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At least 73 records · Page 4

"Foreign material" to verify root fusion in welded joints

Foil or thin wire at weld root is used to verify weld penetration. When weld is adequate, material mixes with weld and traces of it diffuse to weld crown. Spectroscopic analysis of samples identifies foreign material and verifies root has fused. Weld roots are usually inaccessible to visual inspection, and X-ray and ultrasonic inspection techniques are not always reliable. Good results are obtained with use of gold/nickel alloy.

Kleint, R. E.↗

The Microstructure and Pitting Resistance of Weld Joints of 2205 Duplex Stainless Steel

2205 duplex stainless steel (DSS) was welded by submerged arc welding. The effects of both heat input and groove type on the ferrite/austenite ratio and elemental diffusion of weld joints were investigated. The relationships among welding joint preparation, ferrite/austenite ratio, elemental diffusion, and pitting corrosion resistance of weld joints were analyzed. When the Ni content of the weld wire deposit was at minimum 2–4% higher than that of 2205 DSS base metal, the desired ratio of ferrite/austenite and elemental partitioning between the austenite and ferrite phases were obtained. While the pitting sensitivity of weld metal was higher than that of base metal, the self-healing capability of the passive film of weld metal was better than that of the base metal when a single V-type groove was used. Furthermore, the heat input should be carefully controlled since pitting corrosion occurred readily in the coarse-grained heat-affected zone near the fusion line of welded joints.

36 MATERIALS SCIENCE↗

Arc Reflector For Welding Ducts

Arc-light reflector for through-the-torch welding vision system designed expressly for use in welding ducts of small diameter. Cylindrical reflector positioned to reflect light diffusely from welding arc onto nearby surface of workpiece for most advantageous viewing along axis of welding torch.

Gilbert, Jeffrey L.↗

Diffusion in thoriated and nonthoriated nickel and nickel-chromium alloys at 1260 C

Various solid-solid diffusion couples were assembled from thoriated and nonthoriated nickel-base alloys, welded, and diffusion annealed at 1260 C. Concentration profiles indicated that a thoria dispersion does not affect diffusion in Cr(alloy):Ni and Ni-4.8Al:Ni types of couples unless a fine grain structure is retained by the thoria particles. Metallography revealed the presence of thoria-free bands in the thoriated-Ni side of the diffusion zone. The bands contained grain boundaries and, in some cases, non-Kirkendall porosity. A mechanism based on the operation of vacancy sources is proposed to explain the thoria-free bands. In addition, a particular DS-NiCr:Ni couple had negligible Kirkendall porosity. This behavior was related to the grain structure of the particular lot of DS-NiCr.

Whittenberger, J. D.↗

Optimizing diffusion bonding parameters to maximize the strength of AA6061 aluminum and AZ61A magnesium alloy joints

The main difficulty when joining magnesium (Mg) and aluminum (Al) alloys by fusion welding process lies in the existence of oxide films and formation of brittle intermetallic in the weld region. However, solid-state welding processes such as friction welding and diffusion bonding are suitable processes to join these two materials. The diffusion bonding process parameters such as bonding temperature, bonding pressure, holding time, and surface roughness of the bond specimen play a major role to determine the joint strength. In this investigation, an attempt was made to develop empirical relationships to predict the lap shear strength and bonding strength of diffusion bonded dissimilar joints of AZ61A magnesium and AA6061 aluminum alloys, incorporating the above-mentioned parameters. Response surface methodology (RSM) was applied to optimize the diffusion bonding process parameters to attain the maximum shear strength and bonding strength of the joint. From this investigation, it is found that the bonds fabricated with the bonding temperature of 420.43°C, bonding pressure of 7.70 MPa, holding time of 27.15 min, and surface roughness of 0.10 μm exhibited maximum shear strength and bonding strength of 51.24 and 72.10 MPa, respectively.

36 MATERIALS SCIENCE↗

Enhanced diffusion bonding of alloy 617 using electric field-assisted sintering

The development of compact heat exchangers (CHXs) has gained increasing interest in many industries owing to their high thermal efficiency and reduced size. Diffusion bonding (DB) is an advantageous technique for fabricating CHXs. Alloy 617 is a candidate for manufacturing CHXs for high-temperature advanced nuclear reactors due to its elevated-temperature properties. Previous endeavors in DB of Alloy 617 were conducted by hot pressing (HP), which reported precipitates at the diffusion-bond interface, limited grain boundary (GB) migration, and significantly reduced high-temperature mechanical properties. To overcome these challenges, this study investigated DB of Alloy 617 using electric field-assisted sintering (EFAS). Stacks composed of three sheets were bonded with EFAS using different temperatures, pressures, and hold times. DB using HP as the zero-current analog of EFAS was also performed for comparison. The result shows that Cr- and Mo-rich precipitates were formed at the interface of the hot-pressed samples. The electric current and temperature in EFAS play a significant role in precipitation and GB migration. The electric current coupled with correct temperatures can effectively prevent precipitate formation at the interface and achieve excellent GB migration. Nanoscale Al-rich oxide was formed at the interface of the samples made by both HP and EFAS, but grain boundaries can ignore the nanoscale Al-oxide and migrate across the interface. The temperature, pressure, and hold time also affected diffusion. The temperature is a prerequisite for a successful GB migration, and GB migration can be enhanced by increasing pressure and hold time.

