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Laser welding is shown to be preferable to traditional soldering in the assembly of nonferrous and mineral components. Welding conditions that prevent cracking of minerals are presented.
Algorithms for current stabilization in the control of contact welding are considered. The proposed method for specifying and maintaining the welding current permits correction of the thyristor firing angle by means of an approximate formula taking account of the measured current-pulse parameters in phase regulation. The proposed method simplifies the equipment and increases the efficiency of regulation.
Ultrasonic metal welding (UMW) is a solid-state joining technique with varied industrial applications. Despite of its numerous advantages, UMW has a relative narrow operating window and is sensitive to variations in process conditions. As such, it is imperative to quantitatively characterize the influence of welding parameters on the resulting joint quality. The quantification model can be subsequently used to optimize the parameters. Conventional response surface methodology (RSM) usually employs linear or polynomial models, which may not be able to capture the intricate, nonlinear input-output relationships in UMW. Furthermore, some UMW applications call for simultaneous optimization of multiple quality indices such as peel strength, shear strength, electrical conductivity, and thermal conductivity. To address these challenges, this paper develops a machine learning (ML)-based RSM to model the input-output relationships in UMW and jointly optimize two quality indices, namely, peel and shear strengths. The performance of various ML methods including spline regression, Gaussian process regression (GPR), support vector regression (SVR), and conventional polynomial regression models with different orders is compared. A case study using experimental data shows that GPR with radial basis function (RBF) kernel and SVR with RBF kernel achieve the best prediction accuracy. The obtained response surface models are then used to optimize a compound joint strength indicator that is defined as the average of normalized shear and peel strengths. In addition, the case study reveals different patterns in the response surfaces of shear and peel strengths, which has not been systematically studied in the literature. While developed for the UMW application, the method can be extended to other manufacturing processes.
A full range of stress intensity factor solutions for a kinked crack with finite length is developed as a function of weld width and the sheet thickness. When used with the main crack solutions (global stress intensity factors) in terms of the applied load and the specimen geometric parameters, the fatigue lived of the kinked crack can be estimated for the laser-welded lap-shear specimens. The predicted curve for the load range-fatigue life passes through the cluster of experimental data and is in good agreement. A classical solution associated with an infinitesimal kink is also employed. Furthermore, its life prediction tends to overestimate the actual fatigue life. In addition, the traditional fatigue life estimation based on structural stress is performed for completeness. As a result, this non-fracture mechanics approach only agrees well with the experimental data under high cyclic load conditions.
The Waste Package Closure System (WPCS), for the closure of radioactive waste in canisters for permanent storage of spent nuclear fuel (SNF) and high-level waste in the Yucca Mountain Repository was designed, fabricated, and successfully demonstrated at the Idaho National Laboratory (INL). This article focuses on the robotic hardware and tools necessary to remotely weld and inspect the closure lid welds. The system was operated remotely and designed for use in a radiation field, due to the SNF contained in the waste packages being closed.
A full range of stress intensity factor solutions for a kinked crack is developed as a function of weld width and the sheet thickness. When used with the associated main crack solutions (global stress intensity factors) in terms of the applied load and specimen geometry, the fatigue lives can be estimated for the laser-welded lap-shear specimens. The estimations are in good agreement with the experimental data. A classical solution for an infinitesimal kink is also employed in the approach. However, the life predictions tend to overestimate the actual fatigue lives. The traditional life estimations with the structural stress along with the experimental stress-fatigue life data (S-N curve) are also provided. In this case, the estimations only agree with the experimental data under higher load conditions.
The U.S. Nuclear Regulatory Commission has established the Program to Assess the Reliability of Emerging Nondestructive Techniques (PARENT) as a follow-on to the international cooperative Program for the Inspection of Nickel Alloy Components (PINC). The goal of PINC was to evaluate the capabilities of various nondestructive evaluation (NDE) techniques to detect and characterize surface-breaking primary water stress corrosion cracks in dissimilar-metal welds (DMW) in bottom-mounted instrumentation (BMI) penetrations and small-bore (≈400-mm diameter) piping components. A series of international blind round-robin tests were conducted by commercial and university inspection teams. Results from these tests showed that a combination of conventional and phased-array ultrasound techniques provided the highest performance for flaw detection and depth sizing in dissimilar metal piping welds. The effective detection of flaws in BMIs by eddy current and ultrasound shows that it may be possible to reliably inspect these components in the field. The goal of PARENT is to continue the work begun in PINC and apply the lessons learned to a series of open and blind international round-robin tests that will be conducted on a new set of piping components including large-bore (≈900-mm diameter) DMWs, small-bore DMWs, and BMIs. Open round-robin testing will engage universities and industry worldwide to investigate the reliability of emerging NDE techniques to detect and accurately size flaws having a wide range of lengths, depths, orientations, and locations. Blind round-robin testing will invite testing organizations worldwide, whose inspectors and procedures are certified by the standards for the nuclear industry in their respective countries, to investigate the ability of established NDE techniques to detect and size flaws whose characteristics range from easy to very difficult to detect and size. This paper presents highlights of PINC and reports on the plans and progress for PARENT round-robin tests.
