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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Microstructure and mechanical performance of welded joint between a novel heat-resistant steel and Inconel 617 weld metal

Highlights: • MGBs were suspected as the DDC crack source during high-temperature tensile test. • Microhardness variations in different passes of joint denote grain refinement effect induced by the multi-pass welds. • After tensile test, changes in microhardness can be attributed to the extent of deformation and amount of precipitation. - Abstract: In the present study, the microstructure and mechanical performance of a tungsten inert gas welded joint between a novel heat-resistant austenitic steel and Inconel 617 weld metal were examined. Migrated grain boundaries were discovered more frequently in the lower portion of the weld metal that solidifies in austenite type. Ti-rich precipitates were observed in weld metal and Cr-rich and Nb-rich precipitates were observed in base metal. The fusion boundary area had the lowest impact toughness due to the large non-homogeneity of the microstructure. Microhardness profiles of the joint were obtained and the backing passes were found to produce the highest microhardness values, which was caused by the grain refinement effect. Ductile failure with slipping separation occurred in those joints ruptured after tensile tests at both room temperature and 923 K. In addition, multiscale precipitates in the joint after high-temperature tensile tests were inspected, where it was found that nanoscale particles contributed to the high-temperature resistance of the joint. Furthermore, microhardness changes in the joint after tensile tests were analysed according to the precipitation and strain-hardening mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

4140 low-alloy steel↗
DOE OSTI2018

Influence of Cu/Li Ratio on the Welding Forces and Mechanical Properties of Two Bobbin Tool Friction Stir Welded Al-Cu-Li Alloys

Increasing space activities produce a high number of space objects and lead to increasing collision risks which urges leading industries to look for future removal strategies. Material substitution in order to raise demisability during atmospheric reentry is a possible solution. Modern aluminum lithium alloys are under consideration to replace high-temperature melting materials like titanium. Further, friction stir welding was proposed as suitable joining technology in order to avoid high heat inputs during manufacturing. In this work, two modern Al-Li-Cu alloys, AA 2060 and AA 2196, in peak-aged temper were welded using the stationary shoulder variant of bobbin tool friction stir welding. Identical process parameters led to defect-free welds in both alloys. The macrostructural and microstructural features are shown and analyzed. The welds were mechanically tested to an efficiency of 78 and 70% of the base metal ultimate tensile strength for AA 2060 T8 and AA 2196 T8, respectively. The process forces as well as the thermal cycle experienced by the workpiece material were used to explain the mechanical performance. The difference in composition regarding the Cu/Li ratio of the alloys was taken into account when the mechanical properties were correlated with the thermally affected microstructure of the weldments.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Numerical investigation of electromagnetic pulse welded interfaces between dissimilar metals

The quality of an electromagnetic pulse weld is strongly affected by a variety of interacting physical phenomena including large plastic deformation, materials mixing, localised heating and rapid cooling, and possible localised melting and interfacial cracks and void. In the present study, a thermomechanically coupled dynamic model has been developed to quantitatively resolve the high speed impact joining interface characteristics as well as the process induced interface temperature evolution, defect formation and possible microstructural composition variations. Reasonably good agreement has been obtained between the predicted results and the experimental measurements in terms of interfacial morphology characteristics. The modelling framework is expected to provide further understanding of the hierarchical interfacial features of the non-equilibrium material joining process and the weld formation mechanisms.

Xu, W.↗
DOE OSTI2018

Influence of Welding Combined Plastic Forming on Microstructure Stability and Mechanical Properties of Friction Stir-Welded Al-Cu Alloy

A new tailor-welded process, which combines stages of welding, plastic forming, and heat treatment strengthening, was developed to produce a friction stir-welded (FSW) Al-alloy joint. The Al-Cu sheets were FSW under different welding parameters and then were plastic-deformed. The microstructural evolution and mechanical properties of the FSW joint were investigated by scanning electron microscopy and tensile tests. It was found that high heat input during FSW and low solution temperature suppress the abnormal grain growth (AGG) of the joint due to the differential in grain size and grain boundary energy. The microstructure heterogeneity of the FSW joint is effectively improved, as no AGG occurs. The retention of fine equiaxed grains and the increase in the density of precipitates result in excellent mechanical properties. The increase in the strength and micro-hardness of the joint mainly depends on the plastic deformation prior to aging treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Evolution of weld metal microstructure in shielded metal arc welding of X70 HSLA steel with cellulosic electrodes: A case study

