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At least 1,657 records · Page 92
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effect of Preheating and Water Cooling on the Performance of Friction-Stir-Welded Aviation-Grade Aluminum Alloy Joints

This paper examined the effect of preheating and water cooling on the thermal, mechanical, metallurgical, and texture properties of friction-stir-welded AA6082. Joints are fabricated under different preheating (FSW-P) and water cooling (FSW-C) conditions. The experimental outcomes indicate that the preheating and water cooling enhance the mechanical properties of the joint. The maximum tensile strength of 295 MPa is obtained for FSW-P1. It is also observed that preheating has more impact on microhardness. Microstructural analysis using optical microscope and electron backscatter diffraction analysis indicated that FSW produced fine equiaxed grains in the nugget zone due to dynamic recrystallization. Texture analysis shows that finer grain grains are obtained under preheating and water cooling conditions. The minimum grain size of 5.3 µm is obtained under FSW-P1. X-ray diffraction analysis shows that Mg{sub 2}Si phase in nugget zone that is an indication of dissolution and formation of strengthening precipitates. Fracture analysis indicates that preheating also improves the ductility of the joint.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Comparative Study of Deformation Behaviors Between Laser-Welded Joints and Base Metal of Ti-22Al-24.5Nb-0.5Mo Alloy

The tensile deformation behaviors of laser-welded Ti-22Al-24.5Nb-0.5Mo alloy joints have been investigated at room temperature and 650 °C using in situ tensile analysis methods. The α{sub 2} phase had a significant influence on deformation behaviors of base metal at room temperature and 650 °C. The microcracks mainly nucleated in B2/α{sub 2} phase boundaries or within α{sub 2} phase and then propagated along B2/α{sub 2} phase boundaries subsequently. Compared with the plastic fracture of base metal, the fracture modes of the fully B2-phase fusion zone at room temperature and 650 °C were quasi-cleavage and intergranular fracture, respectively. While dislocation slips became foremost deformation mode in the fusion zone at room temperature, there were a great amount of slip bands on the surface of grains caused by the slip systems. The microcracks of fusion zone at 650 °C nucleated and propagated along the grain boundaries of B2 phase. Owing to the lack of grain deformation, the cross-slip bands were in small quantities on the surface of B2 phase grains.

36 MATERIALS SCIENCE↗
DOE OSTI2019

On the Effect of Quenching on Postweld Heat Treatment of Friction-Stir-Welded Aluminum 7075 Alloy

This work focuses on the effect of postweld heat treatment (PWHT) on the mechanical properties and microstructural evolution of aluminum 7075 alloy processed via friction stir welding (FSW). FSW is known to be capable of grain refinement in the nugget zone (NZ). Two different quench media (water and air) were employed for PWHT. Regardless of the quench media, the PWHT led to the occurrence of grain growth in the NZ of the FSWed aluminum 7075 alloy. Abnormal grain growth occurred in the water quenched specimen. It is shown that ductility and strength of FSWed aluminum 7075 alloy are strongly dependent on the quenching rate. Changes in the mechanical properties and microstructure reveal that only at lower cooling rate this alloy is prone to the formation of precipitate-free zones (PFZs) in the vicinity of grain boundaries. Eventually, the PFZs deteriorate mechanical properties of this alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cu Interlayer-Induced High-Strength Laser-Welded AISI 304 Steel-Niobium Joint

Joining niobium to austenitic stainless steel is necessary for the fabrication of particle accelerators. However, the brittle iron-niobium intermetallics formed in the joint significantly reduce the joint strength. Copper was used as an interlayer to prevent the brittle phase formation while joining niobium to AISI 304 steel. The laser beam was first focused on the Cu-steel faying surface and then on the Cu-Nb faying surface. The tensile strength of the joint is greater than that of the Nb. The weld microstructure consists of austenite with Cu-rich precipitates along with the austenitic grain boundaries and Cu-rich phase embedded with Nb-rich particles and dendrites. Solid solution strengthening of Cu by Fe and second-phase strengthening of Cu by Nb play a critical role in improving the mechanical properties of the joint. These results highlight new possibilities for the joining of niobium to steel.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Refill Friction Stir Spot Welding Dissimilar Al/Mg Alloys

Dissimilar Al/Mg alloys were joined by refill friction stir spot welding (RFSSW) in this work. The effect of sleeve plunge depth on microstructure and mechanical properties of the joints was studied. The results showed that sound joint can be obtained at sleeve plunge depth of 2.4 mm. Intermetallic compounds (IMCs) layer, formed by the liquid eutectic phase, were observed at both the sleeve-affected zone and joint center. The IMC at the pin-affected zone was thicker than that at the sleeve-affected zone because of its flow characteristic. Less liquid eutectic phase formed during RFSSW when joint using Mg as the upper sheet because the oxide layer on the Al sheet was hard to break, resulting to thinner IMC layer. The maximum load of 3.6 kN was obtained at 2.6 mm when the Al alloys served as the upper sheet, and the maximum failure of 3.6 kN was also obtained at 2.4 mm when the Mg alloys served as the upper sheet. The RFSSW joint presented shear fracture mode. The XRD patterns showed that the IMC of Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} formed inside the joint.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Molecular dynamics study on interface formation and bond strength of impact-welded Mg-steel joints

