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At least 721 records · Page 40

Characterization of low alloy ferritic steel–Ni base alloy dissimilar metal weld interface by SPM techniques, SEM/EDS, TEM/EDS and SVET

The interface region of welded A508–Alloy 52 M is characterized by scanning probe microscope (SPM) techniques, scanning electron microscopy (SEM)/energy dispersive spectroscopy (EDS), transmission electron microscopy (TEM)/Energy Dispersive Spectroscopy (EDS) and scanning vibrate electrode technique (SVET). The regions along the welded A508–Alloy 52 M interface can be categorized into two types according to their different microstructures. In the type-I interface region, A508 and Alloy 52 M are separated by the fusion boundary, while in the type-II interface region, A508 and Alloy 52 M are separated by a martensite zone. A508, martensite zone and grain boundaries in Alloy 52 M are ferromagnetic while the Alloy 52 M matrix is paramagnetic. The Volta potentials measured by scanning Kelvin probe force microscopy (SKPFM) of A508, martensite zone and Alloy 52 M follow the order: V{sub 52} {sub M} > V{sub A508} > V{sub martensite}. The corrosion behavior of A508–Alloy 52 M interface region is galvanic corrosion, in which Alloy 52 M is cathode while A508 is anode. The martensite dissolves faster than Alloy 52 M, but slower than A508 in the test solution. - Highlights: • The A508–Alloy 52 M interface regions can be categorized into two types. • The chromium depleted region is observed along the Alloy 52 M grain boundary. • The Alloy 52 M grain boundaries which are close to the interface are ferromagnetic. • Martensite zone has lower Volta potential but higher corrosion resistance than A508.

36 MATERIALS SCIENCE↗

Characterization of coarse bainite transformation in low carbon steel during simulated welding thermal cycles

Coarse austenite to bainite transformation in low carbon steel under simulated welding thermal cycles was morphologically and crystallographically characterized by means of optical microscope, transmission electron microscope and electron backscattered diffraction technology. The results showed that the main microstructure changes from a mixture of lath martensite and bainitic ferrite to granular bainite with the increase in cooling time. The width of bainitic laths also increases gradually with the cooling time. For a welding thermal cycle with relatively short cooling time (e.g. t{sub 8/5} is 30 s), the main mode of variant grouping at the scale of individual prior austenite grains changes from Bain grouping to close-packed plane grouping with the progress of phase transformation, which results in inhomogeneous distribution of high angle boundaries. As the cooling time is increased, the Bain grouping of variants becomes predominant mode, which enlarges the effective grain size of product phase. - Highlights: • Main microstructure changes and the width of lath structure increases with cooling time. • Variant grouping changes from Bain zone to close-packed plane grouping with the transformation. • The change of variant grouping results in uneven distribution of high angle grain boundary. • Bain grouping is main mode for large heat input, which lowers the density of high angle boundary.

36 MATERIALS SCIENCE↗

Characterization of yttrium-rich precipitates in a titanium alloy weld

The yttrium-rich (Y-rich) precipitates that form in the fusion zone (FZ) of a Ti–5Al–1Sn–1Zr–1V–0.8Mo (wt.%) alloy, or Ti-5111, gas-tungsten arc welds (GTAW) were characterized. The filler metal was modified by a small concentration of Y in order to refine the microstructure and thus improve the FZ ductility. A high number density of nanoscale Y-rich precipitates were characterized in the weld FZ by atom probe tomography (APT) and scanning transmission electron microscopy (STEM). - Highlights: •A high number density of nanoscale precipitates were observed in the FZ matrix. •The nanoscale precipitates are enriched in yttrium. •Oxygen and sulfur are also present in the Y-rich precipitates and their interfaces.

36 MATERIALS SCIENCE↗

Fabrication, microstructure, and wear performance of WC-Fe composite/metal coating fabricated by resistance seam welding

Highlights: • WC-Fe/metal coating consisted of WC-Fe layer and metal interlayer was fabricated by resistance seam welding. • The microstructure, hardness and wear performance of coatings with different WC particles size were analyzed. • The wear mechanism of coatings showed huge difference following various sliding distance. - Abstract: WC-Fe composite/metal coatings consisting of a WC-Fe composite layer and a metal interlayer were successfully fabricated on an Al 6061 substrate by resistance seam welding. The microstructures and phase compositions of the WC-Fe composite/metal coatings with different WC particle sizes (nano, fine, and coarse) were investigated. The WC-Fe composite layer consisted of WC particles and a Fe-C-Si super hard alloy (SHA) component, whereas the metal interlayer was composed of SHA, FeAl{sub 3}, Fe{sub 2}Al{sub 5}, and Al 6061. The surface microhardness of the WC-Fe composite/metal coating increased with increasing WC particle size. The wear performance of the coatings tested with different sliding distances is discussed in detail. Coating-C (coarse) showed the best wear resistance. The wear rates of both coating-N (nano) and coating-C decreased as the sliding distance increased, while coating-F (fine) demonstrated the opposite behavior. The wear mechanisms of the coatings were drastically different owing to the significantly different WC particle behavior at various sliding distances.

36 MATERIALS SCIENCE↗

Twining and dynamic recrystallization in austenitic Alloy 718 during friction welding

Highlights: • DDRX was the primary grain refinement mechanism in friction welding of Alloy 718. • Two models were developed to explain the twin formation mechanism. • Intragranular twins were caused by grain boundary growth incidents. • Intergranular twin boundaries were ascribed to boundary growth stagnation. - Abstract: Quantitative boundary misorientation analysis verified that discontinuous dynamic recrystallization (DDRX) was the primary grain refinement mechanism in friction welding of Alloy 718. Two models were developed to explain the formation mechanism of intragranular twins and intergranular twins, respectively. Intragranular twins were caused by grain boundary growth incidents. After twin initiation, the twin boundary migrated toward the plastic-deformed grain interior to reduce the stored energy. Additionally, intergranular twin boundaries were ascribed to boundary growth stagnation. When boundary growth stagnation occurred, twin boundaries could form and altered the orientation of the boundary migration front, so that boundary migration could progress, leaving a single twin boundary behind.

36 MATERIALS SCIENCE↗

Influencing mechanism of Al-containing Zn coating on interfacial microstructure and mechanical properties of friction stir spot welded Mg–steel joint

Highlights: • Al-containing Zn coating improved Mg–steel interfacial wettability during friction stir spot welding (FSSW). • Pre-existing Al{sub 5}Fe{sub 2} phase in coating on steel surface promoted Mg–steel metallurgical bonding. • A high tensile-shear load of 4.3 kN was obtained in FSSW AZ31–steel joint. - Abstract: 2.4 mm thick AZ31 Mg alloy sheet and 1.5 mm Q234 steel sheet with a hot-dipped Al-containing Zn coating were friction stir spot welded (FSSW) using a pinless tool. It was shown that the Al-containing Zn coating played a crucial role in joining the Mg alloy and steel during FSSW. The Zn coating observably improved the Mg–steel interfacial wettability during FSSW, and the Al{sub 5}Fe{sub 2} phase in the Zn coating on the steel substrate surface promoted the metallurgical bonding of Mg alloy and steel. It was confirmed that the Al{sub 5}Fe{sub 2} phase on the steel surface resulted from the reaction between the steel substrate and the Al in the Zn coating during hot-dipping, and was not related to the Al-containing Mg alloy substrate. The tensile-shear load of the FSSW Mg–steel joint reached 4.3 kN. The fracture of the joint occurred along the interface on the steel substrate side. The interface between the Al{sub 5}Fe{sub 2} layer and Mg alloy substrate was the weakest region of the Mg–steel joint.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Multi-scale mechanical modeling of Al-steel resistance spot welds

A multi-scale finite element modeling approach was developed to study the deformation and fracture behavior of Al-steel resistance spot welds. First, a micro-scale model was applied to simulate the mechanical responses of the intermetallic compound (IMC) layer having various morphologies and thicknesses under tensile and shear loading conditions. Second, the predicted tensile and shear strength of the IMC layer, that varied along the joint interface per the IMC layer morphology and thickness variation, was then introduced into 3D macro-scale models to predict the overall mechanical performance of weld coupons under coach peel, lap shear and cross-tension testing conditions. In conclusion, the numerical predictions agreed reasonably well with the experimental data.