The microstructure of weld joint in X70 line pipe steel resulted from shielded metal arc welding with E6010 cellulosic electrodes is characterized using optical and electron microscopy. A range of ferritic morphologies have been identified ranging from polygonal inter- and intra-prior austenite grains allotriomorphic, idiomorphic ferrites to Widmanstätten, acicular and bainitic ferrites. Electron Backscatter Diffraction (EBSD) analysis using Image Quality (IQ) and Inverse Pole Figure (IPF) maps through superimposition of IQ and IPF maps and measurement of percentages of high and low angle grain boundaries was identified to assist in differentiation of acicular ferrite from Widmanstätten and bainitic ferrite morphologies. In addition two types of pearlitic structures were identified. There was no martensite detected in this weld structure. The morphology, size and chemistry of non-metallic inclusions are also discussed briefly. - Highlights: • Application of EBSD reveals orientation relationships in a range of phases for shielded metal arc welding of HSLA steel. • Nucleation sites of various ferrite morphologies identified • Formation of upper and lower bainite and their morphologies.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Multi-scale and multi-technic microstructure analysis of a linear friction weld of the metastable-β titanium alloy Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti17) towards a new Post-Weld Heat Treatment

Highlights: • Soft joint showing sharp macro-zones and marked by asymmetrical process effects • Gradient of thermomechanical loads identified through progressive stages of transformation • Highly textured recrystallized β grains at the joint core with distorted β lattice • Lattices, phase fractions, microstructures and hardness homogenized after heat treatment - Abstract: Linear Friction Welding (LFW) is a solid-state joining process producing narrow joints mainly developed for the aircraft industry. The Thermo-Mechanical Processing (TMP) loads imposed on the material cause complex microstructure transformations. This study aimed at characterizing the local microstructures and crystallographic configurations to identify the mechanisms impacting the stability and the mechanical properties of a Ti17 LFW joint with the objective of establishing an innovative homogenizing Post-Weld Heat Treatment (PWHT). The process caused a narrow zone of ±2 mm from the friction interface to reach the isothermal α → β transformation temperature under a heating rate of 500 K/s followed by quenching (−100 K/s). The TMP resulted in the formation a ±3 mm wide soft Process Affected Zone (PAZ) delimited by three characteristic zones: the Welding Line (WL width ≈ 400 μm), The Thermo-Mechanically Affected Zone (TMAZ width ≈ 1 mm) and the Heat Affected Zone (HAZ). β TMP resulted in the total dissolution of the α phase in the joint core (WL + TMAZ) and formed strongly textured {110}<111> β recrystallized grains in the WL by continuous dynamic recrystallization of squeezed prior-β grains in the TMAZ. α + β TMP led to a gradual loss of hardness in the HAZ whose microstructure is similar to the one of the base material (BM) but is subject to gradual α laths dissolution due to the local temperatures experienced during LFW. A PWHT consisting in a β annealing followed by an α + β ageing resulted in a uniformly hardened weld with a homogenized Widmanstätten microstructure in the whole assembly.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Investigation and Numerical Study on the Elimination of Porosity in Aluminum Alloy Laser Welding and Laser–GMA Welding

Keyhole-induced porosity can strongly weaken the joint strength during aluminum alloy laser welding. Two factors are proposed to be responsible for the porosity formation: bubble formation caused by the instability of the keyhole and bubble captured by the solidification interface. Based on numerical and experimental results, the porosity is suppressed with preheating, due to the capillary stability of the keyhole and easy escape of bubble. N{sub 2} shielding gas has a minor effect on keyhole stability, but it reduces the porosity number as N{sub 2} bubble can dissolve into the liquid aluminum alloy melt pool quickly. The laser–gas metal arc (laser–GMA) welding process can stabilize the metallic plume and enlarge the weld pool. As a result, few spatters and bubbles are formed, and bubbles are easily escaped, both of which contribute to the suppression of porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The Simulation of Precipitation Evolutions and Mechanical Properties in Friction Stir Welding with Post-Weld Heat Treatments