It was recently demonstrated that the vaporizing foil actuator welding (VFAW) method can directly join immiscible magnesium and steel alloys without coating or a third chemical element based intermetallic compound layer. The VFAW Mg/steel joint exhibits a mixed interface layer of up to 200μm thickness consisting of Mg matrix and Fe particles. Computer simulations have suggested the formation of the interlayer is from the high-velocity frictional shearing between the Mg/steel substrates during the oblique impact in the VFAW process. This paper investigates the formation of Mg-Fe interlayer under VFAW condition with different shearing velocities using molecular dynamics (MD) model, and studies the bonding strength under different scenarios. Finally, the results elucidate the critical role of shearing velocity and surface roughness in achieving Mg/Fe joint.

36 MATERIALS SCIENCE↗
DOE OSTI2020

On the solid-state-bonding mechanism in friction stir welding

This study is a critical assessment of various solid-state-bonding mechanisms is established for friction stir welding (FSW) processes of engineering alloys. The commonly assumed sintering-like diffusional-bonding hypothesis is criticized in this work as not the dominant mechanism. For the wide spectrum of material constitutive laws and FSW processing conditions examined and employed in realistic applications, the thermomechanical history on the workpiece–workpiece interface traverses in the creep-dominated regime for the growth/shrinkage of interfacial cavities. The evolution of the bonding fraction relies mainly on the creep strain rate in the adjourning workpieces, weakly on stress triaxiality, and negligibly on interfacial diffusion.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Derivation of physical equations for high-speed laser welding using large language models

It is challenging to formulate complex physical phenomena that occur in a manufacturing process, particularly when the available data are limited, rendering conventional data-driven approaches ineffective. This study aims to predict humping onset in high-speed laser welding by introducing a novel framework, namely text-to-equations generative pre-trained transformer (T2EGPT). This method leverages the capabilities of large language models (LLMs), in combination with sparse experimental data and enriched literature data, to derive an interpretable and generalizable equation for predicting humping initiation. By capturing key correlations among physical parameters, T2EGPT generates a compact and dimensionless expression that accurately predicts hump formation. The equation reveals that humping arises from the interplay between inertia-driven backward melt flow and capillary-driven surface stabilization, where inertial forces drive molten metal backward and capillary forces resist surface deformation. Furthermore, compared to traditional data-driven models, T2EGPT demonstrates enhanced predictive accuracy and cross-material transferability. More broadly, this study highlights the potential of LLMs to integrate textual information with data-driven discovery, enabling the extraction of physical laws in data-scarce scientific domains.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Crystallographic texture and microstructural changes in fusion welds of recrystallized Zry-4 rolled plates

This study presents a detailed characterization of the microstructural and crystallographic texture changes observed in the transition region in a weld between two Zircaloy-4 cold rolled and recrystallized plates. The microstructural study was performed by optical microscopy under polarized light and scanning electron microscopy (SEM). Texture changes were characterized at different lengthscales: in the micrometric size, orientation imaging maps (OIM) were constructed by electron backscatter diffraction (EBSD), in the millimetre scale, high energy XRD experiments were done at the Advanced Photon Source (USA) and compared to neutron diffraction texture determinations performed in the HIPPO instrument at Los Alamos National Laboratory. In the heat affected zone (HAZ) we observed the development of Widmanstätten microstructures, typical of the α( hcp ) to β( bcc ) phase transformation. Associated with these changes a rotation of the c-poles is found in the HAZ and fusion zone. While the base material shows the typical texture of a cold rolled plate, with their c-poles pointing 35° apart from the normal direction of the plate in the normal-transversal line, in the HAZ, c-poles align along the transversal direction of the plate and then re-orient along different directions, all of these changes occurring within a lengthscale in the order of mm. The evolution of texture in this narrow region was captured by both OIM and XRD, and is consistent with previous measurements done by Neutron Diffraction in the HIPPO diffractometer at Los Alamos National Laboratory, USA. The microstructural and texture changes along the HAZ were interpreted as arising due to the effect of differences in the cooling rate and β grain size on the progress of the different α variants during transformation. Fast cooling rates and large β grains are associated to weak variant selection during the β–>α transformation, while slow cooling rates and fine β grains result in strong variant selection.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Influence of welding and neutron irradiation on dislocation loop formation and α' precipitation in a FeCrAl alloy

An advanced accident-tolerant FeCