In this study, the effects of tool rotational speed, tool traverse speed, and Zn content on the grain size and hardness of the friction-stir-welded （FSWed） Cu-Zn alloy joints were investigated. The microstructures o...In this study, the effects of tool rotational speed, tool traverse speed, and Zn content on the grain size and hardness of the friction-stir-welded （FSWed） Cu-Zn alloy joints were investigated. The microstructures of the joints were examined using optical microscope （OM） and scanning transmission electron microscope （STEM）. Vickers hardness test was conducted to evaluate the hardness of the joints. In addition, the relationships between the process parameters, grain size, and hardness of the joints were established. The results show that the developed relationships predict the grain size and hardness of the joints accurately. The Zn content of the alloys is the most effective parameter on the grain size and hardness, where the tool traverse speed has the minimum effect. The relationship between the hardness and grain size of the joints has a deviation from the Hall-Petch equation due to formation of high dislocation density inside the grains. At higher Zn amounts, the dislocation tangles with high density form instead of dislocation cells, and hence, lower conformity with the Hall-Petch relationship is observed.展开更多
Sizes of nuggets are often used to evaluate spot weld quality in production. This paper presents a neural estimator used to carry out non-destructive on-line analysis of spot weld quality in which trained ANN function...Sizes of nuggets are often used to evaluate spot weld quality in production. This paper presents a neural estimator used to carry out non-destructive on-line analysis of spot weld quality in which trained ANN functions to map dynamic resistance characteristics into sizes of spot weld nuggets and results confirm the validity of neural network for this type of application.展开更多
AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength and ductility. These attributes make it a favorite for many mechanical components. The pape...AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength and ductility. These attributes make it a favorite for many mechanical components. The paper focuses on developing mathematical models to predict grain size and hardness of pulsed current micro plasma arc welded AISI 304L joints. Four factors, five level, central composite rotatable design matrix is used to optimize the number of experiments. The mathematical models have been developed by Response Surface Method (RSM) and its adequacy is checked by Analysis of Variance (ANOVA) technique. By using the developed mathematical models, grain size and hardness of the weld joints can be predicted with 99% confidence level. The developed mathematical models have been optimized using Hooke and Jeeves algorithm to minimize grain size and maximize the hardness.展开更多
The temperature field and thermal cycling curve in the heat-affected zone during welding 400 MPa ultra fine grained steel by plasma arc were simulated using finite element method. The principle of grain growth kinetic...The temperature field and thermal cycling curve in the heat-affected zone during welding 400 MPa ultra fine grained steel by plasma arc were simulated using finite element method. The principle of grain growth kinetics was used to predict the grain size in the heat-affected zone under different welding parameters. The simulation results show that the growing tendency of HAZ grain could be controlled by adjusting the welding parameters, but the growth of HAZ grain could not be eliminated at all. The HAZ grain size became small with increasing of the cooling rate and added with increasing of welding current, arc voltage and welding speed.展开更多
The effect of heat input on martensite formation and impact properties of gas metal arc welded modified ferritic stainless steel （409M） sheets （as received） with thickness of 4 mm was described in detail in this w...The effect of heat input on martensite formation and impact properties of gas metal arc welded modified ferritic stainless steel （409M） sheets （as received） with thickness of 4 mm was described in detail in this work. The welded joints were prepared under three heat input conditions, i.e. 0.4, 0.5 and 0.6 kJ/mm using two different austenitic filler wires （308L and 316L） and shielding gas composition of Ar ＋ 5% CO2. The welded joints were evaluated by microstructure and charpy impact toughness. The dependence of weld metal microstructure on heat input and filler wires were determined by dilution calculation, Creq/Nieq ratio, stacking fault energy （SFE）, optical microscopy （OM） and transmission electron microscopy （TEM）. It was observed that the microstructure as well as impact property of weld metal was significantly affected by the heat input and filler wire. Weld metals prepared by high heat input exhibited higher amount of martensite laths and toughness compared with those prepared by medium and low heat inputs, which was true for both the filler wires. Furthermore, 308L weld metals in general provided higher amount of martensite laths and toughness than 316L weld metals.展开更多
Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and depende...Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.展开更多
A major dilemma faced in the nuclear industry is repair of stainless steel reactor components that have been exposed to neutron irradiation. When conventional fusion welding is used for repair, intergranular cracks de...A major dilemma faced in the nuclear industry is repair of stainless steel reactor components that have been exposed to neutron irradiation. When conventional fusion welding is used for repair, intergranular cracks develop in the heat-affected zone(HAZ). Friction stir processing(FSP), which operates at much lower peak temperatures than fusion welding, was studied as a crack repair method for irradiated 304 L stainless steel. A numerical simulation of the FSP process in 304 L was developed to predict temperatures and recrystallized grain size in the stir zone. The model employed an Eulerian finite element approach,where flow stresses for a large range of strain rates and temperatures inherent in FSP were used as input. Temperature predictions in three locations near the stir zone were accurate to within 4%, while prediction of welding power was accurate to within 5% of experimental measurements. The predicted recrystallized grain sizes ranged from 7.6 to 10.6 μm, while the experimentally measured grains sizes in the same locations ranged from 6.0 to 7.6 μm. The maximum error in predicted recrystallized grain size was about 39%, but the associated stir zone hardness from the predicted grain sizes was only different from the experiment by about 10%.展开更多
Microstructural characteristics of different sub-regions of heat affected zone （HAZ） of low welding crack susceptibility steel weldment were investigated by using optical microscopy and scanning electron microscopy ...Microstructural characteristics of different sub-regions of heat affected zone （HAZ） of low welding crack susceptibility steel weldment were investigated by using optical microscopy and scanning electron microscopy equipped with electron backscattered diffraction system. And the focus was put on the correlation between microstructural characteristics and HAZ toughness of the weldment. The results reveal that the toughness of fusion line zone （FLZ） specimens is much lower than that of fine grained HAZ （FGHAZ） specimens. The coarse inclusions in the weld metal and the large martensite-austenite constituents in the coarse grained HAZ （CGHAZ） have an obvious negative effect on the crack initiation energy of FLZ. Meanwhile, the coarse granular bainite with large effective grain decreases the crack propagation energy seriously. By contrast, fine crystallographic grains in the FGHAZ play a key role in increasing toughness, especially in improving crack propagation energy.展开更多
Though the preferred welding process to weld aluminium alloy is frequently constant current gas tungsten arc welding (CCGTAW),it resulted in grain coarsening at the fusion zone and heat affected zone(HAZ).Hence,pulsed...Though the preferred welding process to weld aluminium alloy is frequently constant current gas tungsten arc welding (CCGTAW),it resulted in grain coarsening at the fusion zone and heat affected zone(HAZ).Hence,pulsed current gas tungsten arc welding(PCGTAW) was performed,to yield finer fusion zone grains,which leads to higher strength of AA6061 (Al-Mg-Si) aluminium alloy joints.In order to determine the most influential control factors which will yield minimum fusion zone grain size and maximum tensile strength of the joints,the traditional Hooke and Jeeves pattern search method was used.The experiments were carried out based on central composite design with 31 runs and an algorithm was developed to optimize the fusion zone grain size and the tensile strength of pulsed current gas tungsten arc welded AA6061 aluminium alloy joints.The results indicate that the peak current (Ip) and base current (IB) are the most significant parameters,to decide the fusion zone grain size and the tensile strength of the AA6061 aluminum alloy joints.展开更多
Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aeros...Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aerospace and petroleum industry. Micro Plasma Arc Welding (MPAW) is one of the important arc welding processes commonly using in fabric- cation of Nickel alloys. In the present paper welding of Inconel 625 sheets using pulsed current micro plasma arc weld- ing was discussed. The paper mainly focuses on studying the weld quality characteristics like weld pool geometry pa- rameters, microstructure, grain size, hardness and tensile properties of Pulsed Current Micro Plasma Arc Welded In- conel 625 sheets at different welding speeds. Results reveals that at a welding speed of 260 mm/minute better weld quality characteristics can be obtained.展开更多
The levels of fluoride airborne particulates emitted from welding processes were investigated. They were sampled with the patented IOM Sampler, developed by J. H Vincent and D. Mark at the Institute of Occupational Me...The levels of fluoride airborne particulates emitted from welding processes were investigated. They were sampled with the patented IOM Sampler, developed by J. H Vincent and D. Mark at the Institute of Occupational Medicine（IOM）, personal inhalable sampler for simultaneous collection of the inhalable and respirable size fractions. Ion chromatography with conductometric detection was used for quantitative analysis. The efficiency of fluoride extraction from the cellulose filter of the IOM sampler was examined using the standard sample of urban air particle matter SRM-1648 a. The best results for extraction were obtained when water and the anionic surfactant N-Cetyl-N-N-Ntrimethylammonium bromide（CTAB） were used in an ultrasonic bath. The limits of detection and quantification for the whole procedure were 8 μg/L and 24 μg/L, respectively The linear range of calibration was 0.01–10 mg/L, which corresponds to 0.0001–0.1 mg of fluorides per m3 in collection of a 20 L air sample. The concentration of fluorides in the respirable fraction of collected air samples was in the range of 0.20–1.82 mg/m3, while the inhalable fraction contained 0.23–1.96 mg/m3 of fluorides during an eight-hour working day in the welding room.展开更多
Non-electric welding is a novel efficient technique for emergency maintenance, which utilizes the heat released by self-propagating combustion to join metals without needing arty power supply or gas sources. Non-elect...Non-electric welding is a novel efficient technique for emergency maintenance, which utilizes the heat released by self-propagating combustion to join metals without needing arty power supply or gas sources. Non-electric welding material, named non-electric welding pen, was prepared by utilizing highly-exothermic thermit （ Cud ＋ Al） with other additive powders. The effects of reactant particle size and mixing uniformity on the combustion characteristic of the welding pen were investigated. The results show that the particle size of reactant powder has a significant effect on combustion velocity. With increasing the particle size of reactant powder, the combustion velocity decreases obviously. Moreover, mixing uniformity and particle size are shown to be main factors influencing heat produced in single time, and accordingly affect the combustion temperature. Welding experiments were performed with 45 steel as the base material, and results show that the joint is of a metallurgie bonding with the tensile strength above 280 MPa, which proves non-electric welding a fusion welding technique.展开更多
Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aeros...Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aerospace and petroleum industry. In the present paper an attempt is made to study various weld quality characteristics like weld bead geometry dimensions, micro hardness, microstructure, grain size and tensile properties of Pulsed Current Micro Plasma Welding of Inconel625sheets. Weld joint was prepared by fusing the two parent metals of Inconel625 sheets. Square butt joint is used and welding was carried out using Pulsed DCEN, without filler wire. Peak current, back current, pulse and pulse width are considered as the main influential input variables during the welding.展开更多
Under the as-welded condition the fatigue crack initiation period was considered nonexistent and Linear Elastic Fracture Mechanics（LEFM） was used to calculate fatigue strength for a range of weld geometries. Fractur...Under the as-welded condition the fatigue crack initiation period was considered nonexistent and Linear Elastic Fracture Mechanics（LEFM） was used to calculate fatigue strength for a range of weld geometries. Fracture mechanics assessment of welded joints requires accurate solutions for stress intensity factor（SIF）. However, the solutions for the SIF of complex welded joints are dificult to determine due to the complicated correction factors. Three methods for SIF prediction are discussed on illet welded specimens containing continuous or semi-elliptical surface cracks, including the traditional correction method Mk, the approximate correction method Kt, and the suggested additional crack size method（ac＋ae）.The new additional crack parameter ae is used to replace the stress concentration effect of weld proile Mk, which simpliies the calculation process. Experimental results are collected to support fatigue strength assessment of the additional crack size method.展开更多
文摘In this study, the effects of tool rotational speed, tool traverse speed, and Zn content on the grain size and hardness of the friction-stir-welded （FSWed） Cu-Zn alloy joints were investigated. The microstructures of the joints were examined using optical microscope （OM） and scanning transmission electron microscope （STEM）. Vickers hardness test was conducted to evaluate the hardness of the joints. In addition, the relationships between the process parameters, grain size, and hardness of the joints were established. The results show that the developed relationships predict the grain size and hardness of the joints accurately. The Zn content of the alloys is the most effective parameter on the grain size and hardness, where the tool traverse speed has the minimum effect. The relationship between the hardness and grain size of the joints has a deviation from the Hall-Petch equation due to formation of high dislocation density inside the grains. At higher Zn amounts, the dislocation tangles with high density form instead of dislocation cells, and hence, lower conformity with the Hall-Petch relationship is observed.
文摘Sizes of nuggets are often used to evaluate spot weld quality in production. This paper presents a neural estimator used to carry out non-destructive on-line analysis of spot weld quality in which trained ANN functions to map dynamic resistance characteristics into sizes of spot weld nuggets and results confirm the validity of neural network for this type of application.
文摘AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength and ductility. These attributes make it a favorite for many mechanical components. The paper focuses on developing mathematical models to predict grain size and hardness of pulsed current micro plasma arc welded AISI 304L joints. Four factors, five level, central composite rotatable design matrix is used to optimize the number of experiments. The mathematical models have been developed by Response Surface Method (RSM) and its adequacy is checked by Analysis of Variance (ANOVA) technique. By using the developed mathematical models, grain size and hardness of the weld joints can be predicted with 99% confidence level. The developed mathematical models have been optimized using Hooke and Jeeves algorithm to minimize grain size and maximize the hardness.
文摘The temperature field and thermal cycling curve in the heat-affected zone during welding 400 MPa ultra fine grained steel by plasma arc were simulated using finite element method. The principle of grain growth kinetics was used to predict the grain size in the heat-affected zone under different welding parameters. The simulation results show that the growing tendency of HAZ grain could be controlled by adjusting the welding parameters, but the growth of HAZ grain could not be eliminated at all. The HAZ grain size became small with increasing of the cooling rate and added with increasing of welding current, arc voltage and welding speed.
文摘The effect of heat input on martensite formation and impact properties of gas metal arc welded modified ferritic stainless steel （409M） sheets （as received） with thickness of 4 mm was described in detail in this work. The welded joints were prepared under three heat input conditions, i.e. 0.4, 0.5 and 0.6 kJ/mm using two different austenitic filler wires （308L and 316L） and shielding gas composition of Ar ＋ 5% CO2. The welded joints were evaluated by microstructure and charpy impact toughness. The dependence of weld metal microstructure on heat input and filler wires were determined by dilution calculation, Creq/Nieq ratio, stacking fault energy （SFE）, optical microscopy （OM） and transmission electron microscopy （TEM）. It was observed that the microstructure as well as impact property of weld metal was significantly affected by the heat input and filler wire. Weld metals prepared by high heat input exhibited higher amount of martensite laths and toughness compared with those prepared by medium and low heat inputs, which was true for both the filler wires. Furthermore, 308L weld metals in general provided higher amount of martensite laths and toughness than 316L weld metals.
文摘Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.
基金supported by the National Science Foundation grant CMMI-1405508
文摘A major dilemma faced in the nuclear industry is repair of stainless steel reactor components that have been exposed to neutron irradiation. When conventional fusion welding is used for repair, intergranular cracks develop in the heat-affected zone(HAZ). Friction stir processing(FSP), which operates at much lower peak temperatures than fusion welding, was studied as a crack repair method for irradiated 304 L stainless steel. A numerical simulation of the FSP process in 304 L was developed to predict temperatures and recrystallized grain size in the stir zone. The model employed an Eulerian finite element approach,where flow stresses for a large range of strain rates and temperatures inherent in FSP were used as input. Temperature predictions in three locations near the stir zone were accurate to within 4%, while prediction of welding power was accurate to within 5% of experimental measurements. The predicted recrystallized grain sizes ranged from 7.6 to 10.6 μm, while the experimentally measured grains sizes in the same locations ranged from 6.0 to 7.6 μm. The maximum error in predicted recrystallized grain size was about 39%, but the associated stir zone hardness from the predicted grain sizes was only different from the experiment by about 10%.
基金supported by the National Natural Science Foundation of China (No. 51074052)the Fundamental Research Funds for the Central Universities(No. N100607001)
文摘Microstructural characteristics of different sub-regions of heat affected zone （HAZ） of low welding crack susceptibility steel weldment were investigated by using optical microscopy and scanning electron microscopy equipped with electron backscattered diffraction system. And the focus was put on the correlation between microstructural characteristics and HAZ toughness of the weldment. The results reveal that the toughness of fusion line zone （FLZ） specimens is much lower than that of fine grained HAZ （FGHAZ） specimens. The coarse inclusions in the weld metal and the large martensite-austenite constituents in the coarse grained HAZ （CGHAZ） have an obvious negative effect on the crack initiation energy of FLZ. Meanwhile, the coarse granular bainite with large effective grain decreases the crack propagation energy seriously. By contrast, fine crystallographic grains in the FGHAZ play a key role in increasing toughness, especially in improving crack propagation energy.
基金Naval Research Board (NRB),Ministry of Defence,New Delhi for the financial support to carry out this investigation through sponsored project No.DNRD/05/4003/NRB/67.
文摘Though the preferred welding process to weld aluminium alloy is frequently constant current gas tungsten arc welding (CCGTAW),it resulted in grain coarsening at the fusion zone and heat affected zone(HAZ).Hence,pulsed current gas tungsten arc welding(PCGTAW) was performed,to yield finer fusion zone grains,which leads to higher strength of AA6061 (Al-Mg-Si) aluminium alloy joints.In order to determine the most influential control factors which will yield minimum fusion zone grain size and maximum tensile strength of the joints,the traditional Hooke and Jeeves pattern search method was used.The experiments were carried out based on central composite design with 31 runs and an algorithm was developed to optimize the fusion zone grain size and the tensile strength of pulsed current gas tungsten arc welded AA6061 aluminium alloy joints.The results indicate that the peak current (Ip) and base current (IB) are the most significant parameters,to decide the fusion zone grain size and the tensile strength of the AA6061 aluminum alloy joints.
文摘Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aerospace and petroleum industry. Micro Plasma Arc Welding (MPAW) is one of the important arc welding processes commonly using in fabric- cation of Nickel alloys. In the present paper welding of Inconel 625 sheets using pulsed current micro plasma arc weld- ing was discussed. The paper mainly focuses on studying the weld quality characteristics like weld pool geometry pa- rameters, microstructure, grain size, hardness and tensile properties of Pulsed Current Micro Plasma Arc Welded In- conel 625 sheets at different welding speeds. Results reveals that at a welding speed of 260 mm/minute better weld quality characteristics can be obtained.
基金supported by the Polish Ministry of Science and Higher Education under grant for statutory I-43
文摘The levels of fluoride airborne particulates emitted from welding processes were investigated. They were sampled with the patented IOM Sampler, developed by J. H Vincent and D. Mark at the Institute of Occupational Medicine（IOM）, personal inhalable sampler for simultaneous collection of the inhalable and respirable size fractions. Ion chromatography with conductometric detection was used for quantitative analysis. The efficiency of fluoride extraction from the cellulose filter of the IOM sampler was examined using the standard sample of urban air particle matter SRM-1648 a. The best results for extraction were obtained when water and the anionic surfactant N-Cetyl-N-N-Ntrimethylammonium bromide（CTAB） were used in an ultrasonic bath. The limits of detection and quantification for the whole procedure were 8 μg/L and 24 μg/L, respectively The linear range of calibration was 0.01–10 mg/L, which corresponds to 0.0001–0.1 mg of fluorides per m3 in collection of a 20 L air sample. The concentration of fluorides in the respirable fraction of collected air samples was in the range of 0.20–1.82 mg/m3, while the inhalable fraction contained 0.23–1.96 mg/m3 of fluorides during an eight-hour working day in the welding room.
文摘Non-electric welding is a novel efficient technique for emergency maintenance, which utilizes the heat released by self-propagating combustion to join metals without needing arty power supply or gas sources. Non-electric welding material, named non-electric welding pen, was prepared by utilizing highly-exothermic thermit （ Cud ＋ Al） with other additive powders. The effects of reactant particle size and mixing uniformity on the combustion characteristic of the welding pen were investigated. The results show that the particle size of reactant powder has a significant effect on combustion velocity. With increasing the particle size of reactant powder, the combustion velocity decreases obviously. Moreover, mixing uniformity and particle size are shown to be main factors influencing heat produced in single time, and accordingly affect the combustion temperature. Welding experiments were performed with 45 steel as the base material, and results show that the joint is of a metallurgie bonding with the tensile strength above 280 MPa, which proves non-electric welding a fusion welding technique.
文摘Nickel alloys had gathered wide acceptance in the fabrication of components which require high temperature resistance and corrosion resistance, such as metallic bellows used in expansion joints used in aircraft, aerospace and petroleum industry. In the present paper an attempt is made to study various weld quality characteristics like weld bead geometry dimensions, micro hardness, microstructure, grain size and tensile properties of Pulsed Current Micro Plasma Welding of Inconel625sheets. Weld joint was prepared by fusing the two parent metals of Inconel625 sheets. Square butt joint is used and welding was carried out using Pulsed DCEN, without filler wire. Peak current, back current, pulse and pulse width are considered as the main influential input variables during the welding.
基金Project supported by the National Natural Science Foundation of China(No.51609185)the State Key Laboratory of Ocean Engineering in Shanghai Jiao Tong University(No.1613)
文摘Under the as-welded condition the fatigue crack initiation period was considered nonexistent and Linear Elastic Fracture Mechanics（LEFM） was used to calculate fatigue strength for a range of weld geometries. Fracture mechanics assessment of welded joints requires accurate solutions for stress intensity factor（SIF）. However, the solutions for the SIF of complex welded joints are dificult to determine due to the complicated correction factors. Three methods for SIF prediction are discussed on illet welded specimens containing continuous or semi-elliptical surface cracks, including the traditional correction method Mk, the approximate correction method Kt, and the suggested additional crack size method（ac＋ae）.The new additional crack parameter ae is used to replace the stress concentration effect of weld proile Mk, which simpliies the calculation process. Experimental results are collected to support fatigue strength assessment of the additional crack size method.