36 MATERIALS SCIENCE↗

Laser weld-induced formation of amorphous Mn–Si precipitate in 304 stainless steel

In this paper, we report the formation of partially amorphous Mn-Si precipitates due to laser welding of face centered cubic (fcc) 304 stainless steel. Transmission electron microscopy and precession electron diffraction studies in the heat affected zone (HAZ) of the weldment indicate the formation of these precipitates in grain interiors. Precipitates have MnSi stoichiometry and the partially crystalline regions have a lattice constant of 0.45 nm. It is surmised that the rapid cooling rates during the laser weld melt pool solidification process may be sufficient to inhibit the complete crystallization of these precipitates.

304 stainless steel↗

New requirements for digital radiographic testing of welds according to ISO standards

Users of EN 14784-2 (general principles for computed radiography with phosphor imaging plates) reported about difficulties to achieve testing class B in weld testing with imaging plates. One of the reasons is the insufficient consideration of the inherent detector unsharpness (u{sub i}) in the minimum requirements. Digital detectors have a higher inherent unsharpness compared to film, which can even exceed the geometrical unsharpness (u{sub g}) of the typical contact technique. In EN 444 and ISO 5579 (general principles for film radiography) u{sub i} is neglected for the calculation of the minimum source-to-object distance (SOD), because it is small compared to the geometric unsharpness (u{sub g}). Considering u{sub i} for digital detectors results in a new equation for SOD (see ISO/FDIS 17636-2). Therefore, the increase in total image unsharpness requires the compensation by a larger SOD to reduce u{sub g}. This contribution discusses the need for change of the SOD for different setups (detectors, focal spots, etc.) and explains the difference in image quality, achieved on basis of the extended equation of ISO/FDIS 17636-2. Furthermore, the detection of image quality indicators depends on the achieved Contrast-to-Noise ratio (CNR) and total image unsharpness. Both of them are essential parameters, which influence the contrast sensitivity. Additionally, new compensation principles (e.g. compensation of missing spatial resolution by enhanced contrast sensitivity) allow to widen the application range of digital detectors for radiographic weld testing.

42 ENGINEERING↗

Plasma effect on weld pool surface reconstruction by shape-from-polarization analysis

The polarimetric state of the thermal radiations emitted by the weld metal contains geometric information about the emitting surface. Even though the analysed thermal radiation has a wavelength corresponding to a blind spectral window of the arc plasma, the physical presence of the arc plasma itself interferes with the rays radiated by the weld pool surface before attaining the polarimeter, thus modifying the geometric information transported by the ray. In the present work, the effect of the arc plasma-surrounding zone on the polarimetric state and propagation direction of the radiated ray is analyzed. The interaction with the arc plasma zone induces a drop in ray intensity and a refraction of ray optical path.

