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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Parametric Modeling of AZ31-Mg Alloy Friction Stir Weld Temperature Histories

A parametric model of friction stir weld temperature histories is presented that uses constraint conditions, which are three-dimensional isothermal boundary conditions on the calculated temperature fields. This study describes further extension, with respect to formulation, of a parametric-modeling methodology, which is relatively optimal in terms of representation for application to friction stir welding and processing. These parametric representations of temperature histories can be used for modeling friction stir welds whose process conditions are similar to those in this study. Calculations of AZ31-Mg alloy friction stir weld temperature histories are presented, which use temperature-field constraint conditions based on measured weld cross sections and a model for the estimation of weld stir zone temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Work Hardening Behavior of Micro-plasma Arc Welded AISI 316L Sheet Joint

The aim of this research is to investigate the microstructural changes and work hardening behavior of AISI 316L 0.5-mm-thick sheet due to micro-plasma arc welding. AISI 316L similar sheets were welded in single-pass square butt joint configuration. The microstructure in the fusion zone typically contains a variety of complex δ-ferrite-austenitic structure, which significantly increased hardness value compared to the base material because of rapid solidification of the weld pool. Systematic tensile test was performed to investigate strain rate sensitivity of the welded joint under quasi-static loading conditions. The multistage work hardening behavior was determined by Kocks–Mecking (K–M) model and differential Crussard–Jaoul analysis. In both the cases, stage III work hardening behavior and stage IV work hardening behavior were observed. The stress–strain curves of welded specimen at different strain rates were analyzed in terms of Hollomon, Ludwik and Swift equations to determine work hardening exponent values. The welded joints were ruptured in the transition zone of heat affected and fusion zones. The fractographic observation exhibited variation in dimple and void density over strain rate from 0.0001 to 0.0015 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Characteristics and Mechanical Properties in the Laser Beam Welded Joints of High-Strength Microalloyed Steel

The laser beam welded joints of the high-strength microalloyed steel consist of the base metal (BM), the partially transformed heat-affected zone I (PTHAZ-I), the partially transformed heat-affected zone II (PTHAZ-II), the fully transformed heat-affected zone (FTHAZ) and the fusion zone (FZ). The martensite/austenite (M/A) islands of the bainites in the PTHAZ-II are dense versus those in the PTHAZ-I, and the martensites exist in the FTHAZ and the FZ together with the bainites under the slow welding speed. The M/A islands of the bainites and/or the martensites in the PTHAZ become denser under the high welding speed, and the martensites in the FTHAZ and the FZ predominate. The low-angle boundary density and the high local misorientation proportion are used to identify the constituents roughly, consistent with the microstructural characteristics in the welded joints. The misorientation angle distributions are employed to evaluate the degree of the phase transformation, reflecting the change law of the degree of the phase transformation in the welded joints. The hardness and the tensile tests indicate that the HAZ and the FZ are stronger than the BM, dependent on the microstructures in the welded joints. The strengthening in the HAZ and the FZ is mainly attributed to the products of non-equilibrium phase transformation with the high dislocation density.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Weighting Grade-Based Optimization Method for Determining Refill Friction Stir Spot Welding Process Parameters

The welding process used in fabricating thin-walled structures by refill friction stir spot welding (RFSSW) should be characterized by a high strength of welds and high process repeatability which is demonstrated by a small dispersion of the load capacity of the joints. The present work is designed to optimize RFSSW process parameters for 7075-T6 Alclad aluminum alloy sheets used to fabricate aircraft structures. The optimization was performed by scalarization of the objective function using the weighting grades method. The study considers the effect of process parameters, i.e., tool plunge depth, duration of welding, tool rotational speed, on the tensile/shear strength of the joints, and dispersion of the load capacity. It was found that it was possible to choose the optimal welding parameters taking into account maximization of the load capacity and minimization of the dispersion of the joint strength via a best compromise between the tool rotational speed ensuring adequate plasticization of the base material and the duration of welding ensuring that a fine-grained joint microstructure is obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Mechanical Behavior of Friction Stir-Welded Sc-Modified Al-Zn-Mg Alloys Made Using Different Base Metal Tempers

The microstructure and property of friction stir weld joints of a Sc-modified Al-Zn-Mg alloy developed using base metal in hot-rolled (HR) and T6 temper were studied and compared in this work. The results showed that the microstructure and property exhibited significant difference between the two friction stir weld joints. The weld efficiency of the FSW joint developed using base metal in HR condition is over 90%, while that of the FSW joint developed using base metal in T6 condition is only 70%. The hardness of the weld nugget of HR joint is obviously higher than that of the weld nugget of T6 joint, due to the different changes in the original precipitates during the friction stir welding process. The strengthening mechanism in different zones of the two FSW joints was discussed to examine the microstructure–properties relationship, and the main difference of the strengthening mechanism between the two FSW joints was revealed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Failure Analysis of Pinch Weld Electrodes

We present that Savannah River Site uses brazed copper/tungsten electrodes for a specialized weld referred to as a pinch weld. An alternative method to produce the pinch weld electrodes was sought to improve quality and to reduce the manufacturing steps. Backcasting of pinch weld electrodes was selected as such a process. During preliminary testing, deformation of the electrodes was observed. A failure analysis assessment was conducted and the strength of the electrodes was found to be significantly less than required to enable welding of the tubes. This assessment includes compression testing metallographic analysis. The pinch weld electrodes fabricated by backcasting do not meet the requirements with respect to strength. Additionally, a minimum strength requirement for conventionally prepared electrodes is recommended.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The effect of filament peaking on electron beam weld quality

Electron beam welding uses high intensity beams that are generated by an electron emitting cathode under high vacuum conditions. The cathode, typically a ribbon or wire filament of refractory metal, must be heated to sufficiently high temperatures for electron emission to occur and must be carefully controlled to produce the desired beam current while at the same time optimizing filament lifetime. Traditional methods for doing this in commonly used triode gun assemblies consist of first finding the filament knee point in the filament current versus beam current relationship that produces the desired beam current for a given beam voltage. The filament current is then increased by some amount, typically 5–10%, per conventional wisdom to produce a peaked beam. This investigation studies and quantifies the beam and weld quality produced by underkneed and overpeaked filaments using electron beam diagnostics to measure the power density distribution of these beams. Underkneed filaments are shown to have power densities that drop off very quickly below the traditional knee, resulting in poor weld penetration. Kneed filaments do not reach the full beam intensity and also produce shallow welds. Increasing the filament current 10% above the traditional knee was shown to produce a circular Gaussian-like beam with peaked intensity optimized for welding and for filament lifetime. Further increases in the filament current that produce overpeaked beams do not significantly change the beam or weld quality and would only contribute to a reduced filament lifetime.

Electron Beam Welding↗
DOE OSTI2016

Hydrogen accelerated fatigue crack growth of friction stir welded X52 steel pipe

Friction stir welded steel pipelines were tested in high pressure hydrogen gas to examine the effects of hydrogen accelerated fatigue crack growth. Fatigue crack growth rate (da/dN) vs. stress-intensity factor range (ΔK) relationships were measured for an X52 friction stir welded pipe tested in 21 MPa hydrogen gas at a frequency of 1 Hz and R = 0.5. Tests were performed on three regions: base metal (BM), center of friction stir weld (FSW), and 15 mm off-center of the weld. For all three material regions, tests in hydrogen exhibited accelerated fatigue crack growth rates that exceeded an order of magnitude compared to companion tests in air. Among tests in hydrogen, fatigue crack growth rates were modestly higher in the FSW than the BM and 15 mm off-center tests. Select regions of the fracture surfaces associated with specified ΔK levels were examined which revealed intergranular fracture in the BM and 15 mm off-center specimens but an absence of intergranular features in the FSW specimens. In conclusion, the X52 friction stir weld and base metal tested in hydrogen exhibited fatigue crack growth rate relationships that are comparable to those for conventional arc welded steel pipeline of similar strength found in the literature.

08 HYDROGEN↗
DOE OSTI2024

Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. Here, in this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several techniques are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other weld problems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Stress characterization for friction-stir-welded electric vehicle battery trays with application of neutron diffraction

The battery tray is an essential component that protects and controls battery-cell temperatures in electric and plug-in hybrid vehicles. The functional stress limit of the battery tray heavily depends on the residual stress acquired from the manufacturing process. Consequently, exceeding the stress limit of the battery tray during operation could compromise the battery-cell banks and may risk the vehicle's safety. Hence, understanding residual stress formation is vital for design and safety concerns. Here, in the current study, AA 6061-plates were friction stir welded to an A365 high-pressure die-cast battery tray to create sealed coolant channels in the battery tray. However, this multi-material lap friction stir weld introduces residual stress into the battery tray, resulting in distortion. This distortion was mitigated using burnishing or coining operations, though straightening the battery tray had initially unknown effects on the residual stress. Therefore, neutron diffraction was utilized to characterize residual stresses after straightening. The results indicate that the friction stir welding (FSW) operation generated residual stresses exceeding the yield strength of the material, consequently deforming the battery tray by ±3 mm from the pre-weld geometry. The burnishing operation reduced the residual stresses below the material's yield strength while restoring the tray to within ±0.75 mm of the pre-weld geometry. Similarly, the coining operation restored the battery tray to within ±0.75 mm of the pre-weld geometry, however, increasing the number of locations where the residual stress exceeds the yield strength of the material.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructure and mechanical properties of ultrasonic spot welding of AA7075-T6 and A380 casting aluminum alloy

Ultrasonic spot welding (USW) was employed to join AA7075-T6 and casting Al alloy A380. Under a constant welding power, the influence of the welding time duration (from 1 s to 3 s) on peak temperature, microstructure, hardness, and mechanical strength of the joints were studied. It was found that the peak temperature increased with welding time. A sound solid-state metallurgical bonding was obtained at the joint interface. The cracks occurred at the edge of the joints were eventually eliminated as the welding time increased. A layer of refined grains formed in A380 adjacent to the bonding line. Further, hardness reduction occurred in AA7075 at the joint interface and the degree of hardness reduction and the volume increased with the peak temperature. By increasing welding time, lap shear tensile tests show that the peak load increased from 5.3 kN to 6.55 kN. The corresponding interfacial shear strength ranged from 96.29 MPa to 99.72 MPa, lower than the shear strength of both base materials (331 MPa for AA7075 and 185 MPa for A380). All joint samples exhibited interfacial fracture after lap shear tensile testing, with a thin layer of A380 remnant attached to AA7075 at the center of the fractured surface.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Characterization of Mg/Al butt joints welded by gas tungsten arc filling with Zn–29.5Al–0.5Ti filler metal

The multivariate alloying design of a welding joint is used in the Mg to Al welding process. A Zn–29.5Al–0.5Ti alloy is added as filler metal in gas tungsten arc welding of Mg and Al alloy joint based on the analysis of Al and Mg alloy characteristics. The tensile strength, microstructure, and phase constitution of the weld seam are analyzed. The formation of brittle and hard Mg–Al intermetallic compounds is avoided because of the effects of Zn, Al, and Ti. The average tensile strength of the joint is 148 MPa. Al{sub 3}Ti is first precipitated and functions as the nucleus of heterogeneous nucleation during solidification. Moreover, the precipitated Al–MgZn{sub 2} hypoeutectic phase exhibited a feather-like structure, which enhances the property of the Mg–Al dissimilar joint. - Highlights: • Mg alloy AZ31B and Al alloy 6061 are butt welded by fusion welding. • The effect of Ti in filler metal is investigated. • The formation of Mg–Al intermetallic compounds is avoided.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of cooling conditions on microstructure and mechanical properties of friction stir welded 7055 aluminium alloy joints

Highlights: • Water cooling improves tensile properties of friction stir welded 7055 Al alloy. • Water cooling results in smaller grains and second phase in nugget zone. • Water cooling results in finer second phase in thermos-mechanically affected zone. • Water cooling results in finer second phase in heat affected zone. • Fracture surface is flat for air-cooled joint but zig-zag for water-cooled one. - Abstract: The microstructure and mechanical properties of friction stir welded 7055 aluminium alloy under air cooling and water cooling were investigated by means of hardness and tensile testing, optical microscopy and transmission electron microscopy. Water cooling results in reduced softening in the weld zone and therefore higher tensile strength compared to air cooling. Fracture generally occurs within the thermo-mechanically affected zone (TMAZ) and heat affected zone (HAZ) on the retreating side in joints welded under air cooling but shifts towards the TMAZ and nugget zone (NZ) in the joints welded under water cooling. The fracture surfaces are generally flat for the air-cooled joint, but exhibits a zig-zag feature for the water-cooled joint. The mechanical behaviour of the weld has been discussed in light of the change in grain structure and precipitation in the NZ, TMAZ and HAZ caused by cooling conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Autonomous nondestructive evaluation of resistance spot welded joints

The application of non-destructive evaluation approaches has attracted strong interests in modern automotive industries. Here, we present an autonomous deep-computing framework to analyze raw videos from infrared systems and to predict weld nugget shape and size with unprecedented accuracy and speed. In a comprehensive training and testing experiment with 90 videos (seven sets of welding material stack-ups), a new method was developed to assemble sufficient datasets for neural network training. Our framework successfully predicts all the nugget shapes with F1 scores that range from 0.84 to 0.92. The total training time on Nvidia DGX station takes less than 10 min for each set of welding material stack-up. The real inference time of an individual dataset (with 30 video frames) takes about 0.005 s. The procedure and methods developed in the study can be applied to other image-based weld property prediction, as well as other manufacturing processes. Furthermore, our well-trained neural networks take limited memory resources (2.3 MB) and are suitable for embedded microprocessors for in-situ welding quality control as edge computing within an intelligent welding framework.

42 ENGINEERING↗
DOE OSTI2024

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication of Enhanced Pinch Weld Electrodes

Savannah River Site uses brazed copper / tungsten electrodes for a specialized weld referred to as a pinch weld. As part of an internally funded PDRD program, an alternative method to produce the pinch weld electrodes was sought to improve quality and to reduce the manufacturing steps. Back casting of pinch weld electrodes was selected as such a process. During preliminary testing, deformation of the electrodes was observed. A failure analysis was conducted, and the strength of the electrodes was found to be significantly less than required to enable welding of the tubes. This assessment includes compression testing metallographic analysis. The pinch weld electrodes fabricated by back casting do not meet the requirements with respect to strength. In addition, a minimum strength requirement for conventionally prepared electrodes is recommended.

42 ENGINEERING↗
DOE OSTI2017

Physics-based Creep Simulations of Thick Section Welds in High Temperature and Pressure Applications

During the second quarter of FY17, research efforts have been focused on modeling and simulation of the creep behavior of welds in Alloy 740H. Additionally, welded material has been sent to a commercial vendor to make creep specimen with cross-weld orientation as well as creep specimens consisting of all weld metal to evaluate the creep behavior of the different zones in and around the weld. Creep testing and aging of welds continued to evaluate microstructure evolution and the creep behavior as a function of aging time.

36 MATERIALS SCIENCE↗