During the 4th Quarter of FY18, work on this project focused on determination of the growth behavior of gamma prime precipitates with the intent of determining the growth rate constant as a function of temperature. The derived constitutive equation will be incorporated into the modeling and simulation effort for creep behavior of thick section welds in Alloy 740H for fossil energy power generation applications. Additionally, progress has been made on representing the weld and base metal microstructure using Dream3D which will be used by the modeling and simulation effort to incorporate microstructural effects into the creep behavior.
This project explored the use of femtosecond laser welding to form strong, hermetic seals for glass/glass modules. The results showed that glass/glass fs laser welds, when coupled to a new module design, are strong enough to enable a polymer-free module, potentially extending warrantees and forming an easily-recycled product.
This study investigated the microstructural characteristics, mechanical response, and corrosion resistance of Alloy 617 diffusion welded by electric field-assisted sintering (EFAS). The microstructure exhibited good grain boundary (GB) migration across the interface and flat interface in the samples bonded at different conditions. Graded grain size was observed, with grain coarsening being more significant near sample surface due to EFAS-induced temperature gradient. Tensile testing revealed that the specimens fractured in the matrix away from the interface. The peak strength of 807 MPa was obtained in the samples welded at 1000°C. The materials obtained at 1100°C exhibited reduced tensile strength but improved ductility. Strain maps revealed by digital image correlation showed the flat interfaces were less ductile compared to the matrix. The hardness reduced near sample surfaces due to enlarged grains induced by temperature gradient. The interfaces with GB migration exhibited improved corrosion resistance in molten salt compared to the flat interfaces.
Numerous studies have primarily focused on the corrosion mechanism of zirconium alloy base metal. However, the corrosion resistance of weld beads or seams is of vital importance in the degradation of structural components in the reactor. In the present work, the corrosion resistance of the fusion zone and base metal of laser welded zirconium alloy joints was comparatively investigated. The microstructure morphologies, phase structures and strain fields of oxide films formed on fusion zone and base metal were observed and analyzed. The oxide thickness of the fusion zone was thicker than that of the base metal with prolonged corrosion. Compared to the base metal, the lower density of dislocations and level of strain values in the oxide film of the fusion zone indicated that the stress in the oxide film was lower. The phase transition from the tetragonal ZrO{sub 2} to the monoclinic ZrO{sub 2} could be suppressed due to the high level of stress, resulting in the better corrosion resistance of the base metal. Moreover, the second phase particles and non-βZr phase in the base metal contributed to the better corrosion resistance.
A manufacturing and single-cell fuel cell performance study of stamped, laser welded, and gas nitrided ferritic stainless steel foils in an advanced automotive bipolar plate assembly design was performed. Two developmental foil compositions were studied: Fee20Cre4V and Fee23Cre4V wt.%. Foils 0.1 mm thick were stamped and then laser welded together to create single bipolar plate assemblies with cooling channels. The plates were then surface treated by pre-oxidation and nitridation in N2e4H2 based gas mixtures using either a conventional furnace or a short-cycle quartz lamp infrared heating system. Single-cell fuel cell testing was performed at 80 C for 500 h at 0.3 A/cm2 using 100% humidification and a 100%/40% humidification cycle that stresses the membrane and enhances release of the fluoride ion and promotes a more corrosive environment for the bipolar plates. Periodic high frequency resistance potential-current scans during the 500 h fuel cell test and posttest analysis of the membrane indicated no resistance increase of the plates and only trace levels of metal ion contamination.
In this work, deformation mechanism of a laser weld on neutron irradiated AISI 304L stainless steel was studied by in-situ microcompression test at room temperature. The deformation-induced austenite-to-martensite phase transformation occurs in {101}-oriented grains in the irradiated base metal, while deformation twinning prevails in {101}-oriented grains in the weld heat affected zone (HAZ). A high number density of irradiation-induced voids in the base metal provide sufficient nucleation sites for the austenite-to-martensite phase transformation under compression at room temperature. A deformation map is established to predict critical twinning stress for face-centered cubic (fcc) metals and alloys. Our study suggests that irradiation can tailor the deformation-induced phase transformation in austenitic stainless steels.
Friction stir welding and processing (FSW&P) is considered as a new fabrication method for canisters and repair of existing dry cask storage system canisters (generally made of austenitic stainless steel). Low heat input compared to fusion joining processes and grain refinement associated with low-temperature FSW&P result in a material with improved mechanical properties and equivalent generalized corrosion performance relative to the base metal. But FSW&P of austenitic stainless steel requires significant tool forge axis force to produce a weld (or a run). Exploratory runs utilizing forge axis force control were conducted to investigate the minimum force required to achieve defect-free runs. The correlation between forge axis force and resultant plunge depth was also investigated. Furthermore, detailed microstructural characterization was conducted to display the microstructural variation within the nugget zone.
Assembly of dissimilar metals can be achieved by different methods, for example, casting, welding, and additive manufacturing (AM). However, undesired phases formed in liquid-phase assembling processes due to solute segregation during solidification diminish mechanical and other properties of the processed parts. In the present work, an open-source software named MaterialsMap, has been developed based on the CALculation of Phase Diagrams (CALPHAD) approach. The primary objective of MaterialsMap is to facilitate the design of an optimal composition pathway for assembling dissimilar alloys with liquid-phases based on the formation of desired and undesired phases along the pathway. In MaterialsMap, equilibrium thermodynamic calculations are used to predict equilibrium phases formed at slow cooling rate, while Scheil-Gulliver simulations are employed to predict non-equilibrium phases formed during rapid cooling. Additionally, by combining these two simulations, MaterialsMap offers a thorough guide for understanding phase formation in various manufacturing processes, assisting users in making informed decisions during material selection and production. As a demonstration of this approach, a compositional pathway was designed from pure Al to pure Cu through Ag using MaterialsMap. The design was experimentally verified using resistance spot welding (RSW).
Welding fume inhalation causes pulmonary toxicity, including susceptibility to infection. We hypothesized that airway epithelial ion transport is a target of fume toxicity, and investigated the effects of fume particulates from manual metal arc-stainless steel (MMA-SS) and gas metal arc-mild steel (GMA-MS) on ion transport in normal human bronchial epithelium (NHBE) cultured in air-interface. MMA-SS particles, more soluble than GMA-MS particles, contain Cr, Ni, Fe and Mn; GMA-MS particles contain Fe and Mn. MMA-SS or GMA-MS particles (0.0167–166.7 μg/cm{sup 2}) were applied apically to NHBEs. After 18 h transepithelial potential difference (V{sub t}), resistance (R{sub t}), and short circuit current (I{sub sc}) were measured. Particle effects on Na{sup +} and Cl¯ channels and the Na{sup +},K{sup +},2Cl¯-cotransporter were evaluated using amiloride (apical), 5-nitro-2-[(3-phenylpropyl)amino]benzoic acid (NPPB, apical), and bumetanide (basolateral), respectively. MMA-SS (0.0167–16.7 μg/cm{sup 2}) increased basal V{sub t}. Only 16.7 μg/cm{sup 2} GMA-MS increased basal V{sub t} significantly. MMA-SS or GMA-MS exposure potentiated I{sub sc} responses (decreases) to amiloride and bumetanide, while not affecting those to NPPB, GMA-MS to a lesser degree than MMA-SS. Variable effects on R{sub t} were observed in response to amiloride, and bumetanide. Generally, MMA-SS was more potent in altering responses to amiloride and bumetanide than GMA-MS. Hyperpolarization occurred in the absence of LDH release, but decreases in V{sub t}, R{sub t}, and I{sub sc} at higher fume particulate doses accompanied LDH release, to a greater extent for MMA-SS. Thus, Na{sup +} transport and Na{sup +},K{sup +},2Cl¯-cotransport are affected by fume exposure; MMA-MS is more potent than GMA-MS. Enhanced Na{sup +} absorption and decreased airway surface liquid could compromise defenses against infection. - Highlights: • Welding fume particle toxicity was investigated in human bronchial epithelial cells. • MMA-SS fume particles and GMA-MS particles were compared. • Both fumes activated epithelial Na{sup +} channels, MMA-SS more potent than GMA-SS. • MMA-SS is more cytotoxic than GMA-SS with regard to LDH release. • Observed changes may help explain susceptibility to infection in workers.
Under tensile shear loading, fracture modes of dissimilar lap welds produced by friction stir scribe technology were studied. Three fracture modes were observed. For zone A fracture, the initial crack was restrained, and the joint ultimately fractured in the base mild steel. For zone B fracture, the initial crack progressed through the aluminium sheet just above the Al/steel interface. For zone C fracture, the initial crack proceeded along the steel hook to the aluminium sheet surface. Fracture mode and joint strength were greatly influenced by steel hook size, and the steel hook size was affected by welding parameters and tool scribe height. In this study, the experimental joint strength achieved the calculated joint load limit.
The goal of next generation reactors is to increase energy ef?ciency in the production of electricity and provide high-temperature heat for industrial processes. The ef?cient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for ef?ciency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more ef?cient industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required ?ow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design speci?cations for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.