved with appropriate radiation doses and that resources are used efficiently (for example, by minimizing the number of repeat exposures required). Our testing focused on the physical performance, ease of use, and service and maintenance characteristics that affect the use of these devices for periodic, routine measurements of x-ray system parameters. We found that all the evaluated models satisfactorily measure all the parameters normally needed for a QA program. However, we did identify a number of differences among the models--particularly in the range of exposure levels that can be effectively measured and the ease of use. Three models perform well for a variety of applications and are very easy to use; we rate them Preferred. Three additional models have minor limitations but otherwise perform well; we rate them Acceptable. We recommend against purchasing two models because, although each performs acceptably for most applications, neither model can measure low levels of radiation. This Evaluation covers devices designed to measure the output of x-ray tubes noninvasively. These devices, called radiographic quality control (QC) devices, or QC meters, are typically used by medical physicists, x-ray engineers, biomedical engineers, and suitably trained radiographic technologists to make QC measurements. We focus on the use of these devices as part of an overall quality assurance (QA) program. We have not evaluated their use for other applications, such as acceptance testing. To be included in this study, a device must be able to measure the exposure- and kVp-related characteristics of most x

  2. Automated control of the laser welding process of heart valve scaffolds


    Weber Moritz; Hoheisel Anna L.; Glasmacher Birgit


    Using the electrospinning process the geometry of a heart valve is not replicable by just one manufacturing process. To produce heart valve scaffolds the heart valve leaflets and the vessel have to be produced in separated spinning processes. For the final product of a heart valve they have to be mated afterwards. In this work an already existing three-axes laser was enhanced to laser weld those scaffolds. The automation control software is based on the robot operating system (ROS). The mecha...

  3. Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication (United States)

    Jones, C. S.; Gangl, K. J.


    In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

  4. The effect of impurity gasses on variable polarity plasma arc welded 2219 aluminum (United States)

    Mcclure, John C.; Torres, Martin R.; Gurevitch, Alan C.; Newman, Robert A.


    Variable polarity plasma arc (VPPA) welding has been used with considerable success by NASA for the welds on the Space Shuttle External Tank as well as by others concerned with high quality welded structures. The effects of gaseous contaminants on the appearance of VPPA welds on 2219 aluminum are examined so that a welder can recognize that such contamination is present and take corrective measures. There are many possible sources of such contamination including, contaminated gas bottles, leaks in the gas plumbing, inadequate shield gas flow, condensed moisture in the gas lines or torch body, or excessive contaminants on the workpiece. The gasses chosen for study in the program were nitrogen, oxygen, methane, and hydrogen. Welds were made in a carefully controlled environment and comparisons were made between welds with various levels of these contaminants and welds made with research purity (99.9999 percent) gasses. Photographs of the weld front and backside as well as polished and etched cross sections are presented.

  5. Parameter optimization of flux-aided backing-submerged arc welding by using Taguchi method (United States)

    Pu, Juan; Yu, Shengfu; Li, Yuanyuan


    Flux-aided backing-submerged arc welding has been conducted on D36 steel with thickness of 20 mm. The effects of processing parameters such as welding current, voltage, welding speed and groove angle on welding quality were investigated by Taguchi method. The optimal welding parameters were predicted and the individual importance of each parameter on welding quality was evaluated by examining the signal-to-noise ratio and analysis of variance (ANOVA) results. The importance order of the welding parameters for the welding quality of weld bead was: welding current > welding speed > groove angle > welding voltage. The welding quality of weld bead increased gradually with increasing welding current and welding speed and decreasing groove angle. The optimum values of the welding current, welding speed, groove angle and welding voltage were found to be 1050 A, 27 cm/min, 40∘ and 34 V, respectively.

  6. Robotic-Controlled, Autonomous Friction Stir Welding Processes for In-Situ Fabrication, Maintenance, and Repair (United States)

    Zhou, W.

    NASA s new vision of human and robotic missions to the Moon Mars and beyond will demand large and permanent infrastructures on the Moon and other planets including power plants communication towers human and biomass habitats launch and landing facilities fabrication and repair workshops and research facilities so that material utilization and product development can be carried out and subsisted in-situ The conventional approach of transporting pre-constructed fabricated structures from earth to the Moon planets will no longer be feasible due to limited lifting capacity and extremely high transportation costs associated with long duration space travel To minimize transport of pre-made large structures between earth and the Moon planets minimize crew time for the fabrication and assembly of infrastructures on the Moon planets and to assure crew safety and maintain quality during the operation there is a strong need for robotic capabilities for in-situ fabrication maintenance and repair Clearly development of innovative autonomous in-situ fabrication maintenance and repair technologies is crucial to the success of both NASA s unmanned preparation missions and manned exploration missions In-space material joining is not new to NASA Many lessons were learned from NASA s International Space Welding Experiment which employed the Electron Beam Welding process for space welding experiments Significant safety concerns related to high-energy beams arcing spatter elecromagnetic fields and molten particles were

  7. Verification of the Quality of the Weld When Utilising the MAG/CO2 Method

    Directory of Open Access Journals (Sweden)

    Michal Černý


    Full Text Available In contribution there is described the process of welding by using MAG/CO2 method, mechanical (post fact and nondestructivein situ measurement including the discussion of results. The materials of various welding have been used for test. According to ČSN 420002 steel with mark 11 373 has been chosen as a material with guaranteed welding and steel with mark 19 312 has been chosen as a material with hard welding. The sheets with dimensions 30×5×250 mm have been used at welding. The source activity having affect in process of welding is caught on AE records. It is described as per affirmatived forms of individual hits and overshoots at active levels directly into obtained records. The discussion links the findings from visual monitoring of mechanical tests, metallographic and factual monitoring even the acoustic tests. In the field of welding verification stated by producer of steel semifinished products the difference between material with guaranteed welding and material with hard welding by using AE method has been confirmed.

  8. Correlation between Peel Test and Real Time Ultrasonic Test for Quality Diagnosis in Resistance Spot Welding

    Directory of Open Access Journals (Sweden)

    Angelo F. Andreoli

    Full Text Available Abstract: This paper aimed to study the correlation between Real Time Integrated Weld Analyzer measurements and peel test results. The experiment involved study of weld nuggets for different combinations of sheet thicknesses, welding time and current of mild steel samples. The intent was to assess the potential use of a real time integrated ultrasonic system in the industrial environment allowing nondestructive evaluation of 100% of the spot welds produced. The results showed high correlation between nugget penetration into the sheets and nugget size measured ultrasonically and destructively, for all evaluated parameters.

  9. Automated generation of weld path trajectories.

    Energy Technology Data Exchange (ETDEWEB)

    Sizemore, John M. (Northrop Grumman Ship Systems); Hinman-Sweeney, Elaine Marie; Ames, Arlo Leroy


    AUTOmated GENeration of Control Programs for Robotic Welding of Ship Structure (AUTOGEN) is software that automates the planning and compiling of control programs for robotic welding of ship structure. The software works by evaluating computer representations of the ship design and the manufacturing plan. Based on this evaluation, AUTOGEN internally identifies and appropriately characterizes each weld. Then it constructs the robot motions necessary to accomplish the welds and determines for each the correct assignment of process control values. AUTOGEN generates these robot control programs completely without manual intervention or edits except to correct wrong or missing input data. Most ship structure assemblies are unique or at best manufactured only a few times. Accordingly, the high cost inherent in all previous methods of preparing complex control programs has made robot welding of ship structures economically unattractive to the U.S. shipbuilding industry. AUTOGEN eliminates the cost of creating robot control programs. With programming costs eliminated, capitalization of robots to weld ship structures becomes economically viable. Robot welding of ship structures will result in reduced ship costs, uniform product quality, and enhanced worker safety. Sandia National Laboratories and Northrop Grumman Ship Systems worked with the National Shipbuilding Research Program to develop a means of automated path and process generation for robotic welding. This effort resulted in the AUTOGEN program, which has successfully demonstrated automated path generation and robot control. Although the current implementation of AUTOGEN is optimized for welding applications, the path and process planning capability has applicability to a number of industrial applications, including painting, riveting, and adhesive delivery.

  10. Lung cancer risk and welding--preliminary results from an ongoing case-control study. (United States)

    Jöckel, K H; Ahrens, W; Bolm-Audorff, U


    In a hospital-based case-control study, 391 male cases or primary lung cancer and the same number of controls--matched by sex, age, and region--were personally interviewed for their job and smoking histories. The data reported reflect the midpoint of a study aiming at a total of 1,000 cases. One objective of the study was to assess confounding by asbestos exposure in what was thought to be a welding-associated risk. While the odds ratios (OR) increased steeply with cumulative exposure to tobacco smoke and were raised also for lifelong asbestos exposure of over 4,100 working hours (OR = 1.91), the effect of welding exposure was reduced after adjustment for smoking and exposure to asbestos. Furthermore, no consistent dose-response relationship could be shown in relation to welding hours. Therefore the present study supports the hypothesis that some, if not all, of the excess risk of welders observed in the literature may be due to the exposure to asbestos. The finding that the subgroup of employees in the aircraft industry showed an increased odds ratio of 2.14 after adjustment for smoking and exposure to asbestos deserves further attention. This suggests the need for further research on the role of berryllium-containing alloys, which has been suggested by other authors.

  11. The Study on Welding Performance Improvement of Spot Welding with Dynamic Resistance Character

    Energy Technology Data Exchange (ETDEWEB)

    Kim, J.M.; Kim, Y.C.; Won, C.Y. [Sung Kyun Kwan University (Korea, Republic of); Kim, K.S. [Seoul City University (Korea, Republic of); Kim, Y.L. [Anyang University (Korea, Republic of)


    This paper presents a new spatter reduction method of DC spot welder, incorporating single phase full bridge inverter driving high frequency transformer. also, We proposed to the constant power control strategy to improve quality of the welding product of spot welding with dynamic resistance character. Throughout simulation and prototype test, the system is verified with constant power control, and is implemented field test. (author). 6 refs., 17 figs.

  12. Applying of dilatometric effect for resistance welding automation

    Directory of Open Access Journals (Sweden)

    Bondarenko O. F.


    Full Text Available The important issue of resistance spot welding control to obtain high quality welded joints, especially in living tissue welding, is considered. The actual state of the issue is described and analyzed. In order to improve the quality of welded joints, the applying of dilatometric effect to control the resistance spot welding process, namely of shifting the welding electrodes, is suggested. To register the shifting, the use of modern inertial microelectromechanical sensors (MEMS is proposed. The experimental measuring system, which processes the MEMS-sensor signal and makes it suitable for use as a feedback signal, is developed. The structure and operational algorithm of the system are described. The abilities of measuring with MEMS-sensors the values of electrode shifting caused by dilatometric effect under resistance welding are assessed. These method and equipment are recommended for welding the metals, as well as for welding the living tissues. The results of preliminary studies prove the advisability and relevance of the suggested solutions.

  13. Influence of Processing Parameters on the Flow Path in Friction Stir Welding (United States)

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


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

  14. Robotic and automatic welding development at the Marshall Space Flight Center (United States)

    Jones, C. S.; Jackson, M. E.; Flanigan, L. A.


    Welding automation is the key to two major development programs to improve quality and reduce the cost of manufacturing space hardware currently undertaken by the Materials and Processes Laboratory of the NASA Marshall Space Flight Center. Variable polarity plasma arc welding has demonstrated its effectiveness on class 1 aluminum welding in external tank production. More than three miles of welds were completed without an internal defect. Much of this success can be credited to automation developments which stabilize the process. Robotic manipulation technology is under development for automation of welds on the Space Shuttle's main engines utilizing pathfinder systems in development of tooling and sensors for the production applications. The overall approach to welding automation development undertaken is outlined. Advanced sensors and control systems methodologies are described that combine to make aerospace quality welds with a minimum of dependence on operator skill.

  15. Sensor integration for robotic laser welding processes

    NARCIS (Netherlands)

    Iakovou, D.; Aarts, Ronald G.K.M.; Meijer, J.; Ostendorf, A; Hoult, A.; Lu, Y.


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

  16. Acoustic-Emission Weld-Penetration Monitor (United States)

    Maram, J.; Collins, J.


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

  17. Automated control of the laser welding process of heart valve scaffolds

    Directory of Open Access Journals (Sweden)

    Weber Moritz


    Full Text Available Using the electrospinning process the geometry of a heart valve is not replicable by just one manufacturing process. To produce heart valve scaffolds the heart valve leaflets and the vessel have to be produced in separated spinning processes. For the final product of a heart valve they have to be mated afterwards. In this work an already existing three-axes laser was enhanced to laser weld those scaffolds. The automation control software is based on the robot operating system (ROS. The mechatronically control is done by an Arduino Mega. A graphical user interface (GUI is written with Python and Kivy.

  18. Modeling, simulation and control of pulsed DE-GMA welding process for joining of aluminum to steel (United States)

    Zhang, Gang; Shi, Yu; Li, Jie; Huang, Jiankang; Fan, Ding


    Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme

  19. SIMBAD quality-control (United States)

    Lesteven, Soizick


    The astronomical database SIMBAD developed at the Centre de donnees astronomiques de Strasbourg presently contains 760,000 objects (stellar and non-stellar). It has the unique characteristic of being structured specifically for astronomical objects. All types of heterogeneous data (bibliographic references, measurements, and sets of identification) are connected with each object. The attributes that define quality of the database include the following. Reliability: cross-identification should not rely upon just exact values object coordinates. It also means that information attached to one simple object should be consistent. The existing data must be controlled in order to start with a reliable base and to cross-identify new data assuring the quality as data grows. Exhaustivity: delays between publication of new informations and their inclusion in the database should be as short as possible. The integrity of the database has to be maintained as data accumulates. Taking the amount of data into consideration and the rate of new data production, it is necessary to use automatic methods. One of the possibilities is to use multivariate data analysis. The factor-space is a n-dimensional relevancy space which is described by the n-axes representing a set of n subject matter headings; the words and phrases can be used to scale the axes and the documents are then a vector average of the terms within them. The application reported herein is based on the NASA-STI bibliographical database. The selected data concern astronomy, astrophysics, and space radiation (102,963 references from 1975 to 1991 included 8070 keywords). The F-space is built from this bibliographical data. By comparing the F-space position obtained from the NASA-STI keywords with the F-space position obtained from the SIMBAD references, the authors will be able to show whether it is possible to retrieve information with a restricted set of words only. If the comparison is valid, this will be a way to enter

  20. Optimization and Characterization of the Friction Stir Welded Sheets of AA 5754-H111: Monitoring of the Quality of Joints with Thermographic Techniques. (United States)

    De Filippis, Luigi Alberto Ciro; Serio, Livia Maria; Palumbo, Davide; De Finis, Rosa; Galietti, Umberto


    Friction Stir Welding (FSW) is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In particular, the thermal behavior of the material during the process has been investigated and two thermal indexes, the maximum temperature and the heating rate of the material, correlated to the frictional power input, were investigated for different process parameters (the travel and rotation tool speeds) configurations. Moreover, other techniques (micrographs, macrographs and destructive tensile tests) were carried out for supporting in a quantitative way the analysis of the quality of welded joints. The potential of thermographic technique has been demonstrated both for monitoring the FSW process and for predicting the quality of joints in terms of tensile strength.

  1. Development of laser cutting/welding depth control using laser spectroscopy and open architecture control of a robotic system

    Energy Technology Data Exchange (ETDEWEB)

    McKee, G.R.; Meirans, L.; Schmitt, D.J.; Small, D.; Watterberg, P.A. [Sandia National Labs., Albuquerque, NM (United States); Siegel, S. [PaR Systems, Inc., Shoreview, MN (United States)


    This project was driven by the need to identify and provide unique, state-of-the-art solutions to the robotic path planning and precision motion execution problems that face automated processes such as welding and cutting using lasers. The initial LDRD proposal was for a full three years program with a schedule that would create a precision robotic platform capable of providing path planning and precision motion execution using sensor and graphical programming technologies as the first year milestone. Milestones for year two were centered in developing and deploying sensor technologies that support welding and cutting. And year three milestones included the integration of any developed sensors onto the robotic platform under software control to achieve autonomous control of laser welding and cutting processes. The work performed was directed at the goal of establishing a precision robotics platform with the capability to integrate graphical programming, CAD model based path planning, and motion execution under real-time sensor based control. This report covers the progress made toward that goal during the one year of funding.

  2. Nuclear Technology. Course 28: Welding Inspection. Module 28-5, Qualifications. (United States)

    Espy, John

    This fifth in a series of ten modules for a course titled Welding Inspection describes qualification requirements for welding procedures and welders and the role of the nuclear quality assurance/quality control technician. The module follows a typical format that includes the following sections: (1) introduction, (2) module prerequisites, (3)…

  3. Local exhaust ventilation for the control of welding fumes in the construction industry--a literature review. (United States)

    Flynn, Michael R; Susi, Pam


    Arc welding is a common unit operation in the construction industry, where frequent changes in location and welding position make it more difficult to control fume exposures than in industries where fixed locations are the norm. Welders may be exposed to a variety of toxic airborne contaminants including manganese (Mn) and hexavalent chromium (CrVI). Local exhaust ventilation (LEV) is a well-known engineering control for welding fumes but has not been adopted widely in the construction industry. This literature review presents data on the performance of a variety of LEV systems for welding fume control from the construction (five references), shipyard (five references), and other industries. The studies indicate that LEV can reduce fume exposures to total particulate, Mn, and CrVI to levels below currently relevant standards. Field studies suggest that 40-50% or more reduction in exposure is possible with portable or fixed LEV systems relative to natural ventilation but that correct positioning of the hood and adequate exhaust flow rates are essential. Successful implementation of extraction guns for gas metal arc welding (GMAW) and flux core arc welding has been demonstrated, indicating that a successful balance between extraction airflow and shielding gas requirements is possible. Work practices are an important part of achieving successful control of fume exposures; in particular, positioning the hood close to the arc, checking exhaust flow rates, and avoiding the plume. Further research is needed on hood size effects for controlling welding fume with portable LEV systems and identifying and overcoming barriers to LEV use in construction.

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

    Energy Technology Data Exchange (ETDEWEB)

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


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

  5. Optimization of operator and physical parameters for laser welding of dental materials. (United States)

    Bertrand, C; le Petitcorps, Y; Albingre, L; Dupuis, V


    Interactions between lasers and materials are very complex phenomena. The success of laser welding procedures in dental metals depends on the operator's control of many parameters. The aims of this study were to evaluate factors relating to the operator's dexterity and the choice of the welding parameters (power, pulse duration and therefore energy), which are recognized determinants of weld quality. In vitro laboratory study. FeNiCr dental drawn wires were chosen for these experiments because their properties are well known. Different diameters of wires were laser welded, then tested in tension and compared to the control material as extruded, in order to evaluate the quality of the welding. Scanning electron microscopy of the fractured zone and micrograph observations perpendicular and parallel to the wire axis were also conducted in order to analyse the depth penetration and the quality of the microstructure. Additionally, the micro-hardness (Vickers type) was measured both in the welded and the heat-affected zones and then compared to the non-welded alloy. Adequate combination of energy and pulse duration with the power set in the range between 0.8 to 1 kW appears to improve penetration depth of the laser beam and success of the welding procedure. Operator skill is also an important variable. The variation in laser weld quality in dental FeNiCr wires attributable to operator skill can be minimized by optimization of the physical welding parameters.

  6. Use of quality planning methods in optimizing welding wire quality characteristics

    Directory of Open Access Journals (Sweden)

    D. Vykydal


    Full Text Available The quality of a product is given by the extent, to which the product meets customer requirements. It is generally accepted that the extent, to which the product meets such customer requirements, and, consequently, the resulting quality of the product itself, substantially depend on the early stages of the product lifecycle, i.e. on the design and development stages. Appropriate means for effective product quality planning can be found among quality management methods and tools. These methods are typically employed in engineering production and automotive industry. This paper focuses on exploring the potential of Quality Function Deployment (QFD and Failure Mode and Effect Analysis (FMEA methods for use in metallurgical production, an industrial branch where they have not been commonly employed as yet.

  7. The Quality Control of the LHC Continuous Cryostat Interconnections

    CERN Document Server

    Bertinelli, F; Bozzini, D; Cruikshank, P; Fessia, P; Grimaud, A; Kotarba, A; Maan, W; Olek, S; Poncet, A; Russenschuck, Stephan; Savary, F; Sulek, Z; Tock, J P; Tommasini, D; Vaudaux, L; Williams, L


    The interconnections between the Large Hadron Collider (LHC) magnets have required some 40 000 TIG welded joints and 65 000 electrical splices. At the level of single joints and splices, non-destructive techniques find limited application: quality control is based on the qualification of the process and of operators, on the recording of production parameters and on production samples. Visual inspection and process audits were the main techniques used. At the level of an extended chain of joints and splices - from a 53.5 m half-cell to a complete 2.7 km arc sector - quality control is based on vacuum leak tests, electrical tests and RF microwave reflectometry that progressively validated the work performed. Subsequent pressure tests, cryogenic circuits flushing with high pressure helium and cool-downs revealed a few unseen or new defects. This paper presents an overview of the quality control techniques used, seeking lessons applicable to similar large, complex projects.

  8. Heat sink welding of austenitic stainless steel pipes to control distortion and residual stress

    Energy Technology Data Exchange (ETDEWEB)

    Kumar, H.; Albert, S.K.; Bhaduri, A.K. [Materials Technology Div., Indira Gandhi Centre for Atomic Research, Kalpakkam (India)


    Construction of India's Prototype Fast Breeder Reactor (PFBR) involves extensive welding of austenitic stainless steels pipes of different dimensions. Due to high thermal expansion coefficient and poor thermal conductivity of this class of steels, welding can result in significant distortion of these pipes. Attempts to arrest this distortion can lead to high levels of residual stresses in the welded parts. Heat sink welding is one of the techniques often employed to minimize distortion and residual stress in austenitic stainless steel pipe welding. This technique has also been employed to repair welding of the piping of the Boiling Water Reactors (BWRs) subjected to radiation induced intergranular stress corrosion cracking (IGSCC). In the present study, a comparison of the distortion in two pipe welds, one made with heat sink welding and another a normal welds. Pipes of dimensions 350{phi} x 250(L) x 8(t) mm was fabricated from 316LN plates of dimensions 1100 x 250 x 8 mm by bending and long seam (L-seam) welding by SMAW process. Two fit ups with a root gap of 2 mm, land height of 1mm and a groove angle of 70 were prepared using these pipes for circumferential seam (C-seam) welding. Dimensions at predetermined points in the fit up were made before and after welding to check the variation in radius, circumference and and ovality of the pipes. Root pass for both the pipe fit up were carried out using conventional GTAW process with 1.6 mm AWS ER 16-8-2 as consumables. Welding of one of the pipe fit ups were completed using conventions GTAW process while the other was completed using heat sink welding. For second and subsequent layers of welding using this process, water was sprayed at the root side of the joint while welding was in progress. Flow rate of the water was {proportional_to}6 1/minute. Welding parameters employed were same as those used for the other pipe weld. Results of the dimensional measurements showed that there is no circumferential shrinkage in

  9. The Dynamics and Sliding Mode Control of Multiple Cooperative Welding Robot Manipulators

    Directory of Open Access Journals (Sweden)

    Bin Zi


    Full Text Available This paper deals with the design, dynamic modelling and sliding mode control of multiple cooperative welding robot manipulators (MWRMs. The MWRMs can handle complex tasks that are difficult or even impossible for a single manipulator. The kinematics and dynamics of the MWRMs are studied on the basis of the Denavit-Hartenberg and Lagrange method. Following that, considering the MWRM system with nonlinear and unknown disturbances, a non-singular terminal sliding mode control strategy is designed. By means of the Lyapunov function, the stability of the controller is proved. Simulation results indicate that the good control performance of the MWRMs is achieved by the non-singular terminal sliding mode controller, which also illustrates the correctness of the dynamic modelling and effectiveness of the proposed control strategy.

  10. Physics of arc welding (United States)

    Eagar, T. W.


    A discussion of the factors controlling the size and shape of the weld fusion zone is presented along with a description of current theories of heat and fluid flow phenomena in the plasma and the molten metal weld pool. Although experimental results confirm that surface tension, plasma jets, and weld pool convection all strongly influence the fusion zone shape; no comprehensive model is available from which to predict welding behavior. It is proposed that the lack of such an understanding is a major impediment to development of automated welding processes. In addition, sensors for weld torch positioning are reviewed in terms of the mechnical and electromagnetic energy spectra which have been used. New developments in this area are also needed in order to advance the technology of automated welding.

