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At least 1,297 records · Page 72
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Interpretation of Indications Generated by Small Welding Discontinuities in Ultrasonic Time of Flight Diffraction Technique

The article presents results of research on non-destructive ultrasonic time of flight diffraction technique TOFD and metallographic examinations of selected cross-sections of a MAG welded joint. The main objective was to compare the results of TOFD and metallographic examination at the locations where a large number of point-like indications, located on specific depths, have been detected on TOFD images and analyse the impact of this type of indication on results of a welded joint evaluation. Considered, that the indications have not exhibited separations between upper and lower diffraction signals, because of their small heights, measuring of height of indications in those cases was impossible. In all cases, the occurrence of discontinuities of 0.16–0.78 mm in height, in locations indicated by TOFD has been confirmed.

42 ENGINEERING↗
DOE OSTI2018

Influence of the Microstructure on Magnetic Stray Fields of Low-Carbon Steel Welds

This study examines the relationship between the magnetic mesostructure with the microstructure of low carbon steel tungsten inert gas welds. Optical microscopy revealed variation in the microstructure of the parent material, in the heat affected and fusion zones, correlating with distinctive changes in the local magnetic stray fields measured with high spatial resolution giant magneto resistance sensors. In the vicinity of the heat affected zone high residual stresses were found using neutron diffraction. Notably, the gradients of von Mises stress and triaxial magnetic stray field modulus follow the same tendency transverse to the weld. In contrast, micro-X-ray fluorescence characterization indicated that local changes in element composition had no independent effect on magnetic stray fields.

42 ENGINEERING↗
DOE OSTI2018

On the Similarity of Deformation Mechanisms During Friction Stir Welding and Sliding Friction of the AA5056 Alloy

A comparative investigation of the structure of an aluminum-manganese alloy is performed after its friction stir welding and sliding friction. Using the methods of optical and electron microscopy, it is shown that during friction identical ultrafine-grained structures are formed in the weld nugget and in the surface layer, in which the grains measure ~ 5 μm irrespective of the initial grain size of the alloy. An assumption is made that the microstructure during both processes under study is formed by the mechanism of rotational plasticity.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Interfacial Microstructure and Mechanical Properties of Friction Stir Welded Joints of Commercially Pure Aluminum and 304 Stainless Steel

In the present investigation, friction stir welding of commercially pure aluminum and 304 stainless steel was carried out at varying tool rotational speeds from 200 to 1000 rpm in steps of 200 rpm using 60 mm/min traverse speed at 2 (degree) tool tilt angle. Microstructural characterization of the interfacial zone was carried out using optical microscope and scanning electron microscope. Energy-dispersive spectroscopy indicated the presence of FeAl{sub 3} intermetallic phase. Thickness of the intermetallic layer increased with the increase in tool rotational speed. X-ray diffraction studies indicated the formation of intermetallic phases like FeAl{sub 2}, Fe{sub 4}Al{sub 13}, Fe{sub 2}Al{sub 5}, and FeAl{sub 3}. A maximum tensile strength of ~ 90% that of aluminum along with ~ 4.5% elongation was achieved with the welded sample at tool rotational speed of 400 rpm. The stir zone showed higher hardness as compared to base metals, heat affected zone, and thermo-mechanically affected zone due to the presence of intermetallics. The maximum hardness value at the stir zone was achieved at 1000 rpm tool rotational speed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fatigue Properties of Ti-6Al-4V Titanium Alloy Friction Stir Welding Joint

Friction stir welding was used to consolidate 2-mm-thick Ti-6Al-4V titanium alloy sheets, and the static and fatigue properties of the joint were investigated. The results reveal that uniform microhardness distribution of the nugget zone (NZ) after post-weld heat treatment was associated with the uniform equiaxed microstructure of the NZ. The joint fatigue limit predicted by the S–N curve reached 640.84 MPa, up to 64.76% of joint tensile strength. Fatigue specimens fractured at the transition zone between the base material and NZ, and the positions of fatigue crack initiation sites were relatively random. The fracture surface of the fatigue crack propagation region was composed of radial strips and striations, and numerous dimples were observed on the final fast fracture surface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reducing Intermetallic Compounds of Mg/Al Joint in Friction Stir Lap Welding

To reduce intermetallic compounds (IMCs) of Al{sub 12}Mg{sub 17} and Al{sub 3}Mg{sub 2} in Mg/Al friction stir lap welding joint, pin tip was plunged into the lower sheet at a small distance. Results showed that at a fixed welding speed of 50 mm/min, sound joints were obtained using rotating speeds from 750 to 500 rpm, and the IMCs zones were rather small. Cracks easily appeared inside IMCs inside onion ring and at lap interface. Therefore, reducing the IMC was beneficial for reducing the crack. Joint lap shear stress firstly increased and then decreased with decrease in the rotating speed. The maximum shear stress of 50.2 MPa was attained at a rotating speed of 500 rpm because of reduced IMC.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Mechanical Properties of Friction Stir Welded Q235 Low-Carbon Steel