36 MATERIALS SCIENCE↗

Numerical model of the plasma formation at electron beam welding

The model of plasma formation in the keyhole in liquid metal as well as above the electron beam welding zone is described. The model is based on solution of two equations for the density of electrons and the mean electron energy. The mass transfer of heavy plasma particles (neutral atoms, excited atoms, and ions) is taken into account in the analysis by the diffusion equation for a multicomponent mixture. The electrostatic field is calculated using the Poisson equation. Thermionic electron emission is calculated for the keyhole wall. The ionization intensity of the vapors due to beam electrons and high-energy secondary and backscattered electrons is calibrated using the plasma parameters when there is no polarized collector electrode above the welding zone. The calculated data are in good agreement with experimental data. Results for the plasma parameters for excitation of a non-independent discharge are given. It is shown that there is a need to take into account the effect of a strong electric field near the keyhole walls on electron emission (the Schottky effect) in the calculation of the current for a non-independent discharge (hot cathode gas discharge). The calculated electron drift velocities are much bigger than the velocity at which current instabilities arise. This confirms the hypothesis for ion-acoustic instabilities, observed experimentally in previous research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Experimental study of cyclic creep and high-cycle fatigue of welded joints of St3 steel by the DIC technique

In the paper the mechanisms of plastic deformation and fracture of welded joints of steel St3 were investigated at high-cycle fatigue and cyclic creep by the digital image correlation (DIC) technique. The evolution of strain rate is studied for the following regions: base metal, HAZ, and fusion zone. This strain rate evolution can be considered as a mechanical response of material. Three stages of deformation evolution are shown: deformation hardening (I), fatigue crack initiation (II), and the last stage is related to main crack (III). Two criteria are offered to evaluate the current mechanical state of welded joints.

36 MATERIALS SCIENCE↗

Strain and distortion monitoring during arc welding by 3D digital image correlation

A novel three-dimensional (3D) digital image correlation (DIC) approach using a stereovision system was developed to measure the evolution of strain and distortion near the fusion zone during the gas tungsten arc welding process. Unlike the previously reported two-dimensional (2D) DIC approach using a single camera, the 3D DIC method was immune to the out-of-plane displacement and was capable of measuring 3D deformation. Both 2D and 3D DIC approaches in welding applications were based on the utilisation of the novel high-temperature speckle and the pulsed laser illumination plus bandpass filters. However, the speckle pattern was partially specular reflective causing issues in subset matching in the 3D approach. A new algorithm and experimental procedure was incorporated to solve this problem.

47 OTHER INSTRUMENTATION↗

Stability of Y–Ti–O precipitates in friction stir welded nanostructured ferritic alloys

Nanostructured ferritic alloys, which have complex microstructures which consist of ultrafine ferritic grains with a dispersion of stable oxide particles and nanoclusters, are promising materials for fuel cladding and structural applications in the next generation nuclear reactor. This paper evaluates microstructure of friction stir welded nanostructured ferritic alloys using electron microscopy and atom probe tomography techniques. Atom probe tomography results revealed that nanoclusters are coarsened and inhomogeneously distributed in the stir zone and thermomechanically affected zone. Three hypotheses on coarsening of nanoclusters are presented. Finally, the hardness difference in different regions of friction stir weld has been explained.

36 MATERIALS SCIENCE↗

CHARACTERIZATION OF Pro-Beam LOW VOLTAGE ELECTRON BEAM WELDING MACHINE

The purpose of this paper is to present and discuss data related to the performance of a newly acquired low voltage electron beam welding machine. The machine was made by Pro-Beam AG &Co. KGaA of Germany. This machine was recently installed at LANL in building SM -39; a companion machine was installed in the production facility. The PB machine is substantially different than the EBW machines typically used at LANL and therefore, it is important to understand its characteristics as well as possible. Our basic purpose in this paper is to present basic machine performance data and to compare those with similar results from the existing EBW machines. It is hoped that this data will provide a historical record of this machine’s characteristics as well as possibly being helpful for transferring welding processes from the old EBW machines to the PB machine or comparable machines that may be purchased in the future.

Electron Beam Welding, Electron Beam Measurement↗

Phased Array Ultrasonic Examination of Reactor Coolant System (Carbon Steel-to-CASS) Dissimilar Metal Weld Mockup Specimen

In the summer of 2009, Pacific Northwest National Laboratory (PNNL) staff traveled to the Electric Power Research Institute (EPRI) NDE Center in Charlotte, North Carolina, to conduct phased-array ultrasonic testing on a large bore, reactor coolant pump nozzle-to-safe-end mockup. This mockup was fabricated by FlawTech, Inc. and the configuration originated from the Port St. Lucie nuclear power plant. These plants are Combustion Engineering-designed reactors. This mockup consists of a carbon steel elbow with stainless steel cladding joined to a cast austenitic stainless steel (CASS) safe-end with a dissimilar metal weld and is owned by Florida Power & Light. The objective of this study, and the data acquisition exercise held at the EPRI NDE Center, were focused on evaluating the capabilities of advanced, low-frequency phased-array ultrasonic testing (PA-UT) examination techniques for detection and characterization of implanted circumferential flaws and machined reflectors in a thick-section CASS dissimilar metal weld component. This work was limited to PA-UT assessments using 500 kHz and 800 kHz probes on circumferential flaws only, and evaluated detection and characterization of these flaws and machined reflectors from the CASS safe-end side only. All data were obtained using spatially encoded, manual scanning techniques. The effects of such factors as line-scan versus raster-scan examination approaches were evaluated, and PA-UT detection and characterization performance as a function of inspection frequency/wavelength, were also assessed. A comparative assessment of the data is provided, using length-sizing root-mean-square-error and position/localization results (flaw start/stop information) as the key criteria for flaw characterization performance. In addition, flaw signal-to-noise ratio was identified as the key criterion for detection performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of Novel Functionally Graded Transition Joints for Improving the Creep Strength of Dissimilar Metal Welds in Nuclear Applications

Steam generators of the small modular Very High Temperature Reactor (VHTR) will require use of Alloy 800 and 2.25Cr-1Mo steel in different regions depending on temperature and corrosion resistance requirements. As a result, Dissimilar Metal Welds (DMWs) between these two materials are critical for design, development, and manufacturing of the VHTR. DMWs are also used in many other applications in the power generation and petrochemical industries. Experience has demonstrated that failures of such DMWs can occur prematurely well below the expected creep life of either base metal, and these failures have significant consequences in terms of plant reliability, safety, and economic impact. These DMWs failures are caused by the abrupt change in composition that occurs at the weld interface between the two alloys. In this research, the concept of developing and optimizing Graded Transition Joints (GTJ) was developed through an integrated modeling and experimental approach. With GTJs, the composition is gradually graded between the two alloys, thus eliminating the sharp change in composition that causes failure. Microstructural modeling was first conducted to identify the optimum grade length required for improved resistance to carbon diffusion that is largely responsible for premature failure. Next, GTJs were fabricated and characterized in detail to understand how the microstructure evolves during fabrication and long term aging. Finally, the creep behavior of the GTJs was investigated and compared to that of conventional DMWs to demonstrate the superior creep strength of the GTJs. The results of this research provide significant insight into design, fabrication, microstructural evolution, and resultant performance of GTJs that can be used for reducing or eliminating DMW failures in a number of high temperature applications. The results also demonstrate that the GTJs can be readily fabricated with either conventional or additive manufacturing processes, and detailed guidelines are provided on the length of grades needed for optimal performance. The results of this research benefits the general public by improving the reliability of power generation and petrochemical plants that rely on DMWs for safe and reliable operation to deliver power and other products.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Rotary Table Design for the Modular In-Chamber Electron Beam Welding System

The Modular In-Chamber Electron Beam Welding (MIC-EBW) system which is being designed and assembled under DOE Projects DE-NE0008846 (Phase 1--completed) and DE-NE0009039 (Phase 2—in progress) includes several major components: four modules (the lower vacuum module, electron beam module, a spacer module, and a lid), a robust rotary table, large vacuum pumps/system, electron beam welding system controls/power supply, and an electron beam generator/gun. Many of these components and their functions were described in the earlier EPRI-DOE report 3002018146. This report provides an overview of one of the primary components, the rotary table, that has been designed and will be manufactured by Rusach International in Phase 2 of the project.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