36 MATERIALS SCIENCE↗

Evaluation of Zn-rich coatings for IMC reaction control in aluminum-magnesium dissimilar welds

Highlights: • Thermodynamic and diffusion simulations have estimated the Zn conc. required to change the IMC reaction in Al-Mg dissimilar welding. • The selected coating alloy was effective in changing the Al-Mg reaction path by forming τ-(Al,Zn){sub 49}Mg{sub 32} as a substitute for β-Al{sub 3}Mg{sub 2}. • Refill™ friction stir spot welds produced with the coating alloy exhibited a thinner reaction layer and an increase in lap shear strength. - Abstract: The dissimilar welding of Al to Mg is very challenging owing to the rapid formation of an intermetallic (IMC) reaction layer at the joint interface, typically comprised of the binary phases γ-Al{sub 12}Mg{sub 17} and β-Al{sub 3}Mg{sub 2}. A potential metallurgical solution has been explored that aimed to change the reaction path by using Al-Zn alloy coatings to promote alternative IMCs with a slower growth rate. To determine the optimum composition for the coating, combined CALPHAD thermodynamic calculations and diffusion simulations were used to estimate the minimum Zn concentration (20 at.%) required to suppress the formation of the faster growing Al{sub 3}Mg{sub 2} phase. This prediction was verified by both static diffusion and Refill™ friction stir spot welding (FSSW) experiments. In each case the selected coating alloy was effective in changing the Al-Mg reaction path by forming the τ-(Al,Zn){sub 49}Mg{sub 32} phase as a substitute for β-Al{sub 3}Mg{sub 2}. However, in static heat treatments there was no reduction in the IMC reaction layer thickness due to the new phase having similar growth kinetics to the β-Al{sub 3}Mg{sub 2} phase it replaced. Nevertheless, Refill™ friction stir spot welds prepared with the new AL-Zn coating alloy exhibited a thinner reaction layer and an increase in lap shear strength. This benefit was attributed to the Zn addition reducing the joint interface liquation temperature, which resulted in a lower peak weld temperature and less IMC reaction; although an increase in local eutectic melting limited the improvement observed.

36 MATERIALS SCIENCE↗

Iodine effective diffusion coefficients through volcanic rock: Influence of iodine speciation and rock geochemistry

Accurate prediction of the subsurface transport of iodine species is important for the assessment of long-term nuclear waste repository performance, as well as monitoring compliance with the Comprehensive Nuclear-Test-Ban Treaty, given that radioiodine decays into radioxenon. However, the transport of iodine through intact geologic media is not well understood, compromising our ability to assess risk associated with radioiodine migration. The current study's goal is to quantify the matrix diffusion of iodine species through saturated volcanic rock, with particular attention paid to the redox environment and potential speciation changes. Here, diffusion experiments were run for iodide through lithophysae-rich lava, lithophysae-poor lava, and welded tuff, whereas iodate diffusion was studied through welded tuff. Iodine transport was compared with a conservative tracer, HDO, and effective diffusion coefficients were calculated. Likely due to a combination of size and anion exclusion effects, iodine species diffused more slowly than the conservative tracer through all rock types tested. Furthermore, oxidation of iodide to iodate was observed in the lithophysae-poor lava, affecting transport. Results provide much needed data for subsurface transport models that predict radioiodine migration from underground sources, and indicate the pressing need for geochemical and redox interactions to be incorporated into these models.

58 GEOSCIENCES↗

Interfacial microstructure evolution and weld formation during ultrasonic welding of Al alloy to Cu

Highlights: • Surface oxide layer was fractured and dispersed around the weld interface during ultrasonic welding of Al alloy to Cu. • Mechanical mixing around the weld interface was caused by compressive deformation with ultrasonic vibration. • Once micro-bonds were generated between Al and Cu, shear deformation occurred around the weld interface. • Enhanced Cu diffusion into Al in the severely deformed region significantly contributed to the weld formation. - Abstract: Dissimilar welds of Al alloy 1050 to Cu were prepared via ultrasonic spot welding in order to understand the formation of welds and interfacial microstructures. To observe oxide layer behavior at the weld interface, the anodized Al alloy 1050 was also welded to Cu. Mechanical mixing and material flow during ultrasonic welding broke and dispersed the oxide layers into the Al matrix. This material flow is attributed to compressive deformation that occurred due to ultrasonic vibrations. Direct bonding in the Al/Cu region increased with welding time. Once micro-bonds were generated between Al and Cu, the Al matrix in the vicinity of the weld interface was severely deformed in the direction of the ultrasonic vibrations. Consequently, a recrystallized microstructure with shear texture was formed in the Al matrix. Deformation heating and severe shear deformation formed Al{sub 2}Cu intermetallic compound layers at the weld interface. The growth rate of the Al{sub 2}Cu layer was much faster than had previously been estimated based upon the peak temperature and ultrasonic welding heating time. This is likely due to the increased rate of Cu diffusion into Al in the severely deformed region.

36 MATERIALS SCIENCE↗

Structure and constitution of glass and steel compound in glass-metal composite

The research using methods of optical and scanning electronic microscopy was conducted and it discovered common factors on structures and diffusing zone forming after welding glass C49-1 and steel Ct3sp in technological process of creating new glass-metal composite. Different technological modes of steel surface preliminary oxidation welded with and without glass were investigated. The time of welding was varied from minimum encountering time to the time of stabilizing width of diffusion zone.

36 MATERIALS SCIENCE↗

Monolithic Solid-State Lasers for Spaceflight

A new solution for building high power, solid state lasers for space flight is to fabricate the whole laser resonator in a single (monolithic) structure or alternatively to build a contiguous diffusion bonded or welded structure. Monolithic lasers provide numerous advantages for space flight solid state lasers by minimizing misalignment concerns. The closed cavity is immune to contamination. The number of components is minimized thus increasing reliability. Bragg mirrors serve as the high reflector and output coupler thus minimizing optical coatings and coating damage. The Bragg mirrors also provide spectral and spatial mode selection for high fidelity. The monolithic structure allows short cavities resulting in short pulses. Passive saturable absorber Q-switches provide soft aerturing fro spatial mode filtering and improved pointing stability. We will review our recent commercial and in-house developments toward fully monolithic solid state lasers.

Monolthic laser↗

An extended laser flash technique for thermal diffusivity measurement of high-temperature materials

Knowledge of thermal diffusivity data for high-temperature materials (solids and liquids) is very important in analyzing a number of processes, among them solidification, crystal growth, and welding. However, reliable thermal diffusivity versus temperature data, particularly those for high-temperature liquids, are still far from complete. The main measurement difficulties are due to the presence of convection and the requirement for a container. Fortunately, the availability of levitation techniques has made it possible to solve the containment problem. Based on the feasibility of the levitation technology, a new laser flash technique which is applicable to both levitated liquid and solid samples is being developed. At this point, the analysis for solid samples is near completion and highlights of the technique are presented here. The levitated solid sample which is assumed to be a sphere is subjected to a very short burst of high power radiant energy. The temperature of the irradiated surface area is elevated and a transient heat transfer process takes place within the sample. This containerless process is a two-dimensional unsteady heat conduction problem. Due to the nonlinearity of the radiative plus convective boundary condition, an analytic solution cannot be obtained. Two options are available at this point. Firstly, the radiation boundary condition can be linearized, which then accommodates a closed-form analytic solution. Comparison of the analytic curves for the temperature rise at different points to the experimentally-measured values will then provide the thermal diffusivity values. Secondly, one may set up an inverse conduction problem whereby experimentally obtained surface temperature history is used as the boundary conditions. The thermal diffusivity can then be elevated by minimizing the difference between the real heat flux boundary condition (radiation plus convection) and the measurements. Status of an experimental study directed at measuring the thermal diffusivity of high-temperature solid samples of pure Nickel and Inconel 718 superalloys are presented. Preliminary measurements showing surface temperature histories are discussed.

Shen, F.↗

Advanced radiator concepts utilizing honeycomb panel heat pipes

The feasibility of fabricating and processing moderate temperature range vapor chamber type heat pipes in a low mass honeycomb panel configuration for highly efficient radiator fins for potential use on the space station was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts were evaluated within constraints dictated by existing manufacturing technology and equipment. Concepts evaluated include type of material, material and panel thickness, wick type and manufacturability, liquid and vapor communication among honeycomb cells, and liquid flow return from condenser to evaporator facesheet areas. A thin-wall all-welded stainless steel design with methanol as the working fluid was the initial prototype unit. It was found that an aluminum panel could not be fabricated in the same manner as a stainless steel panel due to diffusion bonding and resistance welding considerations. Therefore, a formed and welded design was developed. The prototype consists of ten panels welded together into a large panel 122 by 24 by 0.15 in., with a heat rejection capability of 1000 watts and a fin efficiency of essentially 1.0.

Fleischman, G. L.↗

Formation mechanism for the nanoscale amorphous interface in pulse-welded Al/Fe bimetallic systems

Pulse or impact welding traditionally has been referred to as “solid-state” welding. By integrating advanced interface characterizations and diffusion calculations, we report that the nanoscale amorphous interface in the pulse-welded Al/Fe bimetallic system is formed by rapid heating and melting of a thin Al layer at the interface, diffusion of iron atoms in the liquid aluminum, and subsequent rapid quenching with diffused iron atoms in solution. This finding challenges the commonly held belief regarding the solid-state nature of the impact-based welding process for dissimilar metals. Elongated ultra-fine grains with high dislocation density and ultra-fine equiaxed grains also are observed in the weld interface vicinity on the steel and aluminum sides, respectively, which further confirms that melting and the subsequent recrystallization occurred on the aluminum side of the interface.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