Three-millimeter-thick Q235 steel plates were friction stir welded using a tool made of tungsten-rhenium alloy in the present study. The microstructure and mechanical properties of welded joints at various traverse speeds from 50 to 150 mm/min were analyzed. It was demonstrated that traverse speed had great impacts on microstructure and mechanical properties of the joints. Phase transformation accompanied with recrystallization occurred during FSW process which resulted in different microstructures in the WNZ, and the grain size in other zones was significantly affected by traverse speed. The highest hardness was located in the nugget zone, while the lowest hardness was found in the heat-affected zone. The transverse tensile test suggested that all the joints showed slightly lower tensile strength than that of the base material, and the tensile strength increased with increasing traverse speed. All the joints fractured in the heat-affected zone with ductile fracture mode. The impact test showed that the impact toughness decreased with the increasing traverse speed and the impact fracture surface could be divided into shear lip zone and fibrous zone which showed a typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure evolution in the fusion zone of laser-welded Mg–Gd–Y–Zr alloy during solution and aging treatment

The microstructure evolution in the fusion zone of laser-welded Mg-Gd-Y-Zr alloy during solution and aging treatment is investigated. The morphology of the Mg{sub 24}(Gd,Y){sub 5} in the divorced eutectic at the grain boundary transforms from a continuous network to disconnected and fragmentized islands and then to spheroidal particles before complete dissolution during the solution treatment at 430 °C. During the subsequent aging treatment at 225 °C, the precipitation sequence in the fusion zone follows the order of supersaturated solid solution (SSSS) → βʺ(D0{sub 19}) → βʹ(cbco) → β{sub 1}(fcc) → β(fcc). High-density precipitates are present at the original grain boundaries of the fusion zone from the welded structure but there are less precipitates in the interior of the original grains. The grain growth during the solution treatment at 430 °C comprises the slowly increasing stage, rapidly increasing stage, and stable stage. The network-distributed Mg{sub 24}(Gd,Y){sub 5} impedes migration of the grain boundaries, restricts grain growth in the first slowly increasing stage, and segregation of zirconium near the grain boundaries also affects migration of the grain boundaries. - Highlights: •Different quantities of precipitates are present at different location of grain. •The network-distributed Mg{sub 24}(Gd,Y){sub 5} restricts grain growth. •Segregation of Zr affects migration of grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure, texture, and mechanical properties of friction stir welded commercial brass alloy

Microstructural evolution during friction stir welding of single-phase brass and corresponding mechanical properties were investigated. For this purpose, 2 mm thick brass plate was friction stir welded at a rotational speed of 450 rpm and traverse speed of 100 mm/min. The microstructure of the joint was studied using optical microscopy, scanning electron microscopy equipped with electron back scattered diffraction system, and scanning transmission electron microscopy. The mechanical properties were measured using hardness and tensile tests. The formation of subgrains and their transformation into new grains in conjunction with existence of A{sub 1}{sup ⁎}, A{sub 2}{sup ⁎} and C texture components revealed that the continuous dynamic recrystallization plays a dominant role in the microstructural evolution. However, grain boundary bulging, along with the formation of twin boundaries, and presence of the G texture component showed that the discontinues dynamic recrystallization may participate in the new grain formation. Furthermore, the different strengthening mechanisms, which caused the higher strength of the joint, were discussed. - Highlights: •Microstructural evolution during FSW of a single phase brass was investigated. •CDRX and DDRX were the main mechanisms of the grain structure formation during FSW. •GDRX and SRX were not contributed in grain structure formation. •The lamellas TBs were formed in the SZ of the joints. •Grain boundary, dislocation, and texture effects resulted in higher strength.

36 MATERIALS SCIENCE↗
DOE OSTI2017

In situ investigation of the tensile deformation of laser welded Ti{sub 2}AlNb joints

The tensile deformation behavior of laser welded Ti{sub 2}AlNb joints was investigated using in situ analysis methods. The fracture mode of the single-B2-phase fusion zone was quasi-cleavage at room temperature and intergranular at 650 °C, while that of base metal was microvoid coalescence at both room temperature and 650 °C. Tensile deformation at room temperature was observed using in situ SEM tensile testing. In base metal, microcracks nucleated and propagated mainly within the O phase or along O/B2 phase boundaries. While both the cross- and multi-slips were found in the single-B2-phase fusion zone, a confocal laser scanning microscopy was used to observe the crack initiation and propagation process in situ at 650 °C. Cracks mainly formed along the B2/O phase boundaries in base metal, along the fragile grain boundaries of B2 phase in the fusion zone. The thermal simulation experiment and following TEM analysis indicated that the precipitation of continuous O-phase films along the B2 grain boundaries resulted in the high temperature brittleness of laser welded Ti{sub 2}AlNb joints. - Highlights: •Cracks formed within O phase or along B2/O boundaries in the base metal. •Cross- and multi-slips relieved stress in the fusion zone at room temperature. •Cracks mainly formed along the B2/O boundaries at 650 °C. •In the fusion zone, intergranular cracks were in situ observed at 650 °C. •O-phase films along B2 grain boundaries caused the high temperature brittleness.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructure of a safe-end dissimilar metal weld joint (SA508-52-316L) prepared by narrow-gap GTAW