  11. Use of a Secondary Current Sensor in Plasma during Electron-Beam Welding with Focus Scanning for Process Control

    Directory of Open Access Journals (Sweden)

    Dmitriy Trushnikov


    Full Text Available We consider questions of building a closed-loop focus control system for electron-beam welding. As a feedback signal, we use the secondary current in the plasma that forms above the welding zone. This article presents a model of a secondary current sensor in plasma during electron-beam welding with focus scanning. A comparison of modeled results with experimental data confirms the adequacy of the model. We show that the best results for focus control are obtained when using phase relationships rather than amplitude relationships. We outline the principles for building an EBW focus control system based on parameters of the secondary current in plasma. We simulate the work of a control system’s circuits and demonstrate the stability of the synthesized system. We have conducted pilot tests on an experimental prototype.

  12. Ultrasonic Stir Welding (United States)

    Nabors, Sammy


    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.

  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. An integrated approach for predictive control of extrusion weld seams: experimental support

    NARCIS (Netherlands)

    Bakker, A.J. den; Werkhoven, R.J.; Sillekens, W.H.; Katgerman, L.


    In hollow aluminium extrusions, longitudinal weld-seams are formed through a solid-state bonding process at elevated temperatures and under conditions of interfacial pressure and plastic deformation. For structurally loaded components, sound weld seams are imperative. In our research, a weld seam

  15. Femtosecond Laser-Controlled Tip-to-Tip Assembly and Welding of Gold Nanorods. (United States)

    González-Rubio, Guillermo; González-Izquierdo, Jesús; Bañares, Luis; Tardajos, Gloria; Rivera, Antonio; Altantzis, Thomas; Bals, Sara; Peña-Rodríguez, Ovidio; Guerrero-Martínez, Andrés; Liz-Marzán, Luis M


    Directed assembly of gold nanorods through the use of dithiolated molecular linkers is one of the most efficient methodologies for the morphologically controlled tip-to-tip assembly of this type of anisotropic nanocrystals. However, in a direct analogy to molecular polymerization synthesis, this process is characterized by difficulties in chain-growth control over nanoparticle oligomers. In particular, it is nearly impossible to favor the formation of one type of oligomer, making the methodology hard to use for actual applications in nanoplasmonics. We propose here a light-controlled synthetic procedure that allows obtaining selected plasmonic oligomers in high yield and with reaction times in the scale of minutes by irradiation with low fluence near-infrared (NIR) femtosecond laser pulses. Selective inhibition of the formation of gold nanorod n-mers (trimers) with a longitudinal localized surface plasmon in resonance with a 800 nm Ti:sapphire laser, allowed efficient trapping of the (n - 1)-mers (dimers) by hot spot mediated photothermal decomposition of the interparticle molecular linkers. Laser irradiation at higher energies produced near-field enhancement at the interparticle gaps, which is large enough to melt gold nanorod tips, offering a new pathway toward tip-to-tip welding of gold nanorod oligomers with a plasmonic response at the NIR. Thorough optical and electron microscopy characterization indicates that plasmonic oligomers can be selectively trapped and welded, which has been analyzed in terms of a model that predicts with reasonable accuracy the relative concentrations of the main plasmonic species.

  16. Analysis of Proportional Integral and Optimized Proportional Integral Controllers for Resistance Spot Welding System (RSWS) - A Performance Perspective (United States)

    Rama Subbanna, S.; Suryakalavathi, M., Dr.


    This paper is an attempt to accomplish a performance analysis of the different control techniques on spikes reduction method applied on the medium frequency transformer based DC spot welding system. Spike reduction is an important factor to be considered while spot welding systems are concerned. During normal RSWS operation welding transformer’s magnetic core can become saturated due to the unbalanced resistances of both transformer secondary windings and different characteristics of output rectifier diodes, which causes current spikes and over-current protection switch-off of the entire system. The current control technique is a piecewise linear control technique that is inspired from the DC-DC converter control algorithms to register a novel spike reduction method in the MFDC spot welding applications. Two controllers that were used for the spike reduction portion of the overall applications involve the traditional PI controller and Optimized PI controller. Care is taken such that the current control technique would maintain a reduced spikes in the primary current of the transformer while it reduces the Total Harmonic Distortion. The performance parameter that is involved in the spikes reduction technique is the THD, Percentage of current spike reduction for both techniques. Matlab/SimulinkTM based simulation is carried out for the MFDC RSWS with KW and results are tabulated for the PI and Optimized PI controllers and a tradeoff analysis is carried out.

  17. Quality control on the frontier

    Directory of Open Access Journals (Sweden)

    Konrad Hubert Paszkiewicz


    Full Text Available In the world of high-throughput sequencing there are numerous challenges to effective data quality control. There are no single quality metrics which are appropriate in all conditions. Here we detail the different open source software used at the Exeter Sequencing Service to provide generic quality control information, as well as more specific metrics for genomic and transcriptomic libraries run on Illumina platforms.

  18. Frontiers in statistical quality control

    CERN Document Server

    Wilrich, Peter-Theodor


    This volume treats the four main categories of Statistical Quality Control: General SQC Methodology, On-line Control including Sampling Inspection and Statistical Process Control, Off-line Control with Data Analysis and Experimental Design, and, fields related to Reliability. Experts with international reputation present their newest contributions.

  19. 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...

  20. Management of laser welding based on analysis informative signals (United States)

    Zvezdin, V. V.; Rakhimov, R. R.; Saubanov, Ruz R.; Israfilov, I. H.; Akhtiamov, R. F.


    Features of formation precision weld of metal were presented. It has been shown that the quality of the welding process depends not only on the energy characteristics of the laser processing facility, the temperature of the surface layer, but also on the accuracy of positioning laser focus relative to seam and the workpiece surface. So the laser focus positioning accuracy is an estimate of the quality of the welding process. This approach allows to build a system automated control of the laser technological complex with the stabilization of the setpoint accuracy of of positioning of the laser beam relative to the workpiece surface.

  1. Influence of laser beam incidence angle on laser lap welding quality of galvanized steels (United States)

    Mei, Lifang; Yan, Dongbing; Chen, Genyu; Wang, Zhenhui; Chen, Shuixuan


    Based on the characteristics of laser welded structural parts of auto bodies, the influence of variation in laser beam incidence angle on the lap welding performance of galvanized auto-body sheets was studied. Lap welding tests were carried out on the galvanized sheets for auto-body application at different laser beam incidence angles by using the optimal welding parameters obtained through orthogonal experiment. The effects of incidence angle variation on seam appearance, cross-sectional shape, joint mechanical properties and microstructure of weldments were analyzed. In addition, the main factors influencing the value of incidence angle were investigated. According to the results, the weld seams had a good appearance as well as a fine, and uniform microstructure when the laser beam incidence angle was smaller than the critical incidence angle, and thus they could withstand great tensile and shear loads. Moreover, all tensile-shear specimens were fractured in the base material zone. When the laser beam incidence angle was larger than the critical incidence angle, defects like shrinkage and collapse tended to emerge, thereby resulting in the deteriorated weldability of specimens. Meanwhile, factors like the type and thickness of sheet, weld width as well as inter-sheet gap all had a certain effect on the value of laser beam incidence angle. When the sheet thickness was small and the weld width was narrow, the laser beam incidence angle could be increased appropriately. At the same time, small changes in the inter-sheet gap could greatly impact the value of incidence angle. When the inter-sheet gap was small, the laser beam incidence angle should not be too large.

  2. Hybrid laser arc welding: State-of-art review (United States)

    Acherjee, Bappa


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

  3. Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive. (United States)

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


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

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

    Directory of Open Access Journals (Sweden)

    Antonio Ancona


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

  5. Artificial neural networks for prediction of quality in resistance spot welding; Redes neuronales artificiales para la prediccion de la calidad en soldadura por resistencia por puntos

    Energy Technology Data Exchange (ETDEWEB)

    Martin, O.; Lopez, M.; Martin, F.


    An artificial neural network is proposed as a tool for predicting from three parameters (weld time, current intensity and electrode sort) if the quality of a resistance spot weld reaches a certain level or not. The quality is determined by cross tension testing. The fact of reaching this quality level or not is the desired output that goes with each input of the artificial neural network during its supervised learning. The available data set is made up of input/desired output pairs and is split randomly into a training subset (to update synaptic weight values) and a validation subset (to avoid overfitting phenomenon by means of cross validation). (Author) 44 refs.

  6. Quality control of electricity comsumption

    Energy Technology Data Exchange (ETDEWEB)

    Bondarev, P.P.; Moroz, L.A.


    A foundation is provided for the concept of ''electricity consumption quality''. The principles of controlling electrical consumption quality and its simulation at the level of interaction between electric power systems and industrial consumers, as well as within the enterprise, are examined.

  7. Weld Repair of a Stamped Pressure Vessel in a Radiologically Controlled Zone

    Energy Technology Data Exchange (ETDEWEB)

    Cannell, Gary L. [Fluor Enterprises, Inc.; Huth, Ralph J. [CH2MHill Plateau Remediation Company; Hallum, Randall T. [Fluor Government Group


    In September 2012 an ASME B&PVC Section VIII stamped pressure vessel located at the DOE Hanford Site Effluent Treatment Facility (ETF) developed a through-wall leak. The vessel, a steam/brine heat exchanger, operated in a radiologically controlled zone (by the CH2MHill PRC or CHPRC), had been in service for approximately 17 years. The heat exchanger is part of a single train evaporator process and its failure caused the entire system to be shut down, significantly impacting facility operations. This paper describes the activities associated with failure characterization, technical decision making/planning for repair by welding, logistical challenges associated with performing work in a radiologically controlled zone, performing the repair, and administrative considerations related to ASME code requirements.

  8. Taguchi analysis of dissimilar aluminum sheets joined by friction stir spot welding

    Directory of Open Access Journals (Sweden)

    Mustafa Kemal BİLİCİ


    Full Text Available In recent years, the welding of materials of new and complex structure constitutes a problem for the industry. The solid state welding method for joining of these materials were effective. Sheets produced from aluminum and aluminum alloys, especially in areas such as automotive, railway and defense industry have revealed the requirement of the application of solid state welding methods. The friction stir spot welding is one of the solid state welding method. Welding parameters is very important FSSW in order to obtain the maximum welding strength in FSSW. SKNK as parameters (tool rotational speed, depth, dive team, team and team inclination angle of standby time is selected. In this study has investigated the joining of AA2024-T3 and AA5754-H22 aluminum alloy sheets with FSSW technique by Taguchi analysis. “The highest -the better” quality control characteristic using the Analysis of Variance (ANOVA method were obtained the optimum welding parameters. The results have been analyzed both the graphical methods and numerical data. The most important parameters affecting the weld tensile strength were detected as tool rotation speed (44.74% and the team of waiting time (31.60%. Weld tensile strength by Taguchi analysis result conducted for comparing experiments the increased by 42% compared to the initial parameters.Keywords: Friction stir spot welding, Mechanical properties, Taguchi method, Optimization

  9. SAQC: SNP Array Quality Control

    Directory of Open Access Journals (Sweden)

    Li Ling-Hui


    Full Text Available Abstract Background Genome-wide single-nucleotide polymorphism (SNP arrays containing hundreds of thousands of SNPs from the human genome have proven useful for studying important human genome questions. Data quality of SNP arrays plays a key role in the accuracy and precision of downstream data analyses. However, good indices for assessing data quality of SNP arrays have not yet been developed. Results We developed new quality indices to measure the quality of SNP arrays and/or DNA samples and investigated their statistical properties. The indices quantify a departure of estimated individual-level allele frequencies (AFs from expected frequencies via standardized distances. The proposed quality indices followed lognormal distributions in several large genomic studies that we empirically evaluated. AF reference data and quality index reference data for different SNP array platforms were established based on samples from various reference populations. Furthermore, a confidence interval method based on the underlying empirical distributions of quality indices was developed to identify poor-quality SNP arrays and/or DNA samples. Analyses of authentic biological data and simulated data show that this new method is sensitive and specific for the detection of poor-quality SNP arrays and/or DNA samples. Conclusions This study introduces new quality indices, establishes references for AFs and quality indices, and develops a detection method for poor-quality SNP arrays and/or DNA samples. We have developed a new computer program that utilizes these methods called SNP Array Quality Control (SAQC. SAQC software is written in R and R-GUI and was developed as a user-friendly tool for the visualization and evaluation of data quality of genome-wide SNP arrays. The program is available online (

  10. Automatic welding of stainless steel tubing (United States)

    Clautice, W. E.


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

  11. 75 FR 14243 - Pipeline Safety: Girth Weld Quality Issues Due to Improper Transitioning, Misalignment, and... (United States)


    ... Engineers (ASME) B31.8, Gas Transmission and Distribution Piping Systems or ASME B31.4 Pipeline... appurtenance. ASME B31.4, Figure 434.8.6(a)-(2), Acceptable Butt Welded Joint Design for Unequal Wall Thickness and ASME B31.8, Figure I5, Acceptable Design for Unequal Wall Thickness, give guidance for wall...

  12. Frontiers in statistical quality control

    CERN Document Server

    Wilrich, Peter-Theodor


    The book is a collection of papers presented at the 5th International Workshop on Intelligent Statistical Quality Control in Würzburg, Germany. Contributions deal with methodology and successful industrial applications. They can be grouped in four catagories: Sampling Inspection, Statistical Process Control, Data Analysis and Process Capability Studies and Experimental Design.

  13. Welding Curriculum. (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.…

  14. Relationship between welding fume concentration and systemic inflammation after controlled exposure of human subjects with welding fumes from metal inert gas brazing of zinc-coated materials. (United States)

    Brand, Peter; Bauer, Marcus; Gube, Monika; Lenz, Klaus; Reisgen, Uwe; Spiegel-Ciobanu, Vilia Elena; Kraus, Thomas


    It has been shown that exposure of subjects to emissions from a metal inert gas (MIG) brazing process of zinc-coated material led to an increase of high-sensitivity C-reactive protein (hsCRP) in the blood. In this study, the no-observed-effect level (NOEL) for such emissions was assessed. Twelve healthy subjects were exposed for 6 hours to different concentrations of MIG brazing fumes under controlled conditions. High-sensitivity C-reactive protein was measured in the blood. For welding fumes containing 1.20 and 1.50 mg m zinc, high-sensitivity C-reactive protein was increased the day after exposure. For 0.90 mg m zinc, no increase was detected. These data indicate that the no-observed-effect level for emissions from a MIG brazing process of zinc-coated material in respect to systemic inflammation is found for welding fumes with zinc concentrations between 0.90 and 1.20 mg m.

  15. Acoustic microscopy of internal structure of resistance spot welds. (United States)

    Chertov, Andrey M; Maev, Roman G; Severin, Fedar M


    Acoustic microscopy, although relatively new, has many advantages within the industrial quality control process. Its high degree of sensitivity, resolution, and reliability make it ideal for use in resistance spot weld analysis, aiding in visualization of small-scale nugget failures, as well as other defects, at various depths. Acoustic microscopy makes it possible to inspect fine detail of internal structures, providing reliable inspection and characterization of weld joints. Besides weld size measurements, this technique is able to provide high resolution, three-dimensional images of the weld nuggets, revealing possible imperfections within its microstructure that may affect joint quality. The high degree of accuracy allows one to consider the results of acoustic microscopy an authoritative measure of weld size, particularly in the case of high strength steels, dual phase steel, USIBOR steel, etc. Indeed, this technique is effective even when both conventional ultrasound and hammer and chisel methods are not. In this paper, the potential of scanning acoustic microscopy as a means to provide qualitative and quantitative information about the internal microstructure of the resistance spot welds is demonstrated. Thus, acoustic microscopy is shown to be a unique and effective laboratory instrument for the evaluation and calibration of weld quality.



    Marcos Theodoro Muller; Rafael Rodolfo de Melo; Diego Martins Stangerlin


    The term "wood welding" designates what can be defined as "welding of wood surfaces". This new process, that it provides the joint of wood pieces without the use of adhesives or any other additional material, provokes growing interest in the academic environment, although it is still in laboratorial state. Linear friction welding induced bymechanical vibration yields welded joints of flat wood surfaces. The phenomenon of the welding occurs in less time than 10 seconds, with the temperature in...

  17. Laser welding of aluminium-magnesium alloys sheets process optimization and welds characterization

    Energy Technology Data Exchange (ETDEWEB)

    Mayer, C. [GEMPPM (CALFETMAT), 69 - Villeurbanne (France); Fouquet, F. [GEMPPM (CALFETMAT), 69 - Villeurbanne (France); Robin, M. [GEMPPM (CALFETMAT), 69 - Villeurbanne (France)


    The purpose of the present study was to obtain good quality welds using a CO2 laser with Al-Mg alloys sheet. Defects formation mechanisms were analyzed and a welding procedure was defined, using several characterization technics, in order to realize low defects welding seams. After laser welding optimization, comparative tensile tests and microstructural analysis were carried out. (orig.)

  18. Local Cooling during Welding : Prediction and Control of Residual Stresses and Buckling Distortion

    NARCIS (Netherlands)

    Van der Aa, E.M.


    One of the major problems during welding of thin plate structures is the occurrence of buckling distortion. This type of distortion is caused by the formation of compressive welding stresses; when these stresses exceed a certain critical stress level, the structure will buckle. Most methods for

  19. Analytical laboratory quality control charting

    Energy Technology Data Exchange (ETDEWEB)

    O' Bryan, Ervin F.


    In life the importance of setting goals is stressed. The desired end result must be envisioned to chart a path and determine indicators to provide feedback on the process. Quality does not happen by accident but is achieved through a constant process of setting goals, process development, monitoring process indicators, fine tuning the process, and achieving results. These goals are to be focused and clearly measurable. In industry and life the setting of goals with clear process indicators is often difficult because of the variable end result and scarcity of measurements. Laboratories are fortunate in that they have a plethora of measurements with known or desired end results (controls) to monitor the process and give instantaneous feedback on quality. A key quality tool used by the laboratory to monitor and evaluate the lab processes is control charting. When properly utilized Quality Control (QC) Charts allow labs to be proactive in addressing problems rather than reactive. Several methods are available for control charting and some are listed in the references/information sources. The content for this paper is based on the control-charting program utilized at the Department of Energy's Fernald site. This control-charting program has specific areas of emphasis, simple charts, trend analyses, and effective follow-up.

  20. Improvement of stable technique and welding efficiency of digital controlled pulse MAG welder; Digital seigyo pulse MAG yosetsuki ni okeru anteika gijutsu to yosetsu seino no kojo

    Energy Technology Data Exchange (ETDEWEB)

    Nakamata, T.; Uezono, T. [Daihen Corporation, Osaka (Japan)


    This paper describes the digital control technology of pulse MAG welders for stable operation and performance improvement. Pulse welding forms a droplet at a wire tip during pulse period, and separates the droplet by pinching it by pulse electromagnetic pinch force. This technology automatically optimizes and stabilizes welding current waveform by digital control to obtain such smooth one pulse- one droplet transfer under various welding conditions, and also controls external characteristics of welding power sources to obtain a constant arc length regardless of the distance between the tip and matrix. The technology offers superior welding stability in a small current range below 100A, and superior high-speed weldability, arc startability and transient responsibility. The newly developed pulse MAG welder mounts the control function of penetration for the first time as pulse welder, and allows stable penetration regardless of torch height. In addition, the welder allows reduction of noise level, superior weldability of galvanized steel sheets, superior basic welding performance, and automatic setting of welding conditions. 2 refs., 19 figs.

  1. Welding technology for rails. Rail no setsugo gijutsu

    Energy Technology Data Exchange (ETDEWEB)

    Okumura, M.; Karimine, K. (Nippon Steel Corp., Tokyo (Japan)); Uchino, K.; Sugino, K. (Nippon Steel Corp., Kitakyushu, Fukuoka (Japan). Technical Research Inst. of Yawata Works); Ueyama, K. (JR Railway Technical Research Inst., Tokyo (Japan))


    The rail joining technology is indispensable for making long welded rails. Flush butt welding, gas welding, enclosed arc welding, and thermit welding are used properly as the welding methods. A method for improving the joint reliability by controlling the residual stress distribution of welded joint is investigated to prepare high carbon component weld metal similar to the rail. Problems with each of the welding methods and the newly developed technology to solve the problems are outlined. Composition of the coating is improved also, and a high C system welding rod is developed which has satisfactory weldability. High performance and high efficient new enclosed arc welding technology not available by now is developed which utilizes high carbon welding metal as a new EA welding work technology, and put to practical use. As a result of this study, useful guides are obtained for the establishment of satisfactory thermit welding technology. 17 refs., 16 figs., 1 tab.

  2. Quality assurance and statistical control

    DEFF Research Database (Denmark)

    Heydorn, K.


    In scientific research laboratories it is rarely possible to use quality assurance schemes, developed for large-scale analysis. Instead methods have been developed to control the quality of modest numbers of analytical results by relying on statistical control: Analysis of precision serves...... to detect analytical errors by comparing the a priori precision of the analytical results with the actual variability observed among replicates or duplicates. The method relies on the chi-square distribution to detect excess variability and is quite sensitive even for 5-10 results. Interference control...... through the origo. Calibration control is an essential link in the traceability of results. Only one or two samples of pure solid or aqueous standards with accurately known content need to be analyzed. Verification is carried out by analyzing certified reference materials from BCR, NIST, or others...

  3. [Evaluation of measurement uncertainty of welding fume in welding workplace of a shipyard]. (United States)

    Ren, Jie; Wang, Yanrang


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

  4. Frontiers in statistical quality control

    CERN Document Server

    Wilrich, Peter-Theodor


    Like the preceding volumes, and met with a lively response, the present volume is collecting contributions stressed on methodology or successful industrial applications. The papers are classified under four main headings: sampling inspection, process quality control, data analysis and process capability studies and finally experimental design.

  5. Advanced Welding Concepts (United States)

    Ding, Robert J.


    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.

  6. A Brief Introduction to the Theory of Friction Stir Welding (United States)

    Nunes, Arthur C., Jr.


    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 is already an important welding process for the aerospace industry, where welds of optimal quality are demanded. The structure of welds determines weld properties. The structure of friction stir welds is determined by the flow field in the weld metal in the vicinity of the weld tool. A simple kinematic model of the FSW flow field developed at Marshall Space Flight Center, which enables the basic features of FSW microstructure to be understood and related to weld process parameters and tool design, is explained.

  7. Resistance welding

    DEFF Research Database (Denmark)

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


    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...

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

    DEFF Research Database (Denmark)

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


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

  9. Quality control of EUVE databases (United States)

    John, L. M.; Drake, J.


    The publicly accessible databases for the Extreme Ultraviolet Explorer include: the EUVE Archive mailserver; the CEA ftp site; the EUVE Guest Observer Mailserver; and the Astronomical Data System node. The EUVE Performance Assurance team is responsible for verifying that these public EUVE databases are working properly, and that the public availability of EUVE data contained therein does not infringe any data rights which may have been assigned. In this poster, we describe the Quality Assurance (QA) procedures we have developed from the approach of QA as a service organization, thus reflecting the overall EUVE philosophy of Quality Assurance integrated into normal operating procedures, rather than imposed as an external, post facto, control mechanism.


    Directory of Open Access Journals (Sweden)

    BURCA Mircea


    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.

  11. Automatic welding systems for large ship hulls (United States)

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


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

  12. Optimization and Characterization of the Friction Stir Welded Sheets of AA 5754-H111: Monitoring of the Quality of Joints with Thermographic Techniques

    Directory of Open Access Journals (Sweden)

    Luigi Alberto Ciro De Filippis


    Full Text Available Friction Stir Welding (FSW is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In particular, the thermal behavior of the material during the process has been investigated and two thermal indexes, the maximum temperature and the heating rate of the material, correlated to the frictional power input, were investigated for different process parameters (the travel and rotation tool speeds configurations. Moreover, other techniques (micrographs, macrographs and destructive tensile tests were carried out for supporting in a quantitative way the analysis of the quality of welded joints. The potential of thermographic technique has been demonstrated both for monitoring the FSW process and for predicting the quality of joints in terms of tensile strength.

  13. Automatic inspection of electron beam weld for stainless steel using phased array method; Controle automatique par ultrasons multielements de soudures inox realisees par faisceau d'electrons

    Energy Technology Data Exchange (ETDEWEB)

    Bleuze, A. [Metalscan - Groupe Tecnatom, 71100 Saint-Remy (France); Schwartz, C. [Commissariat a l' Energie Atomique, Centre de Valduc - 21120 Is-Sur-Tille - (France)


    The CEA laboratory of Non destructive testing of Valduc implements various techniques of controls (radiography, sealing by tracer gas helium, ultrasounds...) to check the quality of the welding and health matter of materials. To have a perfect command of the manufacture of the welding and to detect any anomaly during the manufacturing process (lacks of penetration, defects of joining, porosities...), it developed in partnership with company METALSCAN an ultrasonic technique of imagery phased array designed to the complete and automatic control of homogeneous stainless steel welding carried out by electron beam. To achieve this goal, an acoustic study by simulation with software CIVA was undertaken in order to determine the optimal characteristics of the phased array probes (their number and their site). Finally, the developed method allows, on the one hand, to locate lacks of fusion of welding equivalents to flat holes with bottom 0,5 mms in diameter, and on the other hand, to detect lacks of penetration of 0,1 mm. In order to ensure a perfect reproducibility of controls, a mechanical system ensuring the setting in rotation of the part, allows to inspect the whole of the welding. The results are then analyzed automatically using application software ensuring the traceability of controls. The method was first of all validated using parts spread out, then it was brought into service after confrontation of the results obtained on real defects with other techniques (metallographic radiography and characterizations). (authors) [French] Le laboratoire de Controles Non Destructifs du CEA de Valduc met en oeuvre differentes techniques de controles (radiographie, etancheite par gaz traceur helium, ultrasons...) pour verifier la qualite des soudures et la sante matiere des materiaux. Pour maitriser parfaitement la fabrication des soudures et detecter toute anomalie durant le processus de fabrication (manques de penetration, defauts de collage, porosites...), il a developpe

  14. Robotic weld overlay coatings for erosion control. Final technical progress report, July 1992--July 1995

    Energy Technology Data Exchange (ETDEWEB)

    Levin, B.F.; DuPont, J.N.; Marder, A.R.


    The erosion behavior of weld overlay coatings has been studied. Eleven weld overlay alloys were deposited on 1018 steel substrates using the plasma arc welding process and erosion tested at 400{degrees}C at 90{degrees} and 30{degrees} particle impact angles. The microstructure of each coating was characterized before erosion testing. A relative ranking of the coatings erosion resistance was developed by determining the steady state erosion rates. Ultimet, Inconel-625, and 316L SS coatings showed the best erosion resistance at both impact angles. It was found that weld overlays that exhibit good abrasion resistance did not show good erosion resistance. Erosion tests were also performed for selected wrought materials with chemical composition similar to weld overlays. Eroded surfaces of the wrought and weld alloys were examined by Scanning Electron Microscopy (SEM). Microhardness tests were performed on the eroded samples below the erosion surface to determine size of the plastically deformed region. It was found that one group of coatings experienced significant plastic deformation as a result of erosion while the other did not. It was also established that, in the steady state erosion regime, the size of the plastically deformed region is constant.

  15. Dynamic Interaction between Machine, Tool, and Substrate in Bobbin Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Mohammad K. Sued


    Full Text Available The bobbin friction stir welding (BFSW process has benefits for welding aluminium alloy 6082-T6 in the boat-building industry. However this alloy is difficult to weld in the thin state. There are a large number of process variables and covert situational factors that affect weld quality. This paper investigates how tool holder and machine-type affect BFSW weld quality of 4 mm Al6082-T6. The variables were tool features (three types, machine-controller type (two types, and tool holder (fixed versus floating. Fourier analysis was performed on motor spindle current to determine the frequency response of the machine. An interaction was found between the computer numerical control (CNC, the degrees of freedom of the tool holder, and the substrate (workpiece. The conventional idea that the welding tool has a semisteady interaction with the substrate is not supported. Instead the interaction is highly dynamic, and this materially affects the weld quality. Specific vibrational interactions are associated with poor welding. The CNC machine-type also emerges as a neglected variable that needs to be given attention in the selection of process parameters. Although compliance in the tool holder might seem useful, it is shown to have negative consequences as it introduces tool positioning problems.

  16. Gas Shielding Technology for Welding and Brazing (United States)

    Nunes, Arthur J.; Gradl, Paul R.


    Welding is a common method that allows two metallic materials to be joined together with high structural integrity. When joints need to be leak-tight, light-weight, or free of contaminant-trapping seams or surface asperities, welding tends to be specified. There are many welding techniques, each with its own advantages and disadvantages. Some of these techniques include Forge Welding, Gas Tungsten Arc Welding, Friction Stir Welding, and Laser Beam Welding to name a few. Whichever technique is used, the objective is a structural joint that meets the requirements of a particular component or assembly. A key practice in producing quality welds is the use of shielding gas. This article discusses various weld techniques, quality of the welds, and importance of shielding gas in each of those techniques. Metallic bonds, or joints, are produced when metals are put into intimate contact. In the solid-state "blacksmith welding" process, now called Forge Welding (FOW), the site to be joined is pounded into intimate contact. The surfaces to be joined usually need to be heated to make it easier to deform the metal. The surfaces are sprinkled with a flux to melt surface oxides and given a concave shape so that surface contamination can be squeezed out of the joint as the surfaces are pounded together; otherwise the surface contamination would be trapped in the joint and would weaken the weld. In solid-state welding processes surface oxides or other contamination are typically squeezed out of the joint in "flash."

  17. Welding Technician (United States)

    Smith, Ken


    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…

  18. Control of Porosity and Spatter in Laser Welding of Thick AlMg5 Parts Using High-Speed Imaging and Optical Microscopy

    Directory of Open Access Journals (Sweden)

    Andrei C. Popescu


    Full Text Available We report on a feedback mechanism for rapid identification of optimal laser parameters during welding of AlMg5 coupons using real-time monitoring by high-speed imaging. The purpose was to constrain the liquid movement in the groove in order to obtain pore-free welds in this otherwise difficult-to-weld alloy. High-speed imaging of the welding process via an optical microscope allowed for recording at millimeter level, providing new information on liquid-metal dynamics during laser irradiation as well as plausible explanations for spatter occurrence and pores formation. The pore formation and especially the position of these pores had to be controlled in order to weld 3 mm thick samples. By tuning both laser power and pulse duration, pores were aligned on a single line, at the bottom of the weld. A laser pass of reduced power on that side was then sufficient for removing all pores and providing a suitable weld.

  19. A Review of Dissimilar Welding Techniques for Magnesium Alloys to Aluminum Alloys

    Directory of Open Access Journals (Sweden)

    Liming Liu


    Full Text Available Welding of dissimilar magnesium alloys and aluminum alloys is an important issue because of their increasing applications in industries. In this document, the research and progress of a variety of welding techniques for joining dissimilar Mg alloys and Al alloys are reviewed from different perspectives. Welding of dissimilar Mg and Al is challenging due to the formation of brittle intermetallic compound (IMC such as Mg17Al12 and Mg2Al3. In order to increase the joint strength, three main research approaches were used to eliminate or reduce the Mg-Al intermetallic reaction layer. First, solid state welding techniques which have a low welding temperature were used to reduce the IMCs. Second, IMC variety and distribution were controlled to avoid the degradation of the joining strength in fusion welding. Third, techniques which have relatively controllable reaction time and energy were used to eliminate the IMCs. Some important processing parameters and their effects on weld quality are discussed, and the microstructure and metallurgical reaction are described. Mechanical properties of welds such as hardness, tensile, shear and fatigue strength are discussed. The aim of the report is to review the recent progress in the welding of dissimilar Mg and Al to provide a basis for follow-up research.

  20. A Review of Dissimilar Welding Techniques for Magnesium Alloys to Aluminum Alloys (United States)

    Liu, Liming; Ren, Daxin; Liu, Fei


    Welding of dissimilar magnesium alloys and aluminum alloys is an important issue because of their increasing applications in industries. In this document, the research and progress of a variety of welding techniques for joining dissimilar Mg alloys and Al alloys are reviewed from different perspectives. Welding of dissimilar Mg and Al is challenging due to the formation of brittle intermetallic compound (IMC) such as Mg17Al12 and Mg2Al3. In order to increase the joint strength, three main research approaches were used to eliminate or reduce the Mg-Al intermetallic reaction layer. First, solid state welding techniques which have a low welding temperature were used to reduce the IMCs. Second, IMC variety and distribution were controlled to avoid the degradation of the joining strength in fusion welding. Third, techniques which have relatively controllable reaction time and energy were used to eliminate the IMCs. Some important processing parameters and their effects on weld quality are discussed, and the microstructure and metallurgical reaction are described. Mechanical properties of welds such as hardness, tensile, shear and fatigue strength are discussed. The aim of the report is to review the recent progress in the welding of dissimilar Mg and Al to provide a basis for follow-up research. PMID:28788646


    Directory of Open Access Journals (Sweden)



    Full Text Available Acoustic Emission (AE signatures of various weld defects of stainless steel 316L nuclear grade weld material are investigated. The samples are fabricated by Tungsten Inert Gas (TIG Welding Method have final dimension of 140 mm x 15 mm x 10 mm. AE signals from weld defects such as Pinhole, Porosity, Lack of Penetration, Lack of Side Fusion and Slag are recorded under dynamic load conditions by specially designed mechanical jig. AE features of the weld defects were attained using Linear Location Technique (LLT. The results from this study concluded that, stress release and structure deformation between the sections in welding area are load conditions major part of Acoustic Emission activity during loading.

  2. Technology of welding aluminum alloys-III (United States)

    Harrison, J. R.; Kor, L. J.; Oleksiak, C. E.


    Control of porosity in weld beads was major objective in development of aluminum welding program. Porosity, most difficult defect to control, is caused by hydrogen gas unable to escape during solidification. Hard tooling allows hotter bead than free-fall tooling so hydrogen bubbles can boil out instead of forming pores. Welding position, moisture, and cleanliness are other important factors in control of porosity.

  3. Family Control and Earnings Quality

    Directory of Open Access Journals (Sweden)

    Carolina Bona Sánchez


    Full Text Available El trabajo analiza la relación entre el control familiar y la calidad de la información contable en un contexto en el que el tradicional conflicto de agencia entre directivos y accionistas se desplaza a la divergencia de intereses entre accionistas controladores y minoritarios. Los resultados alcanzados muestran que, en comparación con las no familiares, las empresas de naturaleza familiar divulgan unos resultados de mayor calidad, tanto en términos de menores ajustes por devengo discrecionales como de mayor capacidad de los componentes actuales del resultado para predecir los cash flows futuros. Además, el aumento en los derechos de voto en manos de la familia controladora incrementa la calidad de los resultados contables. La evidencia obtenida se muestra consistente con la presencia de un efecto reputación/vinculación a largo plazo asociado a la empresa familiar. Adicionalmente, el trabajo refleja que a medida que disminuye la divergencia entre los derechos de voto y de cash flow en manos de la familia controladora, aumenta la calidad de la información contable.PALABRAS CLAVE: derechos de voto, divergencia, empresa familiar, calidad delresultado, reputación, beneficios privados.This work examines the relationship between family control and earnings quality in a context where the salient agency problem shifts away from the classical divergence between managers and shareholders to conflicts between the controlling owner and minority shareholders. The results reveal that, compared to non-family firms, family firms reveal higher earnings quality in terms of both lower discretionary accruals and greater predictability of future cash flows. They also show a positive relationship between the level of voting rights held by the controlling family and earnings quality. The evidence is consistent with the presence of a reputation/long-term involvement effect associated with the family firm. Moreover, the work reflects that, as the divergence

  4. Quality control in breast tomosynthesis

    Energy Technology Data Exchange (ETDEWEB)

    Jakubiak, R.R.; Messias, P.C.; Santos, M.F., E-mail: [Universidade Tecnologia Federal do Parana (UTFPR), Curitiba, PR (Brazil). Departamento Academico de Fisica; Urban, L.A.B.D., E-mail: [Diagnostico Avancado por Imagem, Curitiba, PR (Brazil)


    In Brazil, breast cancer is the most common and the leading cause of death among women, with estimated 57,000 new cases in 2014. The mammography (2D) plays an important role in the early detection of breast cancer, but in some cases can be difficult to detect malignant lesions due overlap of breast tissues. The Digital Breasts Tomosynthesis (DBT: 3D) reduces the effects of overlap, providing improved characterization of mammographic findings. However, the dose may double as compared with mammography. This study presents results of Contrast to Noise Ratio (CNR) and image quality evaluation on Siemens mammography equipment Mammomat Inspiration with tomosynthesis. The CNR was determined with Polymethylmethacrylate (PMMA) layers of 20 to 70 mm thick and an aluminum foils of 0,2 mm thickness and area of 10 mm². Image quality was assessed with the ACR Breast Simulator. In the evaluation of image quality, the detectability of fibers and masses was identical in 2D and 3D systems. Displaying fibers were 4,5 and 4 mass in both modes. In 2D mode were identified 3,5 microcalcifications groups, and 3D showed 3 groups. The Mean Glandular Dose (MGD) for the simulator in 2D mode was 1,17 mGy and 2,35 mGy for the 3D mode. The result reinforces the importance of quality control in the process of obtaining the images and obtained in accordance CNR values, ensuring image quality and compatible dose in 2D and 3D processes. (author)

  5. 40 CFR 51.359 - Quality control. (United States)


    ... 40 Protection of Environment 2 2010-07-01 2010-07-01 false Quality control. 51.359 Section 51.359....359 Quality control. Quality control measures shall insure that emission testing equipment is calibrated and maintained properly, and that inspection, calibration records, and control charts are...

  6. Studies on CO2-laser Hybrid-Welding of Copper

    DEFF Research Database (Denmark)

    Nielsen, Jakob Skov; Olsen, Flemming Ove; Bagger, Claus


    CO2-laser welding of copper is known to be difficult due to the high heat conductivity of the material and the high reflectivity of copper at the wavelength of the CO2-laser light. THis paper presents a study of laser welding of copper, applying laser hybrid welding. Welding was performed...... as a hybrid CO2-laser and GTAW welding process in 2 mm pure copper sheets. The purpose was to identify maximum welding speeds for the three independent welding processes, i.e. GTAW alone, laser alone and combined processes. After welding, representative welds were quality assesed according to inernational...... norms. The paper describes the results obtained, showing significant productivity improvements and good weld qualities applying laser hybrid welding....

  7. Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case-control studies in Montreal. (United States)

    Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack


    We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case-control studies were conducted in Montreal. Study I (1979-1986) included 857 cases and 1066 controls, and Study II (1996-2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist-hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9-1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8-1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7-4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3-3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes.

  8. Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case–control studies in Montreal (United States)

    Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack


    We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case–control studies were conducted in Montreal. Study I (1979–1986) included 857 cases and 1066 controls, and Study II (1996–2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist–hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9–1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8–1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7–4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3–3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes. PMID:23342253

  9. 49 CFR 195.214 - Welding procedures. (United States)


    ... accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and Pressure Vessel Code (incorporated by reference, see § 195.3) . The quality of the test welds used to... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 195.214 Section 195.214...

  10. Laser Ultrasonic System for Surface Crack Visualization in Dissimilar Welds of Control Rod Drive Mechanism Assembly of Nuclear Power Plant

    Directory of Open Access Journals (Sweden)

    Yun-Shil Choi


    Full Text Available In this paper, we propose a J-groove dissimilar weld crack visualization system based on ultrasonic propagation imaging (UPI technology. A full-scale control rod drive mechanism (CRDM assembly specimen was fabricated to verify the proposed system. An ultrasonic sensor was contacted at one point of the inner surface of the reactor vessel head part of the CRDM assembly. Q-switched laser beams were scanned to generate ultrasonic waves around the weld bead. The localization and sizing of the crack were possible by ultrasonic wave propagation imaging. Furthermore, ultrasonic spectral imaging unveiled frequency components of damage-induced waves, while wavelet-transformed ultrasonic propagation imaging enhanced damage visibility by generating a wave propagation video focused on the frequency component of the damage-induced waves. Dual-directional anomalous wave propagation imaging with adjacent wave subtraction was also developed to enhance the crack visibility regardless of crack orientation and wave propagation direction. In conclusion, the full-scale specimen test demonstrated that the multiple damage visualization tools are very effective in the visualization of J-groove dissimilar weld cracks.

  11. 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 examined and evaluated. It is found that both diamond turned DOE’s in zinc sulphide and multilevel etched DOE’s (Diffractive Optical Elements) in fused silica have a good performance. Welding with multiple beams in a butt joint configuration has been tested. Results are presented, showing it has...... 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...

  12. Weld overlay coatings for erosion control. Task A: Literature review, progress report

    Energy Technology Data Exchange (ETDEWEB)

    Levin, B.; DuPont, J.N.; Marder, A.R.


    A literature review was made. In spite of similarities between abrasive wear and solid particle erosion, weld overlay hardfacing alloys that exhibit high abrasion resistance may not necessarily have good erosion resistance. The performance of weld overlay hardfacing alloys in erosive environments has not been studied in detail. It is believed that primary-solidified hard phases such as carbides and intermetallic compounds have a strong influence on erosion resistance of weld overlay hardfacing alloys. However, relationships between size, shape, and volume fraction of hard phases in a hardfacing alloys and erosion resistance were not established. Almost all hardfacing alloys can be separated into two major groups based upon chemical compositions of the primary solidified hard phases: (a) carbide hardening alloys (Co-base/carbide, WC-Co and some Fe base superalloys); and (b) intermetallic hardening alloys (Ni-base alloys, austenitic steels, iron-aluminides).

  13. Thick-section Laser and Hybrid Welding of Austenitic Stainless Steels (United States)

    Kujanpää, Veli

    Austenitic stainless steels are generally known to have very good laser weldability, when ordinary grades of sheets are concerned. But it is not necessarily the case, if special grades of fully austenitic structures with e.g. high molybdenum, or thick-section are used. It is also known that hot cracking susceptibility is strictly controlled by composition and welding parameters. If solidification is primary ferritic, hot cracking resistance is dramatically increased. It is also well known that laser welding needs a careful control of weld edge preparation and air gap between the edges. The dependence on edge quality can be decreased by using filler metal, either cold wire, hot wire or hybrid laser-arc welding. An additional role is high molybdenum contents where micro segregation can cause low local contents in weld which can decrease the corrosion properties, if filler metal is not used. Another feature in laser welding is its incomplete mixing, especially in thick section applications. It causes inhomogeneity, which can make uneven microstructure, as well as uneven mechanical and corrosion properties In this presentation the features of laser welding of thick section austenitic stainless steels are highlighted. Thick section (up to 60 mm) can be made by multi-pass laser or laser hybrid welding. In addition to using filler metal, it requires careful joint figure planning, laser head planning, weld parameter planning, weld filler metal selection, non-destructive and destructive testing and metallography to guarantee high-quality welds in practice. In addition some tests with micro segregation is presented. Also some examples of incomplete mixing is presented.

  14. Phenomenological study and modelling of weld behaviour for the control of GTA process by computer aided welding; Etude phenomenologique et modelisation du comportement du bain de fusion en soudage TIG en vue d'une application au controle du procede

    Energy Technology Data Exchange (ETDEWEB)

    Tissot, F.X


    The CEA-CEREM/LMS has been working on automation of arc welding processes for years. Particularly, a computer aided welding (CAW) system called 'SYLVARC' was developed to compensate the effects of any eventual disturbance, by means of a real-time control of the welding parameters. Images analysis of the topside weld pool permits to maintain its width at a nominal value. For each welding case, the control parameters have to be determined by considering the transient changes in the weld pool shape following a shift of the welding operating conditions around the nominal working setpoint. However, each corresponding empirical law do not allow any prediction nor any interpretation of the variations which are displayed. Thus, a theoretical model has been developed in this study, by using an analytical solution of heat conduction equations in the case of a Gaussian heat source, moving at constant speed at the surface of a thick plate. In parallel, a numerical approach using the finite elements code MARCUS has been carried out to validate the assumption that the eventual effects which could come from the chosen hypothesis (convection flows in the melt, latent heat transfers and temperature-dependence of the thermo-physical properties of the material are neglected) are constant for small variations around the working setpoint. This has shown that the weld behaviour around the working setpoint is easily predicted by the analytical model if restricted to conduction heat transfers. The using conditions of the model have been optimised as a result of a thorough parametric study. Experimental validations of the approach have been carried out focusing on the welding of stainless steel plates of low thickness. Particularly, in the case of a sharp step in the plate thickness, there is a good agreement of the simulation with the transient behaviour of the weld pool. (author)

  15. Robotic system for orbital welding of pipes; Sistema robotizado para soldagem orbital de dutos

    Energy Technology Data Exchange (ETDEWEB)

    Bracarense, Alexandre Queiroz; Lima II, Eduardo Jose; Torres, Guilherme Fortunato; Ramalho, Frederico [Universidade Federal de Minas Gerais (UFMG), Belo Horizonte, MG (Brazil); Felizardo, Ivanilza; Zanon, Gislaine Pires [ROTECH Tecnologia Robotica Ltda., Belo Horizonte, MG (Brazil)


    This work presents the robotic system projected for orbital welding of pipelines of oil and gas. The system consists of a controller (microcomputer), that allows the execution of all the referring tasks to the welding in an autonomous way, and two manipulates, to what are coupled the welding torches that are connected to a welding power source with double wire feeders. With this system, GMA W process is used to execute the root pass, while FCA W process, besides the GMA W, is used for the filling and finishing passes. The system has four degrees of freedom, allowing the control of stick out, travel speed, torch angle and positioning. Besides these, the arc voltage and and welding current are also controlled during the process. Knowing that for each welding position (plane, vertical up and down and over head) a great group of parameters must be used, several tests were accomplished. With these values a controlled variation could be accomplished in an uninterrupted way when welding position changes, getting the increase of the productivity and also the quality of the weld performed by a robotic system. (author)

  16. Survey of welding processes. (United States)


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

  17. Internal quality control: best practice. (United States)

    Kinns, Helen; Pitkin, Sarah; Housley, David; Freedman, Danielle B


    There is a wide variation in laboratory practice with regard to implementation and review of internal quality control (IQC). A poor approach can lead to a spectrum of scenarios from validation of incorrect patient results to over investigation of falsely rejected analytical runs. This article will provide a practical approach for the routine clinical biochemistry laboratory to introduce an efficient quality control system that will optimise error detection and reduce the rate of false rejection. Each stage of the IQC system is considered, from selection of IQC material to selection of IQC rules, and finally the appropriate action to follow when a rejection signal has been obtained. The main objective of IQC is to ensure day-to-day consistency of an analytical process and thus help to determine whether patient results are reliable enough to be released. The required quality and assay performance varies between analytes as does the definition of a clinically significant error. Unfortunately many laboratories currently decide what is clinically significant at the troubleshooting stage. Assay-specific IQC systems will reduce the number of inappropriate sample-run rejections compared with the blanket use of one IQC rule. In practice, only three or four different IQC rules are required for the whole of the routine biochemistry repertoire as assays are assigned into groups based on performance. The tools to categorise performance and assign IQC rules based on that performance are presented. Although significant investment of time and education is required prior to implementation, laboratories have shown that such systems achieve considerable reductions in cost and labour.

  18. Advances of orbital gas tungsten arc welding for Brazilian space applications – experimental setup

    Directory of Open Access Journals (Sweden)

    José A. Orlowski de Garcia


    Full Text Available The present work describes details of the several steps of the technology involved for the orbital Gas Tungsten Arc Welding (GTAW process of pure commercially titanium tubes. These pieces will be used to connect the several components of the propulsion system of the China-Brazilian Satellite CBERS, and is part of the Brazilian aerospace industry development. The implantation involved the steps of environment control; cut and facing of the base metal; cleaning procedures; piece alignment; choice of the type, geometry and installation of the tungsten electrode; system for the pressure of the purge gas; manual tack welding; choice of the welding parameters; and, finally, the qualification of welding procedures. Three distinct welding programs were studied, using pulsed current with increasing speed, continuous current and pulsed current with decreasing amperage levels. The results showed that the high quality criteria required to the aerospace segment is such that usual welding operations must be carefully designed and executed. The three welding developed programs generated welds free of defects and with adequate morphology, allowing to select the condition that better fits the Brazilian aerospace segment, and to be implanted in the welding of the CBERS Satellite Propulsion System.

  19. Identification of Mechanical parameters for Resistance Welding Machines

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels


    Mechanical dynamic responses of resistance welding machine have a significant influence on weld quality and electrode service life, it must be considered when the real welding production is carried out or the welding process is simulated. The mathematical models for characterizing the mechanical ...

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

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels


    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...

  1. Ultrasonic sensing of GMAW: Laser/EMAT defect detection system. [Gas Metal Arc Welding (GMAW), Electromagnetic acoustic transducer (EMAT)

    Energy Technology Data Exchange (ETDEWEB)

    Carlson, N.M.; Johnson, J.A.; Larsen, E.D. (EG and G Idaho, Inc., Idaho Falls, ID (United States)); Van Clark, A. Jr.; Schaps, S.R.; Fortunko, C.M. (National Inst. of Standards and Technology, Boulder, CO (United States))


    In-process ultrasonic sensing of welding allows detection of weld defects in real time. A noncontacting ultrasonic system is being developed to operate in a production environment. The principal components are a pulsed laser for ultrasound generation and an electromagnetic acoustic transducer (EMAT) for ultrasound reception. A PC-based data acquisition system determines the quality of the weld on a pass-by-pass basis. The laser/EMAT system interrogates the area in the weld volume where defects are most likely to occur. This area of interest is identified by computer calculations on a pass-by-pass basis using weld planning information provided by the off-line programmer. The absence of a signal above the threshold level in the computer-calculated time interval indicates a disruption of the sound path by a defect. The ultrasonic sensor system then provides an input signal to the weld controller about the defect condition. 8 refs.

  2. Control of Softening Processes in the Heat-Affected Zone During Welding of High-Strength Steels (United States)

    Efimenko, L. A.; Kapustin, O. E.; Ramus', A. A.; Ramus', R. O.


    The hardness and the structure of the heat-affected zone (HAZ) under welding of tube steels of strength category K60 - K70 are studied. The steels are treated by regimes imitating the thermal cycles of different welding processes applied to tubes starting with manual arc welding and ending with energy-intensive automatic submerged-arc welding. The welding modes causing maximum decrease in the hardness of HAZ regions are determined. The conditions preventing softening under one-pass and multipass welding of high-strength steels are presented.

  3. 14 CFR 21.139 - Quality control. (United States)


    ... 14 Aeronautics and Space 1 2010-01-01 2010-01-01 false Quality control. 21.139 Section 21.139... PROCEDURES FOR PRODUCTS AND PARTS Production Certificates § 21.139 Quality control. The applicant must show that he has established and can maintain a quality control system for any product, for which he...

  4. 7 CFR 930.44 - Quality control. (United States)


    ... 7 Agriculture 8 2010-01-01 2010-01-01 false Quality control. 930.44 Section 930.44 Agriculture Regulations of the Department of Agriculture (Continued) AGRICULTURAL MARKETING SERVICE (Marketing Agreements... Control § 930.44 Quality control. (a) Quality standards. The Board may establish, with the approval of the...

  5. 33 CFR 385.21 - Quality control. (United States)


    ... 33 Navigation and Navigable Waters 3 2010-07-01 2010-07-01 false Quality control. 385.21 Section... Processes § 385.21 Quality control. (a) The Corps of Engineers and the non-Federal sponsor shall prepare a quality control plan, in accordance with applicable Corps of Engineers regulations, for each product that...

  6. 7 CFR 981.42 - Quality control. (United States)


    ... 7 Agriculture 8 2010-01-01 2010-01-01 false Quality control. 981.42 Section 981.42 Agriculture Regulations of the Department of Agriculture (Continued) AGRICULTURAL MARKETING SERVICE (Marketing Agreements... Regulating Handling Quality Control § 981.42 Quality control. (a) Incoming. Except as provided in this...

  7. Study on visual image information detection of external angle weld based on arc welding robot (United States)

    Liu, Xiaorui; Liu, Nansheng; Sheng, Wei; Hu, Xian; Ai, Xiaopu; Wei, Yiqing


    Nowadays, the chief development trend in modern welding technology is welding automation and welding intelligence. External angle weld has a certain proportion in mechanical manufacture industries. In the real-time welding process, due to hot deformation and the fixture of workpieces used frequently, torch will detach welding orbit causes deviation, which will affect welding quality. Therefore, elimination weld deviation is the key to the weld automatic tracking system. In this paper, the authors use the self-developed structured light vision sensor system which has significant advantage compared with arc sensors to capture real-time weld images. In the project of VC++6.0 real-time weld image processing, after binaryzation with threshold value seventy, 3*1 median filter, thinning, obtain weld main stripe. Then, using the extraction algorithm this paper proposed to obtain weld feature points, and compute position of weld. Experiment result verified that the extraction algorithm can locate feature points rapidly and compute the weld deviation accurately.

  8. Association between product quality control and process quality control of bulk milk

    NARCIS (Netherlands)

    Velthuis, A.; Asseldonk, van M.A.P.M.


    Assessment of dairy-milk quality is based on product quality control (testing bulk-milk samples) and process quality control (auditing dairy farms). It is unknown whether process control improves product quality. To quantify possible association between product control and process control a

  9. Soldadura (Welding). Spanish Translations for Welding. (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. CO2 laser welding of magnesium alloys (United States)

    Dhahri, Mohammed; Masse, Jean Eric; Mathieu, J. F.; Barreau, Gerard; Autric, Michel L.


    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

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


    commbination of flux and gas shielding that protect the weld from nitrogen and oxygen entrapment . Shielding wilI be discussed in the following...Documentation Center The University of Michigan Transportation Research Institute Marine Systems Division 2901 Baxter Road Ann Arbor, MI 48109-2150 Phone: 734-763-2465 Fax: 734-936-1081 E-mail:

  12. Quality Control by Artificial Vision

    Energy Technology Data Exchange (ETDEWEB)

    Lam, Edmond Y. [University of Hong Kong, The; Gleason, Shaun Scott [ORNL; Niel, Kurt S. [Upper Austria University of Applied Science, Engineering and Environmental Studies


    Computational technology has fundamentally changed many aspects of our lives. One clear evidence is the development of artificial-vision systems, which have effectively automated many manual tasks ranging from quality inspection to quantitative assessment. In many cases, these machine-vision systems are even preferred over manual ones due to their repeatability and high precision. Such advantages come from significant research efforts in advancing sensor technology, illumination, computational hardware, and image-processing algorithms. Similar to the Special Section on Quality Control by Artificial Vision published two years ago in Volume 17, Issue 3 of the Journal of Electronic Imaging, the present one invited papers relevant to fundamental technology improvements to foster quality control by artificial vision, and fine-tuned the technology for specific applications. We aim to balance both theoretical and applied work pertinent to this special section theme. Consequently, we have seven high-quality papers resulting from the stringent peer-reviewing process in place at the Journal of Electronic Imaging. Some of the papers contain extended treatment of the authors work presented at the SPIE Image Processing: Machine Vision Applications conference and the International Conference on Quality Control by Artificial Vision. On the broad application side, Liu et al. propose an unsupervised texture image segmentation scheme. Using a multilayer data condensation spectral clustering algorithm together with wavelet transform, they demonstrate the effectiveness of their approach on both texture and synthetic aperture radar images. A problem related to image segmentation is image extraction. For this, O'Leary et al. investigate the theory of polynomial moments and show how these moments can be compared to classical filters. They also show how to use the discrete polynomial-basis functions for the extraction of 3-D embossed digits, demonstrating superiority over Fourier

  13. Comprehensive analysis of the capillary depth in deep penetration laser welding (United States)

    Fetzer, Florian; Boley, Meiko; Weber, Rudolf; Graf, Thomas


    Laser welding is the state of the art joining technology regarding productivity and thermal loads and stress on the workpiece. In deep penetration laser welding the quality of the resultant welds strongly depends on the stability of the capillary. The highly dynamic depth fluctuations are of major influence on the controllability of the laser welding process and on the prevention of weld defects. In the present paper the capillary dynamics is investigated by means of time- and spatially resolved in-process X-ray imaging and optical coherence tomography. The X-ray diagnostics allows measuring the geometry of the capillary with frame rates of 1 kHz, while the optical coherence tomography enables the determination of the capillary depth with an acquisition rate of up to 70 kHz. These measurements are correlated to time varying input laser power to provide profound insight in the dynamics of the laser welding process. The measurements are performed for copper, aluminum and mild steel. The capillary depth resulting from arbitrary laser power modulation was investigated. Thereby, the response of the capillary depth to laser power changes was determined. Based on these measurements the changes of the capillary depth in deep penetration laser welding were described by methods known from control theory. These analyses can be utilized to optimize control strategies, to calibrate transient simulations of deep penetration laser welding and to identify the influence of material properties.

  14. Factors affecting weld root morphology in laser keyhole welding (United States)

    Frostevarg, Jan


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

  15. Thermal insulation of wet shielded metal arc welds (United States)

    Keenan, Patrick J.


    Computational and experimental studies were performed to determine the effect of static thermal insulation on the quality of wet shielded metal arc welds (SMAW). A commercially available heat flow and fluid dynamics spectral-element computer program was used to model a wet SMAW and to determine the potential effect on the weld cooling rate of placing thermal insulation adjacent to the weld line. Experimental manual welds were made on a low carbon equivalent (0.285) mild steel and on a higher carbon equivalent (0.410) high tensile strength steel, using woven fabrics of alumina-boria-silica fibers to insulate the surface of the plate being welded. The effect of the insulation on weld quality was evaluated through the use of post-weld Rockwell Scale hardness measurements on the surface of the weld heat affected zones (HAZ's) and by visual inspection of sectioned welds at 10 X magnification. The computational simulation demonstrated a 150% increase in surface HAZ peak temperature and a significant decrease in weld cooling rate with respect to uninsulated welds, for welds in which ideal insulation had been placed on the base plate surface adjacent to the weld line. Experimental mild steel welds showed a reduction in surface HAZ hardness attributable to insulation at a 77% significance level. A visual comparison of the cross-sections of two welds made in 0.410 carbon equivalent steel-with approximately equivalent heat input-revealed underbead cracking in the uninsulated weld but not in the insulated weld.

  16. WELDING TORCH (United States)

    Correy, T.B.


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

  17. ARC+(Registered Trademark) and ARC PC Welding Simulators: Teach Welders with Virtual Interactive 3D Technologies (United States)

    Choquet, Claude


    123 Certification Inc., a Montreal based company, has developed an innovative hands-on welding simulator solution to help build the welding workforce in the most simple way. The solution lies in virtual reality technology, which has been fully tested since the early 90's. President and founder of 123 Certification Inc., Mr. Claude Choquet Ing. Msc. IWE. acts as a bridge between the welding and the programming world. Working in these fields for more than 20 years. he has filed 12 patents world-wide for a gesture control platform with leading edge hardware related to simulation. In the summer of 2006. Mr Choquet was proud to be invited to the annual IIW International Weld ing Congress in Quebec City to launch the ARC+ welding simulator. A 100% virtual reality system and web based training center was developed to simulate multi process. multi-materiaL multi-position and multi pass welding. The simulator is intended to train welding students and apprentices in schools or industries. The welding simulator is composed of a real welding e[eetrode holder (SMAW-GTAW) and gun (GMAW-FCAW). a head mounted display (HMD), a 6 degrees of freedom tracking system for interaction between the user's hands and head. as well as external audio speakers. Both guns and HMD are interacting online and simultaneously. The welding simulation is based on the law of physics and empirical results from detailed analysis of a series of welding tests based on industrial applications tested over the last 20 years. The simulation runs in real-time, using a local logic network to determine the quality and shape of the created weld. These results are based on the orientation distance. and speed of the welding torch and depth of penetration. The welding process and resulting weld bc.1d are displayed in a virtual environment with screenplay interactive training modules. For review. weld quality and recorded process values can be displayed and diagnosed after welding. To help in the le.tming process, a

  18. Width Criterion For Weld-Seam-Tracking Data (United States)

    Lincir, Mark R.


    Image-processing algorithm in "through-torch-vision" (T3V) system developed to guide gas/tungsten arc welding robot along weld seam modified, according to proposal, reducing incidence of inaccurate tracking of weld seam. Developmental system intended to provide closed-loop control of motion of welding robot along weld seam on basis of lines in T3V image identified by use of image-processing algorithm and assumed to coincide with edges of weld seam. Use of width criterion prevents tracking of many false pairs of lines, with consequent decrease in incidence of inaccurate tracking and increase in confidence in weld-tracking capability of robotic welding system.

  19. A study of processes for welding pipelines

    Energy Technology Data Exchange (ETDEWEB)

    Weston, J. (ed.)


    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.

  20. Closed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Part Qualification Project (United States)

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

  1. Colosed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Ppart Qualification Project (United States)

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

  2. On Improving the Quality of Gas Tungsten Arc Welded 18Ni 250 Maraging Steel Rocket Motor Casings (United States)

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


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

  3. Plasma arc welding weld imaging (United States)

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


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

  4. Quality assurance in electron beam welding of NaS high performance batteries in mass production; Qualitaetssicherung beim Elektronenstrahlschweissen von NaS-Hochleistungsbatterien in der Massenfertigung

    Energy Technology Data Exchange (ETDEWEB)

    Fritz, D. [PTR Praezisionstechnik GmbH, Maintal (Germany); Lenz, F. [ABB Hochenergiebatterie GmbH, Heidelberg (Germany)


    Due to the new legal conditions and forced to minimise risks, the car industry is now requiring a quality standard which would have been unthinkable a few years ago. This requirement can only be taken into account in the production of mass-produced parts by new strategies in quality assurance. For a modern NaS high performance battery, which is intended to drive an electric car in the future, `quasi-zero fault` manufacture with a process capability of {+-}6 sigma is aimed at, ie: From a statistical point of view, fewer than 4 parts per million workpieces may be faulty. The article shows, using the example of electron beam welding of the NaS batteries, how, with an independent computer-aided quality assurance system, comprehensive process control was achieved and the precondition for 100 percent manufacturing documentation was created. (orig.) [Deutsch] Die Automobilindustrie fordert schon heute durch neue gesetzliche Rahmenbedingungen und unter dem Zwang der Risikominimierung einen Qualitaetsstandard, der vor wenigen Jahren undenkbar war. Nur durch neue Strategien in der Qualitaetssicherung kann dieser Forderung in der Produktion von Massenteilen Rechnung getragen werden. So wird fuer eine moderne NaS-Hochleistungsbatterie, die spaeter ein Elektroauto antreiben soll, eine `quasi null Fehler` Fertigung mit einer Prozessfaehigkeit von {+-}6 Sigma angestrebt, d.h. statistisch gesehen duerfen weniger als 4 Teile pro 1 Mio Werkstuecke fehlerhaft sein. Der Beitrag zeigt am Beispiel des Elektronenstrahlschweissens der NaS-Batterien, wie durch ein unabhaengiges computergestuetztes Qualitaetssicherungssystem eine umfassende Prozesskontrolle erreicht und die Voraussetzung fuer eine 100-prozentige Fertigungsdokumentation geschaffen wurde. (orig.)

  5. Pulsed ultrasonic stir welding method (United States)

    Ding, R. Jeffrey (Inventor)


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

  6. The effect of reconditioning techniques by welding on the quality of deposits on crankshafts, case study SMAW (United States)

    Chivu, O. R.; Cicic, D. T.; Rontescu, C.; Vasile, I. M.; Petriceanu, C.


    Currently, we are searching for a range of solutions for repairing the crankshafts that had snapped during operation. The paper deals with the extension of the two methods for reconditioning by welding in the energy industry in the field of repairing the crankshafts in the automotive industry. The results obtained through the application of methods for reconditioning Weld Toe Tempering Technique and filling layers of sidings, which was used as a welding procedure SMAW. Qualitative and quantitative comparisons between the results of the two methods based on the criterion of rigidity are carried out.

  7. Seafood quality control: processing plants

    National Research Council Canada - National Science Library

    Nickelson, R

    .... Maintaining high quality in the product is vital to the management for two basic reasons. First, the plant must produce high quality seafood with maximum shelf-life in order to compete for its fair share of the market...

  8. 30 CFR 74.6 - Quality control. (United States)


    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Quality control. 74.6 Section 74.6 Mineral... of the CMDPSU will be maintained in production through adequate quality control procedures, MSHA and... DUST SAMPLING DEVICES Approval Requirements for Coal Mine Dust Personal Sampler Unit § 74.6 Quality...

  9. Human biomonitoring of aluminium after a single, controlled manual metal arc inert gas welding process of an aluminium-containing worksheet in nonwelders. (United States)

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


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

  10. Electron Beam Welding of Thick Copper Material

    Energy Technology Data Exchange (ETDEWEB)

    Broemssen, Bernt von [IVF Industriforskning och utveckling AB, Stockholm (Sweden)


    The purpose of this study was to review the two variants of the Electron Beam Welding (EBW) processes developed (or used) by 1- SKB, Sweden with assistance from TWI, England and 2 - POSIVA, Finland with assistance from Outokumpu, Finland. The aim was also to explain the principle properties of the EBW method: how it works, the parameters controlling the welding result but also giving rise to benefits, and differences between the EBW variants. The main conclusions are that both SKB and POSIVA will within a few years succeed to qualify their respective EBW method for welding of copper canisters. The Reduced Pressure EBW that SKB use today seems to be very promising in order to avoid root defects. If POSIVA does not succeed to avoid root defects with the high vacuum method and the beam oscillation technique it should be possible for POSIVA to incorporate the Reduced Pressure technique albeit with significant changes to the EBW equipment. POSIVA has possibly an advantage over SKB with the beam oscillation technique used, which gives an extra degree of freedom to affect the weld quality. The beam oscillation could be of importance for closing of the keyhole. Before EBW of lids, the material certification showing the alloy content (specifying min and max impurity percentages) and the mechanical properties should be checked. The welded material needs also to be tested for mechanical properties. If possible the weld should have a toughness level equal to that of the unwelded parent material. Specifically some conclusions are reported regarding the SKB equipment. Suggestions for further development are also given in the conclusion chapter.

  11. TIG welding power supply with improved efficiency

    Directory of Open Access Journals (Sweden)

    Сергій Володимирович Гулаков


    Full Text Available In the article, the influence of the DC component of the welding current during TIG (Tungsten Inert Gas welding is discussed. Known methods of DC current cancellation are reviewed, such as capacitor bank or diode/thyristor network insertion in the secondary circuit of the welding transformer. A new method of controlling the magnitude and shape of the TIG welding current is proposed. The idea is to insert a controlled voltage source in the secondary circuit of the welding transformer. This controlled voltage source is realized using a full-bridge voltage source inverter (VSI. VSI control system design issues are discussed. VSI is controlled by a three-level hysteretic current controller, while current reference is generated using lookup table driven by PLL (Phase Locked Loop locked to the mains frequency. Simulation results are shown. The proposed topology of TIG power supply allows to provide magnitude and shape control of the welding current, with the limitation that its DC component must be zero. Thus, some capabilities of professional AC-TIG welders are obtained using substantially lower cost components: VSI built using high-current low voltage MOSFETs with control system based on 32-bit ARM microcontroller. The use of proposed TIG welding power supply will eliminate the DC component of the welding current, improve welding transformer’s power factor and improve welding technology by increasing the welding arc stability

  12. Analysis and Comparison of Aluminum Alloy Welded Joints Between Metal Inert Gas Welding and Tungsten Inert Gas Welding (United States)

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


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

  13. Inert-Gas Diffuser For Plasma Or Arc Welding (United States)

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


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

  14. WELDING METHOD (United States)

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


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

  15. Quality control in tile production (United States)

    Kalviainen, Heikki A.; Kukkonen, Saku; Hyvarinen, Timo S.; Parkkinen, Jussi P. S.


    This work studies visual quality control in ceramics industry. In tile manufacturing, it is important that in each set of tiles, every single tile looks similar. For example, the tiles should have similar color and texture. Our goal is to design a machine vision system that can estimate the sufficient similarity or same appearance to the human eye. Currently, the estimation is usually done by human vision. Differing from other approaches our aim is to use accurate spectral representation of color, and we are comparing spectral features to the RGB color features. A laboratory system for color measurement is built. Experimentations with five classes of brown tiles are presented. We use chromaticity RGB features and several spectral features for classification with the k-NN classifier and with a neural network, called Self-Organizing Map. We can classify many of the tiles but there are several problems that need further investigations: larger training and test sets are needed, illuminations effects must be studied further, and more suitable spectral features are needed with more sophisticated classifiers. It is also interesting to develop further the neural approach.

  16. 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.

  17. Welding--Trade or Profession? (United States)

    Albright, C. E.; Smith, Kenneth


    This article discusses a collaborative program between schools with the purpose of training and providing advanced education in welding. Modern manufacturing is turning to automation to increase productivity, but it can be a great challenge to program robots and other computer-controlled welding and joining systems. Computer programming and…

  18. Study the Effect of SiO2 Based Flux on Dilution in Submerged Arc Welding (United States)

    kumar, Aditya; Maheshwari, Sachin


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

  19. Shipping/Receiving and Quality Control (United States)

    Federal Laboratory Consortium — Shipping receiving, quality control, large and precise inspection and CMM machines. Coordinate Measuring Machines, including "scanning" probes, optical comparators,...

  20. Technological parameters of welding of branch saddles to polyethylene pipes at low temperatures (United States)

    Starostin, N. P.; Vasilieva, M. A.


    The present paper outlines a procedure for determination of dynamics of the temperature field during the welding of the branch saddle to the polyethylene gas pipeline at ambient temperatures below the normative. The analysis is accomplished by the finite element method with the heat of the phase transition taken into account. Methods of the visualization of data sets reveal the possibility of controlling the thermal process by preheating and thermal insulation during welding of the branch saddle to the pipe at low temperatures and the possibility of obtaining the dynamics of the temperature field at which a high-quality welded joint is formed.

  1. Experimental Investigation and Optimization of TIG Welding Parameters on Aluminum 6061 Alloy Using Firefly Algorithm (United States)

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


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

  2. 77 FR 19192 - Circular Welded Carbon-Quality Steel Pipe From India: Preliminary Affirmative Countervailing Duty... (United States)


    ...-Quality Steel Pipe from India: Respondent Selection Memorandum,'' dated December 19, 2011. The public... Brazilian, Korean, and Mexican orders on these products exclude ``Standard pipe that is dual or triple... preliminary determination is based on AFA. Selection of the Adverse Facts Available Rate In deciding which...

  3. Establishment for quality control of experimental animal

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Tae Hwan; Kim, Soo Kwan; Kim, Tae Kyoung


    Until now, because we have imported experimental animal from foreign experimental animal corporation, we could have saved money by establishing the quality control of animal in barrier system. In order to improve the quality of animal experiment and efficiency of biomedical study, it is indispensable to control many factors that effect in the experiment. Therefore, it is essential to organize the system of laboratory animal care for enhancing reliability and revivability of experimental results. The purpose of the present investigation was to establish the quality control system of experimental animals that we can provide good quality animals according to the experimental condition of each investigator although the exact quality control system to estimate the infection of bacteria and virus easily remains ill-defined yet. Accordingly, we established the useful quality control system for microbiologic monitoring and environmental monitoring to protect experimental animal from harmful bacteria and virus.


    Directory of Open Access Journals (Sweden)

    Nachimani Charde


    Full Text Available The resistance spot welding process is accomplished by forcing huge amounts of current flow from the upper electrode tip through the base metals to the lower electrode tip, or vice versa or in both directions. A weld joint is established between the metal sheets through fusion, resulting in a strong bond between the sheets without occupying additional space. The growth of the weld nugget (bond between sheets is therefore determined from the welding current density; sufficient time for current delivery; reasonable electrode pressing force; and the area provided for current delivery (electrode tip. The welding current and weld time control the root penetration, while the electrode pressing force and electrode tips successfully accomplish the connection during the welding process. Although the welding current and weld time cause the heat generation at the areas concerned (electrode tip area, the electrode tips’ diameter and electrode pressing forces also directly influence the welding process. In this research truncated-electrode deformation and mushrooming effects are observed, which result in the welded areas being inconsistent due to the expulsion. The copper to chromium ratio is varied from the tip to the end of the electrode whilst the welding process is repeated. The welding heat affects the electrode and the electrode itself influences the shape of the weld geometry.

  5. Residual stress characterization of welds and post-weld processes using x-ray diffraction techniques (United States)

    Brauss, Michael E.; Pineault, James A.; Eckersley, John S.