A finite element model of friction stir welding capable of re-meshing is used to simulate the temperature variations. Re-meshing of the finite element model is used to maintain a fine mesh resolving the gradients of the solution. The Kampmann–Wagner numerical model for precipitation is then used to study the relation between friction stir welds with post-weld heat treatment (PWHT) and the changes in mechanical properties. Results indicate that the PWHT holding time and PWHT holding temperature need to be optimally designed to obtain FSW with better mechanical properties. Higher precipitate number with lower precipitate sizes gives higher strength in the stirring zone after PWHT. The coarsening of precipitates in HAZ are the main reason to hinder the improvement of mechanical property when PWHT is used.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Assessing Gaseous Hydrogen Assisted Fatigue Crack Growth Susceptibility of Pipeline Steel Weld Fusion Zones and Heat Affected Zones

The objective of this work was twofold: (1) measure reliable fatigue crack growth relationships for X65 steel and its girth weld in high-pressure hydrogen gas to enable structural integrity assessments of hydrogen pipelines, and (2) evaluate the hydrogen accelerated fatigue crack growth susceptibility of the weld fusion zone and heat-affected zone relative to the base metal. Fatigue crack growth relationships (da/dN versus ΔK) were measured for girth welded X65 pipeline steel in high pressure hydrogen gas (21 MPa) and in air. Hydrogen assisted fatigue crack growth was observed for the base metal (BM), fusion zone (FZ), and heat-affected zone (HAZ), and was manifested through crack growth rates reaching nearly an order of magnitude acceleration over rates in air. Addditionally, at higher ΔK values, crack growth rates of BM, FZ, and HAZ were coincident; however, at lower ΔK, the fatigue crack growth relationships exhibited some divergence with the fusion zone having the highest crack growth rates. These relative fatigue crack growth rates in the BM, FZ, and HAZ were provisional, however, since both crack closure and residual stress contributed to the crack-tip driving force in specimens extracted from the HAZ. Despite the relatively high applied R-ratio (R = 0.5), crack closure was detected in the heat affected zone tests, in contrast to the absence of crack closure in the base metal tests. Crack closure corrections were performed using the adjusted compliance ratio method and the effect of residual stress on K max was determined by the crack-compliance method. Crack-tip driving forces that account for closure and residual stress effects were quantified as a weighted function of ΔK and K max (i.e., K norm ), and the resulting da/dN versus K norm relationships showed that the HAZ exhibited higher hydrogen accelerated fatigue crack growth rates than the BM at lower K norm values.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Through-Thickness Friction Stir Processing Parameters on Weld Repair and Modification of Fusion-Welded AA6061 Aluminum Alloy

Through-thickness friction stir processing was successfully carried out for microstructure modification and elimination of fusion defects of the gas metal arc welds by applying the process on as-welded joints. Variation in rotational speed from 750 to 1050 rpm and traveling speed from 50 to 200 mm/min resulted in minor changes (approximately 1 µm) in the grain size of nugget zone, while this variation in elongation result was up to 40%. The hardness profile, the width of softening zone, minimum hardness and fracture location also changed for different processing conditions. Furthermore, the defects were vanished efficiently across the welds profile by this method. The results also verified the geometric dynamic recrystallization phenomena as a dominant mechanism of microstructural modification.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Report on FY 2020 Welding Parameters Optimization and the Fabrication of Qualified Alloy 709 Welds

Alloy 709 is an attractive candidate construction material for the Sodium Fast Reactor (SFR). As part of the Alloy 709 Intermediate Term Test Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. The phase of research reported herein focused on the issue of weld solidification cracking recently experienced in both experimental heats and a commercial heat of Alloy 709 with relatively high phosphorous levels.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Understanding Weld Formation and Microstructure Evolution in Laser Welded Stainless Steels and Ti-6Al-4V

High energy density welding processes are used for many industrial applications, such as aerospace and defense, and certain joint configurations and welding situations render post-weld inspection techniques difficult. Due to the inability to confirm penetration, there is a continual industrial need to improve prediction capabilities to aid in parameter selection. It is also necessary to understand the microstructural evolution to modify phase fractions and mitigate weldability related concerns such as solidification cracking or reduced corrosion performance.