The microstructure, residual strain and interfacial chemical composition distribution of a safe-end dissimilar metal weld joint (DMWJ, SA508-52-316L) prepared by narrow-gap gas-tungsten arc welding (NG-GTAW) were studied by optical microscope (OM) and scanning electron microscope equipped with an energy dispersive X-ray microanalysis (SEM/EDX) and an electron back scattering diffraction (EBSD) system. Complex microstructure and chemical composition distribution are found, especially at the SA508-52 interface and the 52-316L interface. In brief, a complicated microstructure transition exists within the SA508 heat affected zone (HAZ); the residual strain, the fraction of high angle random grain boundaries and low angle boundaries decrease with increasing the distance from the fusion boundary in 316L HAZ; neither typical type II boundary nor obvious carbon-depleted zone is found near the SA508-52 interface; dramatic and complicated changes of the contents of the main elements, Fe, Cr and Ni, are observed at the distinct interfaces, especially at the SA508-52 interface. No carbon concentration is found at the SA508-52 interface. - Highlights: •Residual strain and GBCD change as a function of the distance from FB in 316L HAZ. •Neither type II boundary nor obvious carbon-depleted zone is found in SA508 HAZ. •No carbon concentration is found at the SA508-52 interface. •The middle part of the DMWJ has the highest residual strain.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Synchrotron experiment and simulation studies of magnesium-steel interface manufactured by impact welding

The effective weight reduction in the automotive industry by the wide adoption of lightweight magnesium (Mg) alloys demands high-quality joint between magnesium alloys and massively-used steels in order to wring the excess weight with strength and safety assurance. However, Mg-steel joint is difficult to achieve because there is no mutual solubility between magnesium and steel and huge disparity in physical properties. An impact-based welding method recently showed successful Mg-steel joining. In this work, the characteristics of Mg-steel interface joined by the impact welding method were investigated. Synchrotron high-energy X-ray computed tomography and diffraction were applied to characterize the microstructure across Mg-steel interface. Results revealed a deposit layer formed at the joint interface where Fe-rich particles spread deep into the Mg matrix. High-resolution 3D morphology of Mg-steel interface demonstrated the trapped pores and cracks inside the deposit layer. Finally, the formation of the deposit layer and the void/cracking evolution were analyzed by using finite element models. These findings provide insights into the immiscible Mg-steel joining process.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Eutectic structures in friction spot welding joint of aluminum alloy to copper

A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl{sub 2} eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Features of the microstructure development under conditions, reproducing the process of friction stir welding. Molecular-dynamics study

Friction stir welding is a recently developed technology which is used in various branches of modern engineering. The basis of this technology is the friction of the rotating cylindrical or specially shaped tool between two metal plates brought together either to meet their ends of one above another with the overlap. When applying the FSW process in various economical sectors, the important task is to study the mechanisms and identify the physical laws and factors leading to formation of structural inhomogeneities and discontinuities in the weld seam. This paper analyzes the basic mechanisms behind the structural state generation in the material subjected to severe plastic deformation and heating. To investigate the atomic mechanisms of structural changes in FSW, the modeling at atomic scale has been carried out. Results of work can be a basis for new knowledge about the microstructure evolution in FSW.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Microstructure based modeling of friction stir welded joint of dissimilar metals using crystal plasticity

We report the friction stir welding (FSW) process shows promising results in joining dissimilar metals which are otherwise almost impossible to join using traditional welding techniques. Being a new technique, the deformation and the failure mechanism of the joints made by the FSW process needs to be investigated. In this work, a joint between AZ31 Mg alloy and DP590 steel is modeled using phenomenological crystal plasticity formulation on the mesoscale in the form of a representative volume element (RVE). The interface of the two materials is modeled using a cohesive zone model. A parametric study has been performed to understand the effect of grain size and interface fracture toughness as well as strength on the mechanical performance of the joint. It was found that the grain size of AZ31 Mg alloy, as well as DP590 steel, has little effect on the overall joint performance. On the other hand, interface fracture toughness and strength have a significant impact on the mechanical properties of the joint

36 MATERIALS SCIENCE↗