    This paper illustrates the importance of residual stress characterization in welds and post weld processes. The failure to characterize residual stresses created during welding and/or post weld processes can lead to unexpected occurrences of stress corrosion cracking, distortion, fatigue cracking as well as instances of over design or over processing. The development of automated residual stress mapping and the availability of portable and fast equipment have now made the characterization of residual stresses using x-ray diffraction practical for process control and optimization. The paper presents examples where x-ray diffraction residual stress characterization techniques were applied on various kinds of welds including arc welds, TIG welds, resistance welds, laser welds and electron beam welds. The nondestructive nature of the x-ray diffraction technique has made the residual stress characterization of welds a useful tool for process optimization and failure analysis, particularly since components can be measured before and after welding and post welding processes. Some examples presented show the residual stresses before and after the application of post weld processes such as shot peening, grinding and heat treatment.

  6. Colorado Air Quality Control Regulations and Ambient Air Quality Standards. (United States)

    Colorado State Dept. of Health, Denver. Div. of Air Pollution Control.

    Regulations and standards relative to air quality control in Colorado are defined in this publication. Presented first are definitions of terms, a statement of intent, and general provisions applicable to all emission control regulations adopted by the Colorado Air Pollution Control Commission. Following this, three regulations are enumerated: (1)…

  7. Radiation Tolerance of Controlled Fusion Welds in High Temperature Oxidation Resistant FeCrAl Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Gussev, Maxim N. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Field, Kevin G. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)


    High temperature oxidation resistant iron-chromium-aluminum (FeCrAl) alloys are candidate alloys for nuclear applications due to their exceptional performance during off-normal conditions such as a loss-of-coolant accident (LOCA) compared to currently deployed zirconium-based claddings [1]. A series of studies have been completed to determine the weldability of the FeCrAl alloy class and investigate the weldment performance in the as-received (non-irradiated) state [2,3]. These initial studies have shown the general effects of composition and microstructure on the weldability of FeCrAl alloys. Given this, limited details on the radiation tolerance of FeCrAl alloys and their weldments exist. Here, the highest priority candidate FeCrAl alloys and their weldments have been investigated after irradiation to enable a better understanding of FeCrAl alloy weldment performance within a high-intensity neutron field. The alloys examined include C35M (Fe-13%Cr-5% Al) and variants with aluminum (+2%) or titanium carbide (+1%) additions. Two different sub-sized tensile geometries, SS-J type and SS-2E (or SS-mini), were neutron irradiated in the High Flux Isotope Reactor to 1.8-1.9 displacements per atom (dpa) in the temperature range of 195°C to 559°C. Post irradiation examination of the candidate alloys was completed and included uniaxial tensile tests coupled with digital image correlation (DIC), scanning electron microscopy-electron back scattered diffraction analysis (SEM-EBSD), and SEM-based fractography. In addition to weldment testing, non-welded parent material was examined as a direct comparison between welded and non-welded specimen performance. Both welded and non-welded specimens showed a high degree of radiation-induced hardening near irradiation temperatures of 200°C, moderate radiation-induced hardening near temperatures of 360°C, and almost no radiation-induced hardening at elevated temperatures near 550°C. Additionally, low-temperature irradiations showed

  8. Quality control education in the community college (United States)

    Greene, J. Griffen; Wilson, Steve


    This paper describes the Quality Control Program at Daytona Beach Junior College, including course descriptions. The program in quality control required communication between the college and the American Society for Quality Control (ASQC). The college has machinery established for certification of the learning process, and the society has the source of teachers who are competent in the technical field and who are the employers of the educational products. The associate degree for quality control does not have a fixed program, which can serve all needs, any more than all engineering degrees have identical programs. The main ideas which would be common to all quality control programs are the concept of economic control of a repetitive process and the concept of developing individual potentialities into individuals who are needed and productive.

  9. Welded joints integrity analysis and optimization for fiber laser welding of dissimilar materials (United States)

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


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

  10. Metallography of Battery Resistance Spot Welds (United States)

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


    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

  11. Study of Gravity Effects on Titanium Laser Welding in the Vertical Position (United States)

    Yuan, Zhang; Pu, Haitao; Li, Haigang; Cheng, Hao; Du, Dong; Shan, Jiguo


    To obtain satisfactory welds in positional laser beam welding, it is necessary to know how process parameters will influence the quality of welds in different welding positions. In this study, the titanium alloy Ti6Al4V sheets were laser welded in two vertical welding positions (vertical up and vertical down), and the appearance, porosity, strength, and ductility of the laser joints were evaluated. Results show that undercuts of the vertical up welds were greater than that of vertical down welds, while the porosity contents were much higher in vertical down welds than that in vertical up welds. When welding with a higher heat input, the vertical up welding position resulted in poor weld profiles (undercuts and burn-through holes), whereas the vertical down welding position led to excessive porosity contents in welds. Both severe undercut and excessive porosity were detrimental to the tensile properties of the welds. Weld appearance was improved and porosity contents were reduced by using a lower heat input, achieving better weld quality. Therefore, it is suggested that process parameter settings with relatively high laser powers and welding speeds, which can result in lower heat inputs, are used when laser welding the Ti6Al4V titanium alloys vertically. PMID:28885573

  12. [New welding processes and health effects of welding]. (United States)

    La Vecchia, G Marina; Maestrelli, Piero


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

  13. Professional Development for Water Quality Control Personnel. (United States)

    Shepard, Clinton Lewis

    This study investigated the availability of professional development opportunities for water quality control personnel in the midwest. The major objective of the study was to establish a listing of educational opportunities for the professional development of water quality control personnel and to compare these with the opportunities technicians…

  14. Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach. (United States)

    Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen


    A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design.

  15. Syllabus in Trade Welding. (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…

  16. The National Shipbuilding Research Program. Square Butt Pipe Welding

    National Research Council Canada - National Science Library

    Langhelm, J; Scheltens, James


    .... X-ray quality full penetration square butt weld joints were expected. Significant cost savings can be achieved through the reduction in pipe fitting and welding man-hours by utilization of a saw cut square butt joint design...

  17. Refractory metals welded or brazed with tungsten inert gas equipment (United States)

    Wisner, J. P.


    Appropriate brazing metals and temperatures facilitate the welding or brazing of base metals with tungsten inert gas equipment. The highest quality bond is obtained when TIG welding is performed in an inert atmosphere.

  18. Novel Process Revolutionizes Welding Industry (United States)


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

  19. Water Quality Control, Curriculum Guide. (United States)

    Washington City Board of Education, NC.

    Activities which study how water is used, contaminated, and treated or purified are presented in this curriculum guide, culminating in the investigation of a local water quality problem. Designed as a 12 week mini-course for students in grades eight and nine, the guide first presents a review of the content, objectives, major concepts, and sources…

  20. Laser welding head tailored to tube-sheet joint requirements for heat exchangers manufacturing


    Vandewynckéle, Ambroise; Vaamonde, Eva; Fontán, Marcos; Herwig, Patrick; Mascioletti, Alessandro


    Tube to tube-sheet joints in heat exchangers are currently welded by the orbital TIG process characterized by very high quality of the weld beads and good repeatability. However, due to high number of welds, a reduction in the welding cycle time would have an interesting impact on manufacturing costs and delays and laser welding technology is aimed to improve this factor. The main disadvantage is the positioning accuracy required by the laser welding process since beam deviations from real jo...

  1. Performance Improvement of Friction Stir Welds by Better Surface Finish (United States)

    Russell, Sam; Nettles, Mindy


    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.

  2. Electron beam welding of iridium heat source capsules (United States)

    Mustaleski, Thomas M.; Yearwood, J. Cecil; Burgan, Clyde E.; Green, L. A.


    The development of the welding procedures for the production of DOP-26 iridium alloy cups for heat source encapsulation is described. All the final assembly welds were made using the electron beam welding process. The welding of the 0.13-mm weld shield required the use of computer controlled X-Y table and a run-off tab. Welding of the frit vent to the cup required that a laser weld be made to hold the frit assembly edges together for the final electron beam weld. Great care is required in tooling design and beam placement to achieve acceptable results. Unsuccessful attempts to use laser beam welding for heat shield butt weld are discussed.

  3. Effects of heat input rates on T-1 and T-1A steel welds (United States)

    Davis, R. A.; Olsen, M. G.; Worden, S. W.


    Technology of T-1 and T-1A steels is emphasized in investigation of their weld-fabrication. Welding heat input rate, production weldment circumstances, and standards of welding control are considered.

  4. Process Management Development for Quality Monitoring on Resistance Weldment of Nuclear Fuel Rods

    Energy Technology Data Exchange (ETDEWEB)

    Na, Tae Hyung; Yang, Kyung Hwan; Kim, In Kyu [KEPCO, Daejeon (Korea, Republic of)


    The current, welding force, and displacement are displayed on the indicator during welding. However, real-time quality control is not performed. Due to the importance of fuel rod weldment, many studies on welding procedures have been conducted. However, there are not enough studies regarding weldment quality evaluation. On the other hand, there are continuous studies on the monitoring and control of welding phenomena. In resistance welding, which is performed in a very short time, it is important to find the process parameters that well represent the weld zone formation and the welding process. In his study, Gould attempted to analyze melt zone formation using the finite difference method. Using the artificial neural network, Javed and Sanders, Messler Jr et al., Cho and Rhee, Li and Gong et al. estimated the size of the melt zone by mapping a nonlinear functional relation between the weldment and the electrode head movement, which is a typical welding process parameter. Applications of the artificial intelligence method include fuzzy control using electrode displacement, fuzzy control using the optimal power curve, neural network control using the dynamic resistance curve, fuzzy adaptive control using the optimal electrode curve, etc. Therefore, this study induced quality factors for the real-time quality control of nuclear fuel rod end plug weldment using instantaneous dynamic resistance (IDR), which incorporates the instantaneous value of secondary current and voltage of the transformer, and using instantaneous dynamic force (IDF), obtained real-time during welding.

  5. Lasers in car body construction - substitution of conventional welding techniques or supplement

    Energy Technology Data Exchange (ETDEWEB)

    Imhoff, R.; Behler, K.; Beyer, E.


    In car body construction, laser beam welding competes with resistance spot welding and with projection welding. There are problems concerning the short bridging distance of the laser beam welding, but there are also some advantages, i.e.: lower weight; higher strength and stiffness of the car body; high welding speed (5 to 10 m/min); triple-pass welding; welding at a present depth for attaching reinforcing elements on the inside of visible car parts for the purpose of vibration and noise damping; good process control characteristics. In the long run, laser beam welding is expected to replace conventional welding techniques in car body construction.

  6. Quality criteria for pure titanium casting, laboratory soldering, intraoral welding, and a device to aid in making uncontaminated castings. (United States)

    Hruska, A R; Borelli, P


    Procedures for casting, laboratory soldering, and intraoral welding of titanium for dental restorations are described and illustrated. Pure titanium and titanium 6A1-4Va alloy castings may be used for virtually any prosthodontic rehabilitation as well as for implants, with the proper equipment and technique.

  7. [Comparing quality measurements Part 2: control charts]. (United States)

    Kottner, Jan; Hauss, Armin


    Comparative quality measurements and evaluations in nursing play significant roles. Quality measures are affected by systematic and random error. Statistical Process Control (SPC) offers a method to take random variation adequately into account. In this article, control charts are introduced. Those are graphical displays to show quality measures over time. Attribute variables can be displayed by p-, u- and c-control charts. Special cause variations within the processes can be detected by rules. If signs for special cause variations are absent, the process in considered being in statistical control showing common cause variation. A deviation of one data point greater than three standard deviations from the arithmetic mean is considered the strongest signal for non random variation within the process. Within quality improvement contexts control charts outperform traditional comparisons of means and spreads.

  8. Sensometrics for Food Quality Control

    DEFF Research Database (Denmark)

    Brockhoff, Per B.


    The industrial development of innovative and succesful food items and the measuring of food quality in general is difficult without actually letting human beings evaluate the products using their senses at some point in the process. The use of humans as measurement instruments calls for special...... attention in the modelling and data analysis phase. In this paper the focus is on sensometrics – the „metric“ side of the sensory science field. The sensometrics field is introduced and related to the fields of statistics, chemometrics and psychometrics. Some of the most commonly used sensory testing...


    Directory of Open Access Journals (Sweden)

    Vladimir A. Romanov


    Full Text Available The aim of the investigation is development of innovative strategy of quality control training of engineers and skilled workers (hereinafter – future specialists in educational professional organizations on the principles of social partnership.Methods. Theoretic: theoretic and methodological analysis, polytheoretic synthesis, modeling. Empirical: research and generalization of the system, process and competence – based approaches experience, experiment, observation, surveys, expert evaluation, SWOT-analysis as a method of strategic planning which is to identify the internal and external factors (socio-cultural of the organization surrounding.Results. The strategy of the development of the process of quality control training in educational professional organizations and a predictive model of the system of quality control training for future engineers and workers have been created on the analysis and synthesis of a quantitative specification of the quality, the obtained experience and success in control training of future specialists in educational professional organizations in recent economic and educational conditions.Scientific novelty. There has been built a predicative model of quality control training of future specialists to meet modern standards and the principles of social partnership; the control algorithm of the learning process, developed in accordance with the standards (international of quality ISO in the implementation of the quality control systems of the process approach (matrix-based responsibility, competence and remit of those responsible for the education process in the educational organization, the «problem» terms and diagnostic tools for assessing the quality of professional training of future specialists. The perspective directions of innovation in the control of the quality of future professionals training have been determined; the parameters of a comprehensive analysis of the state of the system to ensure the

  10. The characteristics of welded joints for air conditioning application (United States)

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


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

  11. Study on influence of three kinds of stress on crack propagation in butt welds of spiral coil waterwall for ultra supercritical boiler (United States)

    Yan, Zhenrong; Si, Jun


    The spiral coil waterwall is the main pressure parts and the core functional components of Ultra Supercritical Boiler. In the process of operation, the spiral coil waterwall is under the combined action of welding residual stress, installation defects stress and working fluid stress, Cracks and crack propagation are easy to occur in butt welds with defects. In view of the early cracks in the butt welds of more T23 water cooled walls, in this paper, the influence of various stresses on the crack propagation in the butt welds of spiral coil waterwall was studied by numerical simulation. Firstly, the welding process of T23 water cooled wall tube was simulated, and the welding residual stress field was obtained. Then,on the basis, put the working medium load on the spiral coil waterwall, the supercoated stress distribution of the welding residual stress and the stress of the working medium is obtained. Considering the bending moment formed by stagger joint which is the most common installation defects, the stress field distribution of butt welds in T23 water-cooled wall tubes was obtained by applying bending moment on the basis of the stress field of the welding residual stress and the working medium stress. The results show that, the welding residual stress is small, the effect of T23 heat treatment after welding to improve the weld quality is not obvious; The working medium load plays a great role in the hoop stress of the water cooled wall tube, and promotes the cracks in the butt welds; The axial stress on the water cooled wall tube produced by the installation defect stress is obvious, the stagger joint, and other installation defects are the main reason of crack propagation of spiral coil waterwall. It is recommended that the control the bending moment resulting from the stagger joint not exceed 756.5 NM.

  12. [Quality control of printed patient information]. (United States)

    Herm, Kerstin; Linden, Michael


    Printed material is an important part in patient information and is called bibliotherapy. It is subject to quality control similar to any other types of treatment. This paper presents an outline of important quality criteria and methods of quality control. Important quality criteria are: (a) Correctness and validity of content evaluated by mentioning the expertise of the authors, appraisal through external experts, reference to scientific literature, and empirical tests of the content, (b) Readability in respect to text structure measured by the "Flesch-Reading-Ease-Formula" supported by fair graphical design including fond and structure of text, (c) Comprehensibility tested by feedback of patients or standardized by the Hamburg comprehensibility rating, (d) Utility including securing availability, acceptance, differential indication and use. Writing and publication of patient leaflets must be accompanied by quality control measures. © Georg Thieme Verlag KG Stuttgart · New York.

  13. The influence of high heat input and inclusions control for rare earth on welding in low alloy high strength steel (United States)

    Chu, Rensheng; Mu, Shukun; Liu, Jingang; Li, Zhanjun


    In the current paper, it is analyzed for the influence of high heat input and inclusions control for rare earth on welding in low alloy high strength steel. It is observed for the structure for different heat input of the coarse-grained area. It is finest for the coarse grain with the high heat input of 200 kJ / cm and the coarse grain area with 400 kJ / cm is the largest. The performance with the heat input of 200 kJ / cm for -20 °C V-shaped notch oscillatory power is better than the heat input of 400 kJ / cm. The grain structure is the ferrite and bainite for different holding time. The grain structure for 5s holding time has a grain size of 82.9 μm with heat input of 200 kJ/cm and grain size of 97.9 μm for 10s holding time. For the inclusions for HSLA steel with adding rare earth, they are Al2O3-CaS inclusions in the Al2O3-CaS-CaO ternary phase diagram. At the same time, it can not be found for low melting calcium aluminate inclusions compared to the inclusions for the HSLA steel without rare earth. Most of the size for the inclusions is between 1 ~ 10μm. The overall grain structure is smaller and the welding performance is more excellent for adding rare earth.

  14. Influence of welding current in resistance spot welding on the properties of Zn coated steel DX51D

    Directory of Open Access Journals (Sweden)

    Luboš Kaščák


    Full Text Available The paper deals with the resistance spot welding of three galvanized car body sheets DX51D + Z - EN 10142/2000. The quality of welded joints was evaluated by destructive tests and non-destructive tests. For evaluation of joints quality the shear tension test on spot joints according to DIN 50 124 standard was used. The influence of welding parameters on the structure of a welded joint was observed by metallographic analysis. Influence of welding current from 6.0 to 7.7 kA and influence of welding time from 10 to 12 periods on weld properties was observed. Increasing the welding current led to increased load-bearing capacity of the welded joints. The spot welded joints without any internal defects occurred in samples welded up to 7.0 kA. Increasing the welding time to 12 periods led to increased load-bearing capacity of the welded joints, within all observed values of welding current.

  15. Net analyte signal based statistical quality control

    NARCIS (Netherlands)

    Skibsted, E.T.S.; Boelens, H.F.M.; Westerhuis, J.A.; Smilde, A.K.; Broad, N.W.; Rees, D.R.; Witte, D.T.


    Net analyte signal statistical quality control (NAS-SQC) is a new methodology to perform multivariate product quality monitoring based on the net analyte signal approach. The main advantage of NAS-SQC is that the systematic variation in the product due to the analyte (or property) of interest is

  16. Quality Controlled Local Climatological Data (QCLCD) Publication (United States)

    National Oceanic and Atmospheric Administration, Department of Commerce — Quality Controlled Local Climatological Data (QCLCD) contains summaries from major airport weather stations that include a daily account of temperature extremes,...

  17. Quality Control Guidelines for SAM Chemical Methods (United States)

    Learn more about quality control guidelines and recommendations for the analysis of samples using the chemistry methods listed in EPA's Selected Analytical Methods for Environmental Remediation and Recovery (SAM).

  18. Quality Control Guidelines for SAM Biotoxin Methods (United States)

    Learn more about quality control guidelines and recommendations for the analysis of samples using the pathogen methods listed in EPA's Selected Analytical Methods for Environmental Remediation and Recovery (SAM).

  19. Quality Control Guidelines for SAM Pathogen Methods (United States)

    Learn more about quality control guidelines and recommendations for the analysis of samples using the biotoxin methods listed in EPA's Selected Analytical Methods for Environmental Remediation and Recovery (SAM).

  20. Quality Control Guidelines for SAM Radiochemical Methods (United States)

    Learn more about quality control guidelines and recommendations for the analysis of samples using the radiochemistry methods listed in EPA's Selected Analytical Methods for Environmental Remediation and Recovery (SAM).

  1. Application of TRIZ Methodology in Diffusion Welding System Optimization (United States)

    Ravinder Reddy, N.; Satyanarayana, V. V.; Prashanthi, M.; Suguna, N.


    Welding is tremendously used in metal joining processes in the manufacturing process. In recent years, diffusion welding method has significantly increased the quality of a weld. Nevertheless, diffusion welding has some extent short research and application progress. Therefore, diffusion welding has a lack of relevant information, concerned with the joining of thick and thin materials with or without interlayers, on welding design such as fixture, parameters selection and integrated design. This article intends to combine innovative methods in the application of diffusion welding design. This will help to decrease trial and error or failure risks in the welding process being guided by the theory of inventive problem solving (TRIZ) design method. This article hopes to provide welding design personnel with innovative design ideas under research and for practical application.


    Directory of Open Access Journals (Sweden)

    Afshin Kheidari Monfared


    Full Text Available Welding is a crucial manufacturing process and widely used for manufacturing various products including ships, automobiles, trains and bridges. Welding distortions often occur in welded structures of thin plates due to relatively low stiffness and result in their warpage during assembly process and high manufacturing cost. Therefore, prediction and reduction of welding distortions are important in order to improve quality of welded structures. Welding distortion during the assembly process is caused not only by local shrinkage due to rapid heating and cooling. 3-D thermo-elastic-plastic finite element method (FEM has been used to simulate single-bead-on-plate welding with 1 mm thickness. Experiments have been carried out to prove the simulated results. Comparison of the experimental results and FEM simulation results has confirmed that the proposed method efficiently  predicts level of  welding distortions while making single-bead-on-plate welding with 1 mm thickness.

  3. Fatique Resistant, Energy Efficient Welding Program, Final Technical Report

    Energy Technology Data Exchange (ETDEWEB)

    Egland, Keith; Ludewig, Howard


    The program scope was to affect the heat input and the resultant weld bead geometry by synchronizing robotic weave cycles with desired pulsed waveform shapes to develop process parameters relationships and optimized pulsed gas metal arc welding processes for welding fatique-critical structures of steel, high strength steel, and aluminum. Quality would be addressed by developing intelligent methods of weld measurement that accurately predict weld bead geometry from process information. This program was severely underfunded, and eventually terminated. The scope was redirected to investigate tandem narrow groove welding of steel butt joints during the one year of partial funding. A torch was designed and configured to perform a design of experiments of steel butt weld joints that validated the feasability of the process. An initial cost model estimated a 60% cost savings over conventional groove welding by eliminating the joint preparation and reducing the weld volume needed.


    Directory of Open Access Journals (Sweden)



    Full Text Available Welding is tremendously used in metal joining processes in the manufacturing process. In recent years, diffusion welding method has significantly increased the quality of a weld. Nevertheless, diffusion welding has some extent short research and application progress. Therefore, diffusion welding has a lack of relevant information, concerned with the joining of thick and thin materials with or without interlayers, on welding design such as fixture, parameters selection and inte-grated design. This article intends to combine innovative methods in the application of diffusion welding design. This will help to decrease trial and error or failure risks in the welding process being guided by the theory of inventive problem solving (TRIZ design method. This article hopes to provide welding design personnel with innovative design ideas under research and for practical application.

  5. Laser welding of polypropylene using two different sources (United States)

    Mandolfino, Chiara; Brabazon, Dermot; McCarthy, Éanna; Lertora, Enrico; Gambaro, Carla; Ahad, Inam Ul


    In this paper, laser weldability of neutral polypropylene has been investigated using fibre and carbon dioxide lasers. A design of experiment (DoE) was conducted in order to establish the influence of the main working parameters on the welding strength of the two types of laser. The welded samples were characterized by carrying out visual and microscopic inspection for the welding morphology and cross-section, and by distinguishing the tensile strength. The resulting weld quality was investigated by means of optical microscopy at weld cross-sections. The tensile strength of butt-welded materials was measured and compared to that of a corresponding bulk material.

  6. Versatile Friction Stir Welding/Friction Plug Welding System (United States)

    Carter, Robert


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

  7. Strategies for reduced distortion during laser beam welding of shaft-hub joints

    Energy Technology Data Exchange (ETDEWEB)

    Buschenhenke, F.; Seefeld, T.; Vollertsen, F. [Bremer Institut fuer angewandte Strahltechnik, Bremen (Germany)


    The joining of shaft-hub connections is gaining in importance in the area of power train applications. The quality demands in abrasion and power transmission are playing a major role. Dimensional as well as repeat accuracies are essential quality criteria, which have to be focused on. The understanding of the whole process chain in view of different distortion potentials introduced in each processing step provides the ability to control the distortion of the welded components. The laser beam sources of the new generation permit a high power welding process and high beam quality at the same time. These laser beams are capable of producing deep and narrow weld seams. This work deals with compensation strategies of deformations during laser beam welding in axial welded shaft-hub joints made of steel. Furthermore, simultaneous welding with two laser beams and the influence of the process chain were investigated to characterise the influence of these strategies tactile differential measurements were done. The results were discussed regarding numerical calculations in the FEM application SYSWELD. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  8. A System for Complex Robotic Welding

    DEFF Research Database (Denmark)

    Madsen, Ole; Sørensen, Carsten Bro; Olsen, Birger


    This paper presents the architecture of a system for robotic welding of complex tasks. The system integrates off-line programming, control of redundant robots, collision-free motion planning and sensor-based control. An implementation for pipe structure welding made at Odense Steel Shipyard Ltd......., Denmark, demonstrates the system can be used for automatic welding of complex products in one-of-a-kind production....