42 ENGINEERING↗
DOE OSTI2013

Certification of a weld produced by friction stir welding

Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Dissolution of Nb(C,N) During Post-weld Heat-Treatment of Electric Resistance Welded X70 Line Pipe

The effect of peak temperature for post-weld heat treatment (PWHT) on the dissolution of Nb-rich carbonitrides, Nb(C,N), in the weldline of an electric resistance welded (ERW) X70 grade pipeline steel was investigated. Selected-area electron diffraction patterns and corresponding electron energy loss spectroscopy mappings revealed both Nb-rich carbonitrides and Ti-rich nitrides, (Ti,Nb)N, in the sample heat-treated to 1080 °C peak temperature. However, only Ti-rich nitrides were revealed in the sample heat-treated to 1220 °C peak temperature. During continuous heating to higher than the Ac3 temperature, i.e., near 1100 °C temperature, the dissolution of Nb(C,N) was observed in dilation and derivative of dilation. Notably, this experimental result agreed with the predictions by a DICTRA model. Furthermore, a phenomenological model was developed to explain the volume shrinkage during the dissolution of Nb(C,N) precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Characterization of stress corrosion cracks in Ni-based weld alloys 52, 52M and 152 grown in high-temperature water

Ni-based weld alloys 52, 52M and 152 are extensively used in repair and mitigation of primary water stress corrosion cracking (SCC) in nuclear power plants. In the present study, a series of microstructure and microchemistry at the SCC tips of these alloys were examined with scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy (EDS), scanning transmission electron microscopy (STEM) and energy filtered transmission electron microscopy (EFTEM). The specimens have similar chemical compositions and testing conditions. Intergranular (IG) and transgranular (TG) SCC was observed in all of them. The cracks were filled with nickel-oxides and partial precipitations of chrome carbides (CrCs), niobium carbides (NbCs), titanium nitrides (TiNs) and silicon carbides (SiCs), while iron (Fe) was largely dissolved into the solution. However, the crack densities, lengths and distributions were different for all three specimens. - Highlights: • Microstructure and microchemistry at the SCC tips of Ni-based weld alloys 52, 52M and 152 were examined. • The crack densities, lengths and distributions were found to be different for different alloys. • IGSCC and TGSCC were observed on alloy 52, only TGSCC was observed on alloy 52M and 152. • The cracks were filled by Ni-oxides and precipitated CrCs, NbCs, TiNs and SiCs.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructural and hardness investigations on a dissimilar metal weld between low alloy steel and Alloy 82 weld metal

The investigation on microstructure and hardness at the fusion boundary (FB) region of a dissimilar metal weld (DMW) between low alloy steel (LAS) A508-III and Alloy 82 weld metal (WM) was carried out. The results indicated that there were two kinds of FBs, martensite FB and sharp FB, with obvious different microstructures, alternately distributed in the same FB. The martensite FB region had a gradual change of elemental concentration across FB, columnar WM grains with high length/width ratios, a thick martensite layer and a wide heat affected zone (HAZ) with large prior austenite grains. By comparison, the sharp FB region had a relatively sharp change of elemental concentration across the FB, WM grains with low length/width ratios and a narrow HAZ with smaller prior austenite grains. The martensite possessed a K-S orientation relationship with WM grains, while no orientation relationship was found between the HAZ grains and WM grains at the sharp FB. Compared with sharp FB there were much more Σ3 boundaries in the HAZ beside martensite FB. The hardness maximum of the martensite FB was much higher than that of the sharp FB, which was attributed to the martensite layer at the martensite FB. - Highlights: •Martensite and sharp FBs with different microstructures were found in the same FB. •There were high length/width-ratio WM grains and a wide HAZ beside martensite FB. •There were low length/width-ratio WM grains and a narrow HAZ beside sharp FB. •Compared with sharp FB, there were much more Σ3 boundaries in HAZ of martensite FB. •Hardness maximium of martensite FB was much higher than that of sharp FB.

36 MATERIALS SCIENCE↗