  9. Refurbishment of damaged tools using the combination of GTAW and laser beam welding

    Directory of Open Access Journals (Sweden)

    J. Tušek


    Full Text Available This paper presents the use of two welding processes for the refurbishment of damaged industrial tools. In the first part the problem is presented followed by the comparison of GTAW and laser welding in terms of repair welding of damaged tools. The macrosections of the welds show the difference between both welding processes in repairing of damaged tools. At the conclusion the main findings are presented. In many cases it is useful to use both welding processes in order to achieve better weld quality and to make welding more economical. The order of the technology used depends on the tool material, the use of the tool and the tool damage.

  10. Distribution of Argon Arc Contaminated with Nitrogen as Function of Frequency in Pulsed TIG Welding (United States)

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


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

  11. Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints (United States)

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


    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.

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

    Directory of Open Access Journals (Sweden)

    Everett M. Criss


    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.

  13. Passively damped vibration welding system and method (United States)

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


    A vibration welding system includes a controller, welding horn, an anvil, and a passive damping mechanism (PDM). The controller generates an input signal having a calibrated frequency. The horn vibrates in a desirable first direction at the calibrated frequency in response to the input signal to form a weld in a work piece. The PDM is positioned with respect to the system, and substantially damps or attenuates vibration in an undesirable second direction. A method includes connecting the PDM having calibrated properties and a natural frequency to an anvil of an ultrasonic welding system. Then, an input signal is generated using a weld controller. The method includes vibrating a welding horn in a desirable direction in response to the input signal, and passively damping vibration in an undesirable direction using the PDM.

  14. Possibilities of using welding-on technologies in crane wheel ...

    Indian Academy of Sciences (India)


    Abstract. The paper deals with analysis of welds-on quality of traverse crane wheels made from gr. 90–60 mate- rial, ASTM A148. Three types of welding-on technology with various filling materials were used. On wheel after wearing was welded-on one interlayer by a combination of additional materials, wire A 106 with F 11 ...

  15. Real Time Ultrasonic Aluminum SPOT Weld Monitoring System (United States)

    Regalado, W. Pérez; Chertov, A. M.; Maev, R. Gr.


    Aluminum alloys pose several properties that make them one of the most popular engineering materials: they have excellent corrosion resistance, and high weight-to-strength ratio. Resistance spot welding of aluminum alloys is widely used today but oxide film and aluminum thermal and electrical properties make spot welding a difficult task. Electrode degradation due to pitting, alloying and mushrooming decreases the weld quality and adjustment of parameters like current and force is required. To realize these adjustments and ensure weld quality, a tool to measure weld quality in real time is required. In this paper, a real time ultrasonic non-destructive evaluation system for aluminum spot welds is presented. The system is able to monitor nugget growth while the spot weld is being made. This is achieved by interpreting the echoes of an ultrasound transducer located in one of the welding electrodes. The transducer receives and transmits an ultrasound signal at different times during the welding cycle. Valuable information of the weld quality is embedded in this signal. The system is able to determine the weld nugget diameter by measuring the delays of the ultrasound signals received during the complete welding cycle. The article presents the system performance on aluminum alloy AA6022.

  16. New materials for welding and surfacing (United States)

    Kozyrev, N. A.; Galevsky, G. V.; Kryukov, R. E.; Titova, D. A.; Shurupov, V. M.


    The paper provides description of research into the influence of new materials and technologies on quality parameters of welds and deposited metal carried out in the research and production centre “Welding processes and technologies”. New welding technologies of tanks for northern conditions are considered, as well as technologies of submerged arc welding involving fluxing agents AN - 348, AN - 60, AN - 67, OK.10.71 and carbon-fluorine containing additives; new flux cored wires and surfacing technologies, teaching programs and a trainer for welders are designed.

  17. Femtosecond fiber laser welding of dissimilar metals. (United States)

    Huang, Huan; Yang, Lih-Mei; Bai, Shuang; Liu, Jian


    In this paper, welding of dissimilar metals was demonstrated for the first time, to the best of our knowledge, by using a high-energy high-repetition-rate femtosecond fiber laser. Metallurgical and mechanical properties were investigated and analyzed under various processing parameters (pulse energy, repetition rate, and welding speed). Results showed that the formation of intermetallic brittle phases and welding defects could be effectively reduced. Strong welding quality with more than 210 MPa tensile strength for stainless steel-aluminum and 175 MPa tensile strength for stainless steel-magnesium has been demonstrated. A minimal heat affected zone and uniform and homogenous phase transformation in the welding region have been demonstrated. This laser-welding technique can be extended for various applications in semiconductor, automobile, aerospace, and biomedical industries.

  18. Study of a fiber laser assisted friction stir welding process (United States)

    Casalino, G.; Campanelli, S.; Ludovico, A. D.; Contuzzi, N.; Angelastro, A.


    Friction stir welding is a relatively new joining technique. This technique, which is considered a derivative of the more common friction welding method, was developed mainly for aluminum and its alloys. In recent years, this method has been used to join various other alloys. FSW has many advantages, including the following: the welding procedure is relatively simple with no consumables or filler metal; joint edge preparation is not needed; oxide removal prior to welding is unnecessary; high joint strength has been achieved in aluminum and magnesium alloys; FSW can be used with alloys that cannot be fusion welded due to crack sensitivity. The drawbacks of FSW include the need for powerful fixtures to clamp the workpiece to the welding table, the high force needed to move the welding tool forward, the relatively high wear rate of the welding tool, and weld speeds in FSW are slower, which can lead to longer process times. To overcome these drawbacks, a fiber laser-assisted friction stir welding system was designed (FLAFSW). The system combined a conventional commercial friction machine and a fiber pumped laser system. The scope is to investigate the influence of the laser assistance on the weld quality. A number of different aluminum plates, which are still mentioned to be difficult to be joint as intermetallic phases appear during melting welding techniques, were used. The evaluation of quality was performed through analysis of appearance, mechanical and microstructure characterization of the weld.

  19. Potential Benefits of Ultrasonically Assisted Fusion Welding ...

    African Journals Online (AJOL)

    Many of the processes in which ultrasonic oscillations have been beneficial are similar to fusion welding process where the quality of welds depends on porosity, crystallisation rate, inclusions, inter-metallic compounds, depth of penetration, heat affected zone, etc. Some preliminary tests were performed to assess the effects ...

  20. Improved electron-beam welding technique (United States)

    Schumacher, B.


    Electron-beam generator produces high quality welds without vaporization by relying on the mobility and hydrodynamic properties of the material in its liquid phase. The power density of the beam is relative to the speed of the workpiece, producing an inclined weld-front.

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

    DEFF Research Database (Denmark)

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


    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. Automation system for quality control in manufacture of iodine-125 sealed sources used in brachytherapy

    Energy Technology Data Exchange (ETDEWEB)

    Somessari, Samir L.; Feher, Anselmo; Sprenger, Francisco E.; Rostellato, Maria E.C.M.; Moura, Joao A.; Costa, Osvaldo L.; Calvo, Wilson A.P., E-mail: somessar@ipen.b, E-mail: afeher@ipen.b, E-mail: sprenger@ipen.b, E-mail: elisaros@ipen.b, E-mail: olcosta@ipen.b, E-mail: wapcalvo@ipen.b [Instituto de Pesquisas Energeticas e Nucleares (IPEN/CNEN-SP), Sao Paulo, SP (Brazil)


    The objective of this work is to develop an automation system for Quality Control in the production of Iodine-125 sealed sources, after undergoing the process of laser beam welding. These sources, also known as Iodine-125 seeds are used, successfully, in the treatment of cancer by brachytherapy, with low-dose rates. Each small seed is composed of a welded titanium capsule with 0.8 mm diameter and 4.5 mm in length, containing Iodine-125 adsorbed on an internal silver wire. The seeds are implanted in the human prostate to irradiate the tumor and treat the cancerous cells. The technology to automate the quality control system in the manufacture of Iodine-125 seeds consists in developing and associate mechanical parts, electronic components and pneumatic circuits to control machines and processes. The automation technology for Iodine-125 seed production developed in this work employs programmable logic controller, step motors, drivers of control, electrical-electronic interfaces, photoelectric sensors, interfaces of communication and software development. Industrial automation plays an important role in the production of Iodine-125 seeds, with higher productivity and high standard of quality, facilitating the implementation and operation of processes with good manufacturing practices. Nowadays, the Radiation Technology Center at IPEN-CNEN/SP imports and distributes 36,000 Iodine-125 seeds per year for clinics and hospitals in the whole country. However, the Brazilian potential market is of 8,000 Iodine-125 seeds per month. Therefore, the local production of these radioactive seeds has become a priority for the Institute, aiming to reduce the price and increase the supply to the population in Brazil. (author)

  3. In-Situ Nondestructive Examination of Weld Penetration

    National Research Council Canada - National Science Library

    Chin, Bryan


    The objective of this program is to develop infrared sensing techniques to monitor and control welding penetration in gas tungsten arc and submerged arc welding processes used by the US Navy in the construction of ships...

  4. Quality control of a teleradiology system (United States)

    Lyche, David K.; Willis, Charles E.; Williamson, Morgan P.; Suitor, Charles T.; Romlein, John R.


    Teleradiology is being implemented in the U.S. military. Soft-copy reading of computed radiology (CR) images and film-digitizer (FD) images are becoming a common practice. The Medical Diagnostic Imaging Support (MDIS) Office at the Medical Advanced Technology Management Office (MATMO), Fort Detrick, Maryland, installed an 'off-the-shelf' DICOM teleradiology system by which CR images and FD images acquired at Hickam Air Force Base (AFB), Hawaii, are transmitted electronically over a T-1 telecommunications line to Tripler Army Medical Center (TAMC), Hawaii. The goal was to provide a diagnostic quality teleradiology system to the military services to extend the expertise and training of physicians to remote sites. In order to guarantee a diagnostic quality image throughout the system, a rigid set of quality control standards had to be designed and implemented. This poster presents the results of a successful teleradiology implementation where quality control is maintained throughout the imaging chain.

  5. 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)


    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.

  6. Identification of optimum friction stir spot welding process parameters controlling the properties of low carbon automotive steel joints

    Directory of Open Access Journals (Sweden)

    A.K. Lakshminarayanan


    Full Text Available Friction stir spot welding is a novel solid state process that has recently received considerable attention from various industries including automotive sectors due to many advantages over the resistance spot welding. However to apply this technique, the process parameters must be optimized to obtain improved mechanical properties compared to resistance spot welding. To achieve this, in this investigation, design of experiments was used to conduct the experiments for exploring the interdependence of the process parameters. A second order quadratic model for predicting the lap shear tensile strength of friction stir spot welded low carbon automotive steel joints was developed from the experimental obtained data. It is found that dwell time plays a major role in deciding the joint properties, which is followed by rotational speed and plunge depth. Further optimum process parameters were identified for maximum lap shear tensile strength using numerical and graphical optimization techniques.

  7. Harmonisation Initiatives of Copernicus Data Quality Control (United States)

    Vescovi, F. D.; Lankester, T.; Coleman, E.; Ottavianelli, G.


    The Copernicus Space Component Data Access system (CSCDA) incorporates data contributions from a wide range of satellite missions. Through EO data handling and distribution, CSCDA serves a set of Copernicus Services related to Land, Marine and Atmosphere Monitoring, Emergency Management and Security and Climate Change. The quality of the delivered EO products is the responsibility of each contributing mission, and the Copernicus data Quality Control (CQC) service supports and complements such data quality control activities. The mission of the CQC is to provide a service of quality assessment on the provided imagery, to support the investigation related to product quality anomalies, and to guarantee harmonisation and traceability of the quality information. In terms of product quality control, the CQC carries out analysis of representative sample products for each contributing mission as well as coordinating data quality investigation related to issues found or raised by Copernicus users. Results from the product analysis are systematically collected and the derived quality reports stored in a searchable database. The CQC service can be seen as a privileged focal point with unique comparison capacities over the data providers. The comparison among products from different missions suggests the need for a strong, common effort of harmonisation. Technical terms, definitions, metadata, file formats, processing levels, algorithms, cal/val procedures etc. are far from being homogeneous, and this may generate inconsistencies and confusion among users of EO data. The CSCDA CQC team plays a significant role in promoting harmonisation initiatives across the numerous contributing missions, so that a common effort can achieve optimal complementarity and compatibility among the EO data from multiple data providers. This effort is done in coordination with important initiatives already working towards these goals (e.g. INSPIRE directive, CEOS initiatives, OGC standards, QA4EO

  8. Temporal characterization of plasma cw high-power CO2 laser-matter interaction: contribution to the welding process control (United States)

    Engel, Thierry; Kane, M.; Fontaine, Joel


    During high-power laser welding, gas ionization occurs above the sample. The resulting plasma ignition threshold is related to ionization potential of metallic vapors from the sample, and shielding gases used in the process. In this work, we have characterized the temporal behavior of the radiation emitted by the plasma during laser welding in order to relate the observed signals to the process parameters.

  9. Protein quality control in the nucleus

    DEFF Research Database (Denmark)

    Nielsen, Sofie V.; Poulsen, Esben Guldahl; Rebula, Caio A.


    to aggregate, cells have evolved several elaborate quality control systems to deal with these potentially toxic proteins. First, various molecular chaperones will seize the misfolded protein and either attempt to refold the protein or target it for degradation via the ubiquitin-proteasome system...... to be particularly active in protein quality control. Thus, specific ubiquitin-protein ligases located in the nucleus, target not only misfolded nuclear proteins, but also various misfolded cytosolic proteins which are transported to the nucleus prior to their degradation. In comparison, much less is known about...... these mechanisms in mammalian cells. Here we highlight recent advances in our understanding of nuclear protein quality control, in particular regarding substrate recognition and proteasomal degradation....

  10. Frontiers in statistical quality control 11

    CERN Document Server

    Schmid, Wolfgang


    The main focus of this edited volume is on three major areas of statistical quality control: statistical process control (SPC), acceptance sampling and design of experiments. The majority of the papers deal with statistical process control, while acceptance sampling and design of experiments are also treated to a lesser extent. The book is organized into four thematic parts, with Part I addressing statistical process control. Part II is devoted to acceptance sampling. Part III covers the design of experiments, while Part IV discusses related fields. The twenty-three papers in this volume stem from The 11th International Workshop on Intelligent Statistical Quality Control, which was held in Sydney, Australia from August 20 to August 23, 2013. The event was hosted by Professor Ross Sparks, CSIRO Mathematics, Informatics and Statistics, North Ryde, Australia and was jointly organized by Professors S. Knoth, W. Schmid and Ross Sparks. The papers presented here were carefully selected and reviewed by the scientifi...

  11. A Comparative Study on the Laser Welding of Ti6Al4V Alloy Sheets in Flat and Horizontal Positions

    Directory of Open Access Journals (Sweden)

    Baohua Chang


    Full Text Available Laser welding has been increasingly utilized to manufacture a variety of components thanks to its high quality and speed. For components with complex shapes, the welding position needs be continuously adjusted during laser welding, which makes it necessary to know the effects of the welding position on the quality of the laser welds. In this paper, the weld quality under two (flat and horizontal welding positions were studied comparatively in the laser welding of Ti6Al4V titanium alloy, in terms of weld profiles, process porosity, and static tensile strengths. Results show that the flat welding position led to better weld profiles, less process porosity than that of the horizontal welding position, which resulted from the different actions of gravity on the molten weld metals and the different escape routes for pores under different welding positions. Although undercuts showed no association with the fracture positions and tensile strengths of the welds, too much porosity in horizontal laser welds led to significant decreases in the strengths and specific elongations of welds. Higher laser powers and travel speeds were recommended, for both flat and horizontal welding positions, to reduce weld porosity and improve mechanical properties.

  12. Heavy multi-pass TIG welding


    Maske, Tomas


    This study aims to find the maximum, usable, feed limit at different arc-energies and use the findings in multi-pass welding planning for robotic welding, taking into consideration the high controllability of robot movements. A combined studies using numerical analyses and practical experiments to calculate the feed limits for different arc energies. Each weld where analysed both mathematical, physical and thru observation. The combined results for one experiment will form the bases for th...

  13. Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes. (United States)

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


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

  14. Research on Ultrasonic Flaw Detection of Steel Weld in Spatial Grid Structure (United States)

    Du, Tao; Sun, Jiandong; Fu, Shengguang; Zhang, Changquan; Gao, Qing


    The welding quality of spatial grid member is an important link in quality control of steel structure. The paper analyzed the reasons that the welding seam of small-bore pipe with thin wall grid structure is difficult to be detected by ultrasonic wave from the theoretical and practical aspects. A series of feasible detection methods was also proposed by improving probe and operation approaches in this paper, and the detection methods were verified by project cases. Over the years, the spatial grid structure is widely used the engineering by virtue of its several outstanding characteristics such as reasonable structure type, standard member, excellent space integrity and quick installation. The wide application of spatial grid structure brings higher requirements on nondestructive test of grid structure. The implementation of new Code for Construction Quality Acceptance of Steel Structure Work GB50205-2001 strengthens the site inspection of steel structure, especially the site inspection of ultrasonic flaw detection in steel weld. The detection for spatial grid member structured by small-bore and thin-walled pipes is difficult due to the irregular influence of sound pressure in near-field region of sound field, sound beam diffusion generated by small bore pipe and reduction of sensitivity. Therefore, it is quite significant to select correct detecting conditions. The spatial grid structure of welding ball and bolt ball is statically determinate structure with high-order axial force which is connected by member bars and joints. It is welded by shrouding or conehead of member bars and of member bar and bolt-node sphere. It is obvious that to ensure the quality of these welding positions is critical to the quality of overall grid structure. However, the complexity of weld structure and limitation of ultrasonic detection method cause many difficulties in detection. No satisfactory results will be obtained by the conventional detection technology, so some special

  15. HPLC for quality control of polyimides (United States)

    Young, P. R.; Sykes, G. F.


    High Pressure Liquid Chromatography (HPLC) as a quality control tool for polyimide resins and prepregs are presented. A data base to help establish accept/reject criteria for these materials was developed. This work is intended to supplement, not replace, standard quality control tests normally conducted on incoming resins and prepregs. To help achieve these objectives, the HPLC separation of LARC-160 polyimide precursor resin was characterized. Room temperature resin aging effects were studied. Graphite reinforced composites made from fresh and aged resin were fabricated and tested to determine if changes observed by HPLC were significant.

  16. Statistical quality control a loss minimization approach

    CERN Document Server

    Trietsch, Dan


    While many books on quality espouse the Taguchi loss function, they do not examine its impact on statistical quality control (SQC). But using the Taguchi loss function sheds new light on questions relating to SQC and calls for some changes. This book covers SQC in a way that conforms with the need to minimize loss. Subjects often not covered elsewhere include: (i) measurements, (ii) determining how many points to sample to obtain reliable control charts (for which purpose a new graphic tool, diffidence charts, is introduced), (iii) the connection between process capability and tolerances, (iv)

  17. Influence of welding current in resistance spot welding on the properties of Zn coated steel DX51D


    Luboš Kaščák; Ján Viňáš; Rudolf Mišičko


    The paper deals with the resistance spot welding of three galvanized car body sheets DX51D + Z - EN 10142/2000. The quality of welded joints was evaluated by destructive tests and non-destructive tests. For evaluation of joints quality the shear tension test on spot joints according to DIN 50 124 standard was used. The influence of welding parameters on the structure of a welded joint was observed by metallographic analysis. Influence of welding current from 6.0 to 7.7 kA and infl...

  18. Electron Beam Welding of Gear Wheels by Splitted Beam (United States)

    Dřímal, Daniel


    This contribution deals with the issue of electron beam welding of high-accurate gear wheels composed of a spur gearing and fluted shaft joined with a face weld for automotive industry. Both parts made of the high-strength low-alloy steel are welded in the condition after final machining and heat treatment, performed by case hardening, whereas it is required that the run-out in the critical point of weldment after welding, i. e. after the final operation, would be 0.04 mm max.. In case of common welding procedure, cracks were formed in the weld, initiated by spiking in the weld root. Crack formation was prevented by the use of an interlocking joint with a rounded recess and suitable welding parameters, eliminating crack initiation by spiking in the weld root. Minimisation of the welding distortions was achieved by the application of tack welding with simultaneous splitting of one beam into two parts in the opposite sections of circumferential face weld attained on the principle of a new system of controlled deflection with digital scanning of the beam. This welding procedure assured that the weldment temperature after welding would not be higher than 400 °C. Thus, this procedure allowed achieving the final run-outs in the critical point of gearwheels within the maximum range up to 0.04 mm, which is acceptable for the given application. Accurate optical measurements did not reveal any changes in the teeth dimensions.

  19. Control cards as a statistical quality control resource

    Directory of Open Access Journals (Sweden)

    Aleksandar Živan Drenovac


    Full Text Available Normal 0 false false false MicrosoftInternetExplorer4 This paper proves that applying of statistical methods can significantly contribute increasing of products and services quality, as well as increasing of institutions rating. Determining of optimal, apropos anticipatory and limitary values, is based on sample`s statistical analyze. Control cards represent very confident instrument, which is simple for use and efficient for control of process, by which process is maintained in set borders. Thus, control cards can be applied in quality control of procesess of weapons and military equipment production, maintenance of technical systems, as well as for seting of standards and increasing of quality level for many other activities.

  20. Aplicabilidad del monitoreo de emisiones del arco eléctrico para el control de calidad en el proceso MAG-S Applicability of monitoring of electric arc emissions for quality control in MAG-S process

    Directory of Open Access Journals (Sweden)

    Eber Huanca Cayo


    Full Text Available Garantizar la calidad en soldadura no es una tarea trivial. Para ello diversas inspecciones de control de calidad son realizadas, en detrimento, los costos y tiempos de producción se elevan. Existen diversos sistemas automatizados de soldadura, éstos son auxiliados por sistemas de control basados en el monitoreo de parámetros de soldadura. Sin embargo son reducidos los sistemas automatizados de monitoreo de calidad que en su mayoría son diseñados para el proceso TIG. Durante la soldadura, el arco eléctrico produce emisiones acústicas y electromagnéticas que se manifiestan como sonido y luminosidad. El objetivo del presente trabajo es mostrar que estas emisiones del arco pueden ser utilizados para el monitoreo de la calidad de la soldadura para el proceso MAG-S. Se realizaron múltiples experimentos de soldadura en posición plana donde se indujeron perturbaciones consistentes presencia de grasa y ausencia de gas de protección. En cada experimento se adquirió simultáneamente señales de tensión y corriente así como señales de emisiones del arco eléctrico. A partir de las emisiones acústicas y electromagnéticas en la banda de ultravioleta, se midió la frecuencia de cortocircuitos. A partir de la emisión electromagnética en la banda infrarroja se midió la estabilidad del proceso de soldadura. Los resultados muestran que las emisiones del arco pueden ser utilizadas para el monitoreo y detección de perturbaciones en soldadura y con el entendimiento de las variaciones de cada emisión podría identificarse determinados tipos de perturbaciones.Ensuring quality in welding is not a trivial task. For this purpose several quality control checks are performed, at the expense, costs and production times are increased. There are several automated welding systems and they are assisted by control systems based on monitoring of welding parameters. However, automated quality monitoring systems are limited and they are mostly designed for the

  1. WELDING PROCESS (United States)

    Zambrow, J.; Hausner, H.


    A method of joining metal parts for the preparation of relatively long, thin fuel element cores of uranium or alloys thereof for nuclear reactors is described. The process includes the steps of cleaning the surfaces to be jointed, placing the sunfaces together, and providing between and in contact with them, a layer of a compound in finely divided form that is decomposable to metal by heat. The fuel element members are then heated at the contact zone and maintained under pressure during the heating to decompose the compound to metal and sinter the members and reduced metal together producing a weld. The preferred class of decomposable compounds are the metal hydrides such as uranium hydride, which release hydrogen thus providing a reducing atmosphere in the vicinity of the welding operation.

  2. Al/Cu Dissimilar Friction Stir Welding with Ni, Ti, and Zn Foil as the Interlayer for Flow Control, Enhancing Mechanical and Metallurgical Properties (United States)

    Sahu, Prakash Kumar; Pal, Sukhomay; Pal, Surjya K.


    This research investigates the effects of Ni, Ti, and Zn foil as interlayer, inserted between the faying edges of Al and Cu plates, for controlled intermetallic compound (IMC) formation. The weld tensile strength with Ti and Zn as interlayer is superior to Al base metal strength. This is due to controlled flow of IMCs by diffused Ti interlayer and thin, continuous, and uniform IMC formation in the case of Zn interlayer. Improved flexural stress was observed with interlayer. Weld microhardness varied with different interlayers and purely depends on IMCs present at the indentation point, flow of IMCs, and interlayer hardness. Specimens with interlayer failed at the interface of the nugget and thermomechanical-affected zone (TMAZ) with complete and broken three-dimensional (3-D) grains, indicating transgranular fracture. Phase analysis revealed that Al/Cu IMCs are impeded by Ni and Ti interlayer. The minor binary and ternary IMC phases form adjacent to the interlayer due to diffusion of the material with Al/Cu. Line scan and elemental mapping indicate thin, continuous, and uniform IMCs with enhanced weld metallurgical and mechanical properties for the joints with Zn interlayer. Macrostructural analysis revealed IMC flow variations with and without interlayer. Variation in grain size at different zones is also observed for different interlayers.

  3. Outsourcing University Degrees: Implications for Quality Control (United States)

    Edwards, Julie; Crosling, Glenda; Edwards, Ron


    Education institutions worldwide have and continue to seek opportunities to spread their offerings abroad. While the provision of courses to students located overseas through partner institutions has many advantages, it raises questions about quality control that are not as applicable to other forms of international education. This paper uses a…

  4. Analysis of the Mechanism of Longitudinal Bending Deformation Due to Welding in a Steel Plate by Using a Numerical Model

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Yong Rae; Yan, Jieshen; Kim, Jae-Woong [Yeungnam Univ., Gyeongsan (Korea, Republic of); Song, Gyu Yeong [Gyeongbuk Hybrid Technology Institute, Yeongcheon (Korea, Republic of)


    Welding deformation is a permanent deformation that is caused in structures by welding heat. Welding distortion is the primary cause of reduced productivity, due to welded structural strength degradation, low dimensional accuracy, and appearance. As a result, research and numerous experiments are being carried out to control welding deformation. The aim of this study is to analyze the mechanism of longitudinal bending deformation due to welding. Welding experiments and numerical analyses were performed for this study. The welding experiments were performed on 4 mm and 8.5 mm thickness steel plates, and the numerical analysis was conducted on the welding deformation using the FE software MSC.marc.

  5. Thermo-Mechanical Analysis of a Single-Pass Weld Overlay and Girth Welding in Lined Pipe (United States)

    Obeid, Obeid; Alfano, Giulio; Bahai, Hamid


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

  6. A Study to Increase Weld Penetration in P91 Steel During TIG Welding by using Activating Fluxes (United States)

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


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

  7. Quality and Control of Water Vapor Winds (United States)

    Jedlovec, Gary J.; Atkinson, Robert J.


    Water vapor imagery from the geostationary satellites such as GOES, Meteosat, and GMS provides synoptic views of dynamical events on a continual basis. Because the imagery represents a non-linear combination of mid- and upper-tropospheric thermodynamic parameters (three-dimensional variations in temperature and humidity), video loops of these image products provide enlightening views of regional flow fields, the movement of tropical and extratropical storm systems, the transfer of moisture between hemispheres and from the tropics to the mid- latitudes, and the dominance of high pressure systems over particular regions of the Earth. Despite the obvious larger scale features, the water vapor imagery contains significant image variability down to the single 8 km GOES pixel. These features can be quantitatively identified and tracked from one time to the next using various image processing techniques. Merrill et al. (1991), Hayden and Schmidt (1992), and Laurent (1993) have documented the operational procedures and capabilities of NOAA and ESOC to produce cloud and water vapor winds. These techniques employ standard correlation and template matching approaches to wind tracking and use qualitative and quantitative procedures to eliminate bad wind vectors from the wind data set. Techniques have also been developed to improve the quality of the operational winds though robust editing procedures (Hayden and Veldon 1991). These quality and control approaches have limitations, are often subjective, and constrain wind variability to be consistent with model derived wind fields. This paper describes research focused on the refinement of objective quality and control parameters for water vapor wind vector data sets. New quality and control measures are developed and employed to provide a more robust wind data set for climate analysis, data assimilation studies, as well as operational weather forecasting. The parameters are applicable to cloud-tracked winds as well with minor

  8. 21 CFR 211.22 - Responsibilities of quality control unit. (United States)


    ... 21 Food and Drugs 4 2010-04-01 2010-04-01 false Responsibilities of quality control unit. 211.22... Personnel § 211.22 Responsibilities of quality control unit. (a) There shall be a quality control unit that... have been fully investigated. The quality control unit shall be responsible for approving or rejecting...

  9. 42 CFR 84.41 - Quality control plans; contents. (United States)


    ... 42 Public Health 1 2010-10-01 2010-10-01 false Quality control plans; contents. 84.41 Section 84... AND HEALTH RESEARCH AND RELATED ACTIVITIES APPROVAL OF RESPIRATORY PROTECTIVE DEVICES Quality Control § 84.41 Quality control plans; contents. (a) Each quality control plan shall contain provisions for the...

  10. Vibration welding system with thin film sensor (United States)

    Cai, Wayne W; Abell, Jeffrey A; Li, Xiaochun; Choi, Hongseok; Zhao, Jingzhou


    A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

  11. Introduction to Welding. (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.…

  12. Determination and evaluation of air quality control. Manual of ambient air quality control in Germany

    Energy Technology Data Exchange (ETDEWEB)

    Lahmann, E.


    Measurement of air pollution emissions and ambient air quality are essential instruments for air quality control. By undertaking such measurements, pollutants are registered both at their place of origin and at the place where they may have an effect on people or the environment. Both types of measurement complement each other and are essential for the implementation of air quality legislation, particularly, in compliance with emission and ambient air quality limit values. Presented here are similar accounts of measurement principles and also contains as an Appendix a list of suitability-tested measuring devices which is based on information provided by the manufacturers. In addition, the guide of ambient air quality control contains further information on discontinuous measurement methods, on measurement planning and on the assessment of ambient air quality data. (orig./SR)

  13. Control of Bank Consolidated Financial Statements Quality

    Directory of Open Access Journals (Sweden)

    Margarita S. Ambarchyan


    Full Text Available The author presents the multiple linear regression model of bank consolidated financial statements quality. The article considers six characteristics that can be used to estimate the level of bank consolidated financial statements quality. The multiple linear regression model was developed, using the results of point-based system of consolidated financial statements of thirty European bank and financial groups on the basis of the developed characteristics. The author offers to use the characteristic significance factor in the process of consolidated financial statements appraisal by points. The constructed regression model is checked on accuracy and statistical significance. The model can be used by internal auditors and financial analytics as an instrument for bank and non-bank consolidated financial statements quality control

  14. Characterisation of Dynamic Mechanical Properties of Resistance Welding Machines

    DEFF Research Database (Denmark)

    Wu, Pei; Zhang, Wenqi; Bay, Niels


    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....

  15. Friction Pull Plug Welding in Aluminum Alloys (United States)

    Brooke, Shane A.; Bradford, Vann


    NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

  16. Voltage balancing in modular energy storage of power supply for micro resistance welding

    Directory of Open Access Journals (Sweden)

    Kozhushko Yu. V.


    Full Text Available Micro resistance welding is one of the most effective ways to obtain permanent joints of metal parts. The quality of welded joints strongly depends on the characteristics of the power supply of welding equipment. The power supplies for micro resistance welding based on Energy Storage topology have a softer impact on the network than the ones based on Direct Energy topology. The use of supercapacitors for Energy Storage type power supplies makes it possible to reduce the dimensions of welding equipment and to improve its technical parameters. However, the feature of the supercapacitors is low value of the nominal voltage, which usually does not exceed 3 V. To provide higher voltage, the modules of supercapacitors connected in series are designed. In order to extend the life time of such modules, a voltage balancing system is required. A circuit for balancing the voltage of a modular supercapacitor energy storage of a power supply for micro resistance welding is proposed. The fragments of calculation of control units of a supercapacitor module cell are given. The simulation of the balancing circuit operation is carried out and time charts of the supercapacitor charge process are obtained. The operability and effectiveness of the proposed solution is confirmed. The advantage of the proposed circuit is the possibility of obtaining the high efficiency because of returning the excessive energy of the module cell back into the power supply.

  17. Impurity effects on gas tungsten arc welds in V?Cr?Ti alloys (United States)

    Grossbeck, M. L.; King, J. F.; Hoelzer, D. T.


    Plates 6.4 mm thick of V-Cr-Ti alloys, mostly V-4Cr-4Ti, were welded in a glove box argon atmosphere. A hot titanium getter led to excessive hydrogen concentrations. A cold zirconium-aluminum getter was used to reduce both oxygen and hydrogen. It was observed that a major source of hydrogen was dissociation of water vapor by the electric arc of the welding torch. Careful monitoring of atmospheric impurities and successive pumping and backfilling cycles permitted welds of higher quality than previously achieved. Welds were evaluated primarily by the Charpy impact test. A ductile-to-brittle transition temperature (DBTT) of -28°C was achieved in V-4Cr-4Ti. Previous GTA welds in the same material seldom had a DBTT below room temperature. Electron beam welding can achieve a DBTT of below -90°C in the V-4Cr-4Ti alloy, indicating a lower limit to the DBTT by impurity control.

  18. Advanced Welding Applications (United States)

    Ding, Robert J.


    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.



    S. DOBRINAS; A. SOCEANU; Popescu, V.; G. STANCIU; Suliman, S


    In this paper, we present the characterization of six traditional meat products: smoked file, smoked bacon, pork sausages, sausage prepared from swine’s entrails, pork pastrami, sheep sausages. Organoleptic tests (the aspect and shape, the aspect of freshly cut in the section, smell, taste and consistency), physico-chemical and microbiological determinations (NTG, Salmonella, Listeria monocytogenes and Escherichia coli) were performed. These analyzes are a part of quality control that must be...

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

    DEFF Research Database (Denmark)

    Bagger, Claus; Olsen, Flemming Ove


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

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

    DEFF Research Database (Denmark)

    Andersen, Henrik John


    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...

  2. Quality control methods at a hospital. (United States)

    Canel, Cem; Mahar, Steve; Rosen, Drew; Taylor, John


    Healthcare providers need the information contained in patient records to provide high-quality services. To be effective, patient record assembly must be completed in a timely manner. This study aims to analyse the medical records assembly process for a hospital in Southeastern United States having difficulty meeting standard completion times established by the Joint Commission on the Accreditation of Healthcare Organization. Several quality improvement tools were used to evaluate and improve the assembly process. As a result of the study, a new procedure was implemented. Consequently, the hospital reduced the time required to assemble medical records, thereby improving efficiency and effectiveness. There are hopes to further improve the process. The study provides guidance on how statistical process control techniques can be applied to improve hospital services. The techniques employed can be used to analyze and improve any process. However, results are limited to improving medical record assembly processes at one particular hospital. Past studies considered the application of various statistical process control techniques for improving healthcare quality. The study extends research by employing process improvement efforts to understand and develop medical record assembly in a regional hospital via process flow diagramming and control charts.

  3. Online resistance spot weld NDE using infrared thermography (United States)

    Chen, Jian; Feng, Zhili


    A new online resistance spot weld non-destructive evaluation (NDE) technique based on infrared (IR) thermography has been developed. It is capable of both real-time online (during welding) and post-weld online/offline (after welding) inspections. The system mainly consists of an IR camera and a computer program with proprietary thermal imaging analysis algorithms integrated into existing production lines. For real-time inspection, the heat flow generated from the welding process (with temperature exceeding 1000°C) is monitored by the IR camera. For post-weld inspection, a novel auxiliary heating device is applied to locally heat the weld region, resulting in temperature changes on the order of 10°C, and the transmitted heat flow is monitored. Unlike the conventional IR NDE method that requires surface coating to reduce the influence of unknown emissivity, the new method can be applied on as-is bare metal surface thanks to the unique "thermal signatures" extracted from infrared thermal images, which positively correlates to weld quality with a high degree of confidence. The new method can be used to reliably detect weld size, surface indents and defects such as cold weld with sufficient accuracy for welds made from various combinations of materials, thickness, stack-up configuration, surface coating conditions and welding conditions.

  4. Development of electromagnetic welding facility of flat plates for nuclear industry (United States)

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


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

  5. On the possibilities of electric power quality control via electric loads with active rectifiers

    Directory of Open Access Journals (Sweden)

    Володимир Володимирович Бурлака


    Full Text Available The paper proposes a method for controlling the electric power quality parameters in a distribution network by modifying the control algorithms for electric loads equipped with active rectifiers fed from this network. Thus, by controlling the reactive component of the input current of such rectifiers, it is possible to reduce the voltage fluctuations at the point of common connection (PCC, the efficiency of such a method being higher the higher the X/R ratio of the network is. It is also possible to reduce the voltage harmonics in the PCC by integrating the functions of parallel active filters into active rectifiers. The proposed method allows for limited control over the flow of inactive power in the distribution network, which makes it possible to improve the electric power quality and reduce the required power of the filter compensating devices. The proposed algorithm for controlling the active rectifier is tested on the mathematical model of group loads. A group of high power resistance welding machines (RWMs operating randomly with a normal probability distribution connected to 0,4 kV grid as a non-stationary load is used. The application of the proposed reactive current control method in the RWM power supplies made it possible to reduce the voltage fluctuations in 0,4 kV grid from 12% to 5%.

  6. Onorbit electron beam welding experiment definition (United States)


    The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

  7. Applying GPS to check horizontal control quality

    Directory of Open Access Journals (Sweden)

    Jakub Vincent


    Full Text Available GPS technologies can also be used for check quality in available horizontal point set with coordinates CJ of the frame S-JTSK. When survey and setting-out tasks should be performed in certain area, one can found in it allways some points of the fundamental and detail state controls. To use these points for some actual aims, it is necessary to investigate their compatibility (among the point mark positions and the point coordinate of control points. This can be done using GPS surveying that may be at the same time employed to determine the new point in the relevant area.Principle of quality investigatingf an existing control is founded on determination of point coordinates CJt from GPS measurements. Then, based on discrepancies among the "official" netpoint coordinates CJ and coordinates CJt "given by GPS", it can be estimated the degree and the real compatibility dislocations in the network structure of the existing points.Realisation procedure for the introduced investigation is demonstrated on GPS checking (by SOKKIA STRATUS receivers horizontal control for reconstruction of a railway bridge on river Bodrog in East Slovakia.It can be shown from the results in Table 3, that points P3 and P7 are useless due to their incompatibility (inconsistency in the inspected point set. For other 7 points (Table 7 the average measure of incompatibility reads 9.8 mm that make possible applying these points for precise setting-out

  8. Safety analysis of welding process in Tehran oil refinery and the effectiveness of the control methods

    Directory of Open Access Journals (Sweden)


    The results revealed that in the existing condition, 27.3% of the studied risks have a RPN of 5 (with an extremely high hazard potential, 3% a RPN of 4 (with a high hazard potential and 69.7% with a RPN of 3 (with a medium hazard potential. The results also revealed that with the application of control measures suggested by the expertise team, 21.2% of the studied risks will hold a RPN of 4 (with a high hazard potential, 6.1% will have a RPN of 3 (with a medium hazard potential, 48.5% with a RPN of 2 (with low hazard potential and 18.2% will have a RPN of 1 (with a negligible hazard potential. Statistical tests revealed that the application of control measures, will reduce the average amount of likelihood, severity and risk priority numbers significantly (Pvalue<0.01.

  9. Protein quality control at the mitochondrion. (United States)

    Voos, Wolfgang; Jaworek, Witold; Wilkening, Anne; Bruderek, Michael


    Mitochondria are essential constituents of a eukaryotic cell by supplying ATP and contributing to many mayor metabolic processes. As endosymbiotic organelles, they represent a cellular subcompartment exhibiting many autonomous functions, most importantly containing a complete endogenous machinery responsible for protein expression, folding and degradation. This article summarizes the biochemical processes and the enzymatic components that are responsible for maintaining mitochondrial protein homoeostasis. As mitochondria lack a large part of the required genetic information, most proteins are synthesized in the cytosol and imported into the organelle. After reaching their destination, polypeptides must fold and assemble into active proteins. Under pathological conditions, mitochondrial proteins become misfolded or damaged and need to be repaired with the help of molecular chaperones or eventually removed by specific proteases. Failure of these protein quality control mechanisms results in loss of mitochondrial function and structural integrity. Recently, novel mechanisms have been identified that support mitochondrial quality on the organellar level. A mitochondrial unfolded protein response allows the adaptation of chaperone and protease activities. Terminally damaged mitochondria may be removed by a variation of autophagy, termed mitophagy. An understanding of the role of protein quality control in mitochondria is highly relevant for many human pathologies, in particular neurodegenerative diseases. © 2016 The Author(s). Published by Portland Press Limited on behalf of the Biochemical Society.

  10. Simulation and sensitivity analysis of controlling parameters in resistance spot welding


    Kim, Euiwhan; Eagar, Thomas W


    This study was performed to investigate the fundamental parameters controlling the nugget growth. The parameters were categorized into four groups, i.e. material parameters, electrical parameters, thermal parameters and geometrical parameters. In order to quantify the sensitivity of nugget growth to changes in these parameters, a numerical model which incorporates the electrical, mechanical and thermal contact was developed. As a result, a sensitivity index table was constructed and analyzed ...

  11. Quality Management of CERN Vacuum Controls

    CERN Document Server

    Antoniotti, F; Fortescue-Beck, E; Gama, J; Gomes, P; Le Roux, P; Pereira, H; Pigny, G


    The vacuum controls Section (TE-VSC-ICM) is in charge of the monitoring, maintenance and consolidation of the control systems of all accelerators and detectors in CERN; this represents 6 000 instruments distributed along 128 km of vacuum chambers, often of heterogeneous architectures and of diverse technical generations. In order to improve the efficiency of the services provided by ICM, to vacuum experts and to accelerator operators, a Quality Management Plan is being put into place. The first step was the standardization of the naming convention across different accelerators. The traceability of problems, requests, repairs, and other actions, has also been put into place (VTL). This was combined with the effort to identify each individual device by a coded label, and register it in a central database (MTF). Occurring in parallel, was the gathering of old documents and the centralization of information concerning architectures, procedures, equipment and settings (EDMS). To describe the topology of control c...

  12. Lifetime occupational exposure to metals and welding fumes, and risk of glioma: a 7-country population-based case-control study. (United States)

    Parent, Marie-Elise; Turner, Michelle C; Lavoué, Jérôme; Richard, Hugues; Figuerola, Jordi; Kincl, Laurel; Richardson, Lesley; Benke, Geza; Blettner, Maria; Fleming, Sarah; Hours, Martine; Krewski, Daniel; McLean, David; Sadetzki, Siegal; Schlaefer, Klaus; Schlehofer, Brigitte; Schüz, Joachim; Siemiatycki, Jack; van Tongeren, Martie; Cardis, Elisabeth


    Brain tumor etiology is poorly understood. Based on their ability to pass through the blood-brain barrier, it has been hypothesized that exposure to metals may increase the risk of brain cancer. Results from the few epidemiological studies on this issue are limited and inconsistent. We investigated the relationship between glioma risk and occupational exposure to five metals - lead, cadmium, nickel, chromium and iron- as well as to welding fumes, using data from the seven-country INTEROCC study. A total of 1800 incident glioma cases and 5160 controls aged 30-69 years were included in the analysis. Lifetime occupational exposure to the agents was assessed using the INTEROCC JEM, a modified version of the Finnish job exposure matrix FINJEM. In general, cases had a slightly higher prevalence of exposure to the various metals and welding fumes than did controls, with the prevalence among ever exposed ranging between 1.7 and 2.2% for cadmium to 10.2 and 13.6% for iron among controls and cases, respectively. However, in multivariable logistic regression analyses, there was no association between ever exposure to any of the agents and risk of glioma with odds ratios (95% confidence intervals) ranging from 0.8 (0.7-1.0) for lead to 1.1 (0.7-1.6) for cadmium. Results were consistent across models considering cumulative exposure or duration, as well as in all sensitivity analyses conducted. Findings from this large-scale international study provide no evidence for an association between occupational exposure to any of the metals under scrutiny or welding fumes, and risk of glioma.

  13. Robotic Variable Polarity Plasma Arc (VPPA) Welding (United States)

    Jaffery, Waris S.


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

  14. Influence of electrical Field on Pulsed Laser beam welding of Stainless Steel (304) (United States)

    Fawzý, Salah A. H.; Arýf, Raz N.


    Pulsed laser beam welding experiment were carried out on stainless steel (SUS 304), using vertical and horizontal electric fields of different intensities to study its effectiveness on the welding process, regarding depth and weld quality. Pulsed Nd: YAG laser emitting 10 ms pulses in the TEM00 mode at 1.06 m m wave length was employed, microstructure of welded zone and defect were investigated using optical and scanning electron microscopes. Tensile test and microhardness measurements were carried out to evaluate the weld quality. Welding by this method increased the efficiency tremendously and a depth increase of 85% was achieved.

  15. Influence of surface pretreatment in resistance spot welding of aluminum AA1050

    DEFF Research Database (Denmark)

    Al Naimi, Ihsan K.; Al Saadi, Moneer H.; Daws, Kasim M.


    quality. An experimental study of the influence of pretreatment on weld quality in RSW of AA1050 sheets with three thicknesses, comparing welding of as-received sheet with pretreated sheet by either pickling in NaOH or glass-blasting were investigated. Different weld settings were applied with low...

  16. The Stand for Determination of Service Performance in Load of a Welding Transformer Using the LabVIEW Environment

    Directory of Open Access Journals (Sweden)

    Lenuţa Suciu


    Full Text Available This paper presents the way of performance’s characteristics determi-nation in load of welding transformers` performance parameters using the data acquisition systems through virtual tools. Nowadays observing the parameters of welding service and of welding instruments` charac-teristics means an important step regarding the quality of weld throat.

  17. MM99.81 Projection welding of complex geometries

    DEFF Research Database (Denmark)

    Kristensen, Lars

    The objective of this work has been to establish a profound knowledge about design rules for projection welding geometries dependent of the actual material combination.Design rules and recommendations for geometries and projections in projection welding given in literature is summarised...... and these are catalogued into geometry-classes. A simulation software, SORPAS, based on the finite element method (FEM) is chosen as tool to investigate projection weld quality. SORPAS needs input of the material flow stress as function of strain, strain rate and temperature. Flow stress experiments are performed using...... been investigated.Two different welding geometries, disc with triangular ring projection welded to ring and hat welded to inside hole in ring, are both experimentally and numerically used to investigate the influence of different geometric parameters (thicknesses and angles) on weldability and weld...

  18. Simulation of Temperature Field in HDPE Pipe Thermal Welding

    Directory of Open Access Journals (Sweden)

    LIU Li-jun


    Full Text Available For high density polyethylene pipe connection,welding technology is the key of the high density engineering plastic pressure pipe safety. And the temperature distribution in the welding process has a very important influence on the welding quality. Polyethylene pipe weld joints of one dimensional unsteady overall heat transfer model is established by MARC software and simulates temperature field and stress field distribution of the welding process,and the thermocouple temperature automatic acquisition system of welding temperature field changes were detected,and compared by simulation and experiment .The results show that,at the end of the heating,the temperature of the pipe does not reach the maximum,but reached the maximum at 300 s,which indicates that the latent heat of phase change in the process of pressure welding. In the process of pressure welding, the axial stress of the pipe is gradually changed from tensile stress to compressive stress.

  19. Numerical simulation of explosive welding using Smoothed Particle Hydrodynamics method

    Directory of Open Access Journals (Sweden)

    J Feng


    Full Text Available In order to investigate the mechanism of explosive welding and the influences of explosive welding parameters on the welding quality, this paper presents numerical simulation of the explosive welding of Al-Mg plates using Smoothed Particle Hydrodynamics method. The multi-physical phenomena of explosive welding, including acceleration of the flyer plate driven by explosive detonation, oblique collision of the flyer and base plates, jetting phenomenon and the formation of wavy interface can be reproduced in the simulation. The characteristics of explosive welding are analyzed based on the simulation results. The mechanism of wavy interface formation is mainly due to oscillation of the collision point on the bonding surfaces. In addition, the impact velocity and collision angle increase with the increase of the welding parameters, such as explosive thickness and standoff distance, resulting in enlargement of the interfacial waves.

  20. Optical sensor for real-time weld defect detection (United States)

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


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

  1. Effect of Heat Input During Disk Laser Bead-On-Plate Welding of Thermomechanically Rolled Steel on Penetration Characteristics and Porosity Formation in the Weld Metal

    Directory of Open Access Journals (Sweden)

    Lisiecki A.


    Full Text Available The paper presents a detailed analysis of the influence of heat input during laser bead-on-plate welding of 5.0 mm thick plates of S700MC steel by modern Disk laser on the mechanism of steel penetration, shape and depth of penetration, and also on tendency to weld porosity formation. Based on the investigations performed in a wide range of laser welding parameters the relationship between laser power and welding speed, thus heat input, required for full penetration was determined. Additionally the relationship between the laser welding parameters and weld quality was determined.

  2. Particulate and gaseous emissions when welding aluminum alloys. (United States)

    Cole, Homer; Epstein, Seymour; Peace, Jon


    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.

  3. Optimal design for laser beam butt welding process parameter using artificial neural networks and genetic algorithm for super austenitic stainless steel (United States)

    Sathiya, P.; Panneerselvam, K.; Soundararajan, R.


    Laser welding input parameters play a very significant role in determining the quality of a weld joint. The joint quality can be defined in terms of properties such as weld bead geometry, mechanical properties and distortion. Therefore, mechanical properties should be controlled to obtain good welded joints. In this study, the weld bead geometry such as depth of penetration (DP), bead width (BW) and tensile strength (TS) of the laser welded butt joints made of AISI 904L super austenitic stainless steel were investigated. Full factorial design was used to carry out the experimental design. Artificial Neural networks (ANN) program was developed in MatLab software to establish the relationships between the laser welding input parameters like beam power, travel speed and focal position and the three responses DP, BW and TS in three different shielding gases (Argon, Helium and Nitrogen). The established models were used for optimizing the process parameters using Genetic Algorithm (GA). Optimum solutions for the three different gases and their respective responses were obtained. Confirmation experiment has also been conducted to validate the optimized parameters obtained from GA.

  4. Generation of a dynamic polarized laser beam for applications in laser welding (United States)

    Gräf, Stephan; Staupendahl, Gisbert; Seiser, Carlo; Meyer, Bernd-Jürgen; Müller, Frank A.


    The temporal control and optimization of laser beam parameters, e.g., the beam power, can be employed to enhance the quality and reliability of the welding process. Until now, the influence of a time-dependent beam polarization has been less investigated in welding. The publication describes a new experimental arrangement allowing the fast variation of the polarization of CO2 laser radiation ["dynamic polarization" (DP)]. The key element of the setup is a high power interference laser beam modulator for cw laser power rating of up to 4 kW. Weld seams were produced with different process parameters in the technically relevant steels St37 and Ck45 and in the precoated steel 22MnB5 (USIBOR 1500P). The welds were subsequently characterized by roughness measurements of the top bead surfaces and by the preparation of cross sections and their macroscopic analysis. The experiments on welding with DP showed a significant influence on the keyhole and melt pool dynamics, especially a reduction in the top bead roughness at certain DP frequencies up to a factor of about 3. In addition, a threshold behavior for this effect was observed. It was shown that the cross sectional shape and thus the degree of energy coupling to the material was unaffected by the DP. Finally, during welding USIBOR 1500P with DP an enhanced melt pool stirring was achieved. The results show that the temporal modulation of energy coupling to the material caused by DP is suitable to enhance the quality and reliability of the welding process.

  5. Simulation and sensitivity analysis of controlling parameters in resistance spot welding (United States)

    Kim, Euiwhan; Eagar, Thomas W.


    This study was performed to investigate the fundamental parameters controlling the nugget growth. The parameters were categorized into four groups, i.e. material parameters, electrical parameters, thermal parameters and geometrical parameters. In order to quantify the sensitivity of nugget growth to changes in these parameters, a numerical model which incorporates the electrical, mechanical and thermal contact was developed. As a result, a sensitivity index table was constructed and analyzed to ascertain the relative importance of these characteristic parameters. It was found that the most important factor in determining the variability of nugget growth behavior is the ratio of contact radius to electrode radius and the ratio of electrode radius to the square of specimen thickness. In general for a variation of 10%, the geometrical parameters are most important, followed by the material parameters. The electrical parameters and the thermal parameters are the least important. The importance of contact at the faying interface is greater for the contact area than for the contact resistance.

  6. Heat sink effects in VPPA welding (United States)

    Steranka, Paul O., Jr.


    The development of a model for prediction of heat sink effects associated with the Variable Polarity Plasma Arc (VPPA) Welding Process is discussed. The long term goal of this modeling is to provide means for assessing potential heat sink effects and, eventually, to provide indications as to changes in the welding process that could be used to compensate for these effects and maintain the desired weld quality. In addition to the development of a theoretical model, a brief experimental investigation was conducted to demonstrate heat sink effects and to provide an indication of the accuracy of the model.

  7. [The reconstruction of welding arc 3D electron density distribution based on Stark broadening]. (United States)

    Zhang, Wang; Hua, Xue-Ming; Pan, Cheng-Gang; Li, Fang; Wang, Min


    The three-dimensional electron density is very important for welding arc quality control. In the present paper, Side-on characteristic line profile was collected by a spectrometer, and the lateral experimental data were approximated by a polynomial fitting. By applying an Abel inversion technique, the authors obtained the radial intensity distribution at each wavelength and thus constructed a profile for the radial positions. The Fourier transform was used to separate the Lorentz linear from the spectrum reconstructed, thus got the accurate Stark width. And we calculated the electronic density three-dimensional distribution of the TIG welding are plasma.

  8. Software Quality Control at Belle II (United States)

    Ritter, M.; Kuhr, T.; Hauth, T.; Gebard, T.; Kristof, M.; Pulvermacher, C.; Belle Software Group, II


    Over the last seven years the software stack of the next generation B factory experiment Belle II has grown to over one million lines of C++ and Python code, counting only the part included in offline software releases. There are several thousand commits to the central repository by about 100 individual developers per year. To keep a coherent software stack of high quality that it can be sustained and used efficiently for data acquisition, simulation, reconstruction, and analysis over the lifetime of the Belle II experiment is a challenge. A set of tools is employed to monitor the quality of the software and provide fast feedback to the developers. They are integrated in a machinery that is controlled by a buildbot master and automates the quality checks. The tools include different compilers, cppcheck, the clang static analyzer, valgrind memcheck, doxygen, a geometry overlap checker, a check for missing or extra library links, unit tests, steering file level tests, a sophisticated high-level validation suite, and an issue tracker. The technological development infrastructure is complemented by organizational means to coordinate the development.

  9. Microstructure Evolution during Friction Stir Spot Welding of TRIP Steel

    DEFF Research Database (Denmark)

    Lomholt, Trine Colding; Pantleon, Karen; Somers, Marcel A. J.


    In this study, the feasibility of friction stir spot welding of TRIP steel is investigated. In addition to manufacturing successful welds, the present study aims at a fundamental understanding of the mechanisms occurring at the (sub)micron scale during friction stir spot welding. As one of the main...... parameters to control friction stir welding, the influence of the rotational speed of the tool was investigated. Three different rotational speeds (500 rpm, 1000 rpm and 1500 rpm, respectively) were applied. The microstructure of the welded samples was investigated with reflected light microscopy, scanning...

  10. Passive Visual Sensing in Automatic Arc Welding

    DEFF Research Database (Denmark)

    Liu, Jinchao

    For decades much work has been devoted to the research and development of automatic arc welding systems. However, it has remained a challenging problem. Besides the very complex arc welding process itself, the lack of ability to precisely sense the welding process, including the seam geometry...... and the weld pool, has also prevented the realization of a closed-loop control system for many years, even though a variety of sensors have been developed. Among all the sensor systems, visual sensors have the advantage of receiving visual information and have been drawn more and more attentions. Typical...... industrial solutions for seam detection such as using laser scanners suer from several limitations. For instance, it must be positioned some distance ahead to the molten pool and may cause problem when dealing with shiny surfaces. Existing techniques for weld pool sensing mostly rely on auxiliary light...


    Energy Technology Data Exchange (ETDEWEB)

    Daugherty, W.; Howard, S.; Peterson, K.; Stokes, M.


    Excess plutonium materials in the DOE complex are packaged and stored in accordance with DOE-STD-3013. This standard specifies requirements for the stabilization of such materials and subsequent packaging in dual nested seal-welded containers. Austenitic stainless steels have been selected for container fabrication. The inner 3013 container provides contamination control while the outer 3013 container is the primary containment vessel and is the focus of this paper. Each packaging site chose a process for seal welding the outer 3013 containers in accordance with its needs and expertise. The two processes chosen for weld closure were laser beam welding (LBW) and gas tungsten arc welding (GTAW). Following development efforts, each system was qualified in accordance with DOE-STD-3013 prior to production use. The 3013 outer container closure weld joint was designed to accommodate the characteristics of a laser weld. This aspect of the joint design necessitated some innovative process and equipment considerations in the application of the GTAW process. Details of the weld requirements and the development processes are presented and several potential enhancements for the GTAW system are described.

  12. Reprocessing weld and method

    Energy Technology Data Exchange (ETDEWEB)

    Killian, M.L.; Lewis, H.E.


    A process is described for improving the fatigue resistance of a small primary structural weld at a joint between structural members of a weldment, the weld having been made with the welding energy input of E[sub 1], the process comprising: applying a reprocessing weld on at least a portion of either one or both toes of the primary structural weld, thereby covering said toe portion, the reprocessing weld containing a filler metal and having a cross-sectional area which is less than the corresponding cross-sectional area of the primary structural weld, the reprocessing weld extending onto the face of the primary structural weld at one side of the toe portion covered and onto the structural member at the other side of the toe portion covered, and the total welding energy input, E[sub 2], used in said reprocessing the primary structural weld being less than the welding energy input E[sub 1] of the primary structural weld.

  13. Development of fly ash quality control system

    Energy Technology Data Exchange (ETDEWEB)

    Ban, K. [Chubu Electric Power Company Inc., Nagoya (Japan). Thermal Power Dept.


    Since fly ash is designated as one of the by-products in the Japanese law related to the promotion of effective use of reclaimed materials (the recycling law) that prescribes the promotion of effective use of reclaimed materials, it is necessary to promote its effective use positively. However, there can be problems in using fly ash as it is difficult to assure a product with uniform properties, because the properties of fly ash can vary depending on the type of coal and the burning conditions of the boilers. For this reason, studies were made from 1994 to 1995 through experiments on the ash handling system of the No. 3 coal-fired boiler at the Hekinan Thermal Power Plant. The study was made in response to the needs of the users who wanted to effectively use the ash, and included the development of a quality control system for the selection and storage of ash which measured and analyzed the properties of the ash in real time. This paper outlines this quality control system and describes the results of the studies to date. 10 figs., 4 tabs.

  14. Quality control of iodine-131-labeled metaiodobenzylguanidine. (United States)

    Taşdelen, Betül; Kam, Erol; Asliyuksek, Hızır


    Iodine-131-m-iodobenzylguanidine ([(131)I]mIBG) is used worldwide for the diagnosis and therapy of neuroendocrine tumors, particularly adrenal medullae tumors. After the synthesis and preparation of a radioiodinated MIBG drug formulation, quality control testing to determine its radiochemical purity (RCP) should be performed. European Pharmacopoeia 8.0 requires that the quality control include a test for RCP for the determination of [(131)I]mIBG. Previously reported procedures using reversed-phase conditions require long retention times. Our system enables the separation of [(131)I]mIBG within a few minutes. The aim of this work was to carry out RCP testing for [(131)I]mIBG without any type of sample pretreatment. RCP testing for ([(131)I]mIBG has been carried out using high-performance liquid chromatography and thin-layer chromatography methods. A simple and rapid reversed-phase isocratic system enables the HPLC investigation of RCP testing for [(131)I]mIBG used for therapy within a few minutes. From the point of view of radiation protection, this method is safer, especially for therapeutic amounts of [(131)I]mIBG.

  15. Weld Spot Detection by Color Segmentation and Template Convolution (United States)

    Cambrini, Luigi; Biber, Jürgen; Hönigmann, Dieter; Löhndorf, Maike


    There is a need of non-destructive evaluation of the quality of steel spot welds. A computer-vision based solution is presented performing the analysis of the weld spot imprints left by the electrode on the protection bands. In this paper we propose two different methods to locate the position of the weld spot imprint as a first step in order to verify the quality of the welding process; both methods consist of two stages: (i) the use of the X channel of the XYZ color space as a proper representation, and (ii) the analysis of this image channel by employing specific algorithms.

  16. Contractor Performed Quality Control on KyTC Projects. (United States)


    This report addresses issues related to transferring the responsibility for quality control from the Kentucky Transportation Cabinet (KyTC) to construction contractors. : Several key topics related to Contractor Performed Quality Control (CPQC) are p...

  17. Controlling Angular Distortion in Manual Metal Arc Welding of Austenitic Stainless Steels Using Back-step Technique

    Directory of Open Access Journals (Sweden)

    Abdul Sameea Jasim Abdul Zehra Jilabi


    Full Text Available Nowadays, austenitic stainless steels (A.S.S. have many industrial applications in the fields of chemical and petrochemical processing, marine, medicine, water treatment, petroleum refining, food and drinks processing, nuclear power generation etc. The secret behind this wide range of applications is the fact that A.S.S. have great corrosion resistance, high strength and scale resistance at elevated temperatures, good ductility at low temperatures approached to absolute zero in addition to notable weldability. On the other hand, manual metal arc (MMA is probably the most common process used for the welding of A.S.S. Unfortunately, MMA welding of A.S.S. could be associated with considerable distortion. Uncontrolled or excessive distortion usually increases the cost of the production process due to the high expense of rectification or replacing the weldment by a non-distorted one. MMA welding of A.S.S. was carried out using the back-step technique with various bead lengths, and without using this technique for comparison. Results have showed that the angular distortion was a function of the bead length in the back-step welding of A.S.S. The angular distortion decreased by (14.32% when the back-step technique was used with a (60 mm length for each bead, and by (41.08% when the bead length was (40 mm. On the other hand, it increased by (25% when the back-step technique was done with a (30 mm length for each bead.

  18. Methodical Grounds of Managing the Product Quality Control


    Shapoval Olena A.


    The article analyses the modern state of products quality control management. It justifies a necessity of organisation of the quality control system under conditions of uninterrupted flow line production. It reveals problems connected with a low level of the products quality control management. It forms a set of factors of internal and external environments, which should be taken into account in the process of selection of a type of managerial actions by the products quality control. It consi...

  19. 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 plastic...... materials and provides an extensive knowhow on the industrial plastic welding process. The objectives of the report include: - Provide the general knowhow of laser welding for the beginners - Summarize the state-of-the-art information on the laser welding of plastics - Find the technological limits in terms...... of design, materials and process - Find the best technology, process and machines adaptive to Sonion’s components - Provide the skills to Sonion’s Design Engineers for successful design of the of the plastic components suitable for the laser welding The ultimate goal of this report is to serve...

  20. 21 CFR 640.56 - Quality control test for potency. (United States)


    ... 21 Food and Drugs 7 2010-04-01 2010-04-01 false Quality control test for potency. 640.56 Section...) BIOLOGICS ADDITIONAL STANDARDS FOR HUMAN BLOOD AND BLOOD PRODUCTS Cryoprecipitate § 640.56 Quality control test for potency. (a) Quality control tests for potency of antihemophilic factor shall be conducted...

  1. 21 CFR 864.8625 - Hematology quality control mixture. (United States)


    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Hematology quality control mixture. 864.8625 Section 864.8625 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES... quality control mixture. (a) Identification. A hematology quality control mixture is a device used to...

  2. 14 CFR 145.211 - Quality control system. (United States)


    ... 14 Aeronautics and Space 3 2010-01-01 2010-01-01 false Quality control system. 145.211 Section 145...) SCHOOLS AND OTHER CERTIFICATED AGENCIES REPAIR STATIONS Operating Rules § 145.211 Quality control system. (a) A certificated repair station must establish and maintain a quality control system acceptable to...

  3. Determination of the Reliability of Product Quality Loss and Control ...

    African Journals Online (AJOL)

    Inconsistency in quality control is a major problem which plagues many indigenous firms in Nigeria. When product quality fluctuates, it negatively impacts on brand status, customer loyalty and confidence. The study was carried out to evaluate the best quality control practices for a brewing plant. Control charts were created ...

  4. Managing Air Quality - Control Strategies to Achieve Air Pollution Reduction (United States)

    Considerations in designing an effective control strategy related to air quality, controlling pollution sources, need for regional or national controls, steps to developing a control strategy, and additional EPA resources.

  5. Mixing weld gases offers advantages (United States)

    May, J. L.; Mendenhall, M. M.


    Argon added to helium during gas tungsten arc cover-pass welding in the horizontal position results in a better controlled wider bead width, increased arc stability, and reduction in heat input. Adequate filler material wetness and penetration pass coverage is possible with only one pass.

  6. Welding of Prosthetic Alloys

    Directory of Open Access Journals (Sweden)

    Wojciechowska M.


    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.

  7. Optimization of process parameters of pulsed TIG welded maraging steel C300 (United States)

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


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

  8. Welding Course Curriculum. (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…

  9. Instructional Guidelines. Welding. (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…

  10. Optimization of Fiber Laser Welding of DP980 Steels Using RSM to Improve Weld Properties for Formability (United States)

    Bandyopadhyay, K.; Panda, S. K.; Saha, P.


    The effect of laser parameters on weld quality is a critical laboratory study before implementation of newly developed high-strength dual-phase steels in fabrication of auto-bodies. In present work, dual-phase steels having tensile strength of 980 MPa (DP980) were welded using different welding speeds by Yb-fiber laser source to fabricate similar material combinations laser-welded blanks (LWBs). The weld zone microhardness, microstructure, and formability of DP980 LWBs were compared with those of the DP600 and micro-alloyed interstitial free high-strength steel (IFHS) LWBs. It was found that the formation of soft zone at the outer side of the HAZ was responsible for significant reduction in formability of DP980 LWBs due to strain localization and premature failure. Hence, response surface methodology based on Box-Behnken design was implemented to establish a mathematical model which could correlate the influence of laser process parameters such as power, welding speed, and focal position on weld quality in terms of aspect ratio of fusion zone, width of the soft zone, and surface roughness of weld to improve formability. The model was successfully implemented to optimize the laser parameters, and approximately 13.58% improvement in Erichsen cup height was achieved due to complete weld penetration with simultaneous 67% reduction in soft zone width and 55% reduction in softening. However, the failure was still observed to occur in the soft zone propagating parallel to weld in radial direction.

  11. Quality control of gamma camera systems

    Energy Technology Data Exchange (ETDEWEB)

    Bolster, Alison (ed.)


    This report has been prepared by the Radionuclide Special Interest Group of the Institute of Physics and Engineering in Medicine. It replaces the Institute of Physical Sciences in Medicine Report 66. Since the publication of that report, there have been important advances, particularly with regard to wholebody imaging, single photon emission computed tomography, gamma camera positron emission tomography and gamma camera computer/software development. To reflect this, Chapters 1, 2 and 3 remain relatively unchanged from the previous version, while Chapters 4, 5, 6 and 7 have been added to cover the four topics mentioned above. These chapters include detailed quality control test procedures for each type of imaging. Recommendations on the frequency at which various performance parameters should be assessed are summarised in Chapter 8, and Chapter 9 deals briefly with the subject of specifying equipment. Requirement for Quality Control. There is often some confusion about the distinction between the terms 'quality assurance' and 'quality control'. Quality assurance (QA) is usually taken to refer to all aspects of a procedure which contribute to the quality of the results obtained. In nuclear medicine, this would include staff training, testing of radiopharmaceuticals, assessment of equipment performance and reporting of clinical studies. Quality control (QC) refers to the specification, assessment, optimisation and maintenance of a particular aspect, such as the performance of the imaging equipment. The specification of equipment for tendering purposes may include aspects of performance which are difficult for the purchaser to confirm. Acceptance testing may require access to specialised equipment and may be performed by the supplier's engineers. It is essential that the purchaser, or an appropriately experienced person acting on behalf of the purchaser, should be closely involved in the acceptance testing. However, for routine QC, it is

  12. External quality control for embryology laboratories. (United States)

    Castilla, Jose Antonio; Ruiz de Assín, Rafael; Gonzalvo, Maria Carmen; Clavero, Ana; Ramírez, Juan Pablo; Vergara, Francisco; Martínez, Luis


    Participation in external quality control (EQC) programmes is recommended by various scientific societies. Results from an EQC programme for embryology laboratories are presented. This 5-year programme consisted of the annual delivery of (i) materials to test toxicity and (ii) a DVD/CD-ROM with images of zygotes and embryos on days 2 and 3, on the basis of which the participants were asked to judge the embryo quality and to take a clinical decision. A high degree of agreement was considered achieved when over 75% of the laboratories produced similar classifications. With respect to the materials analysed, the specificity was 68% and the sensitivity was 83%. Concerning embryo classification, the proportion of embryos on which a high degree of agreement was achieved increased during this period from 35% to 55%. No improvement was observed in the degree of agreement on the clinical decision to be taken. Day-3 embryos produced a higher degree of agreement (58%) than did day-2 embryos (32%) (Pembryology laboratories. Copyright (c) 2009 Reproductive Healthcare Ltd. Published by Elsevier Ltd. All rights reserved.

  13. Low temperature friction stir welding of P91 steel

    Directory of Open Access Journals (Sweden)

    Prasad Rao Kalvala


    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. The variable polarity plasma arc welding process: Characteristics and performance (United States)

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


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

  15. Process characteristics of laser beam welding at reduced ambient pressure (United States)

    Börner, Christian; Krüssel, Thomas; Dilger, Klaus


    This paper describes the idea of using a similar vacuum necessary for electron beam welding also for welding with a solid-state laser. While for electron beam welding a fine vacuum is required for the process, with laser beam welding the pressure can be varied as an additional process parameter in order to influence the process result. Test results show that by a reduction of the ambient pressure the metal vapor plume is suppressed and consequently the spattering decreases. Plume and spatters disappear completely at a pressure reduction to p = 10 hPa and below. This enables quality of weldings with the solid-state laser which even with CO2 lasers are only difficult to realize. The quality of these weld seams is comparable to electron beam weldings. In addition, further beneficial properties arise in the quality of the weld seam. With the same process parameters but reduced ambient pressure, the reduction of the pressure effects an increase of the penetration depth and a distinctive modification of the seam geometry. Mild steel plates with a thickness of 10 mm have been successfully welded with a laser power of PL = 6000 W and a feed rate of vW = 2.0 m/min, with a remarkable seam quality without any irregularities. Another advantage of welding with the laser at reduced pressure is the possibility of avoiding a sagging of the seam during welding of thick sheets. Despite excessive energy and power, no geometric irregularities are identified in the cross section. Under atmospheric pressure, the high excess of power would lead to an intense seam collapse. On sheets with thicknesses of 3 mm, the notches occurring by penetration welding can also be avoided by applying reduced pressure.

  16. High-power Laser Welding of Thick Steel-aluminum Dissimilar Joints (United States)

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

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

  17. Application of the S690QL class steels in responsible welded structures

    Directory of Open Access Journals (Sweden)

    Dušan Arsić


    Full Text Available In this paper are considered the most important properties of a special class of high strength steels S690QL, which can be classified into the group of special low alloyed steels. The high strength steels belong into a group of high quality steels. They possess exceptional mechanical properties, especially tensile strength and toughness. Those favorable properties are being achieved by application of special procedures of thermo-mechanical processing and simultaneous alloying with adequate elements. The advantages that the S690QL steels have with respect to other steels are being presented here. However, possibilities for application of those steels in responsible welded structures are limited due to their only relatively good weldability.  The special procedures for improving it are discussed here, primarily preheating, controlled heat input during welding and additional heat treatment of the welded joint.

  18. A novel weld seam detection method for space weld seam of narrow butt joint in laser welding (United States)

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


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

  19. Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Plasma Transferred Arc Surfacing with Adequacy Test


    Bhaskarananda Dasgupta; Pinaky Bhadury


    Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based...

  20. 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


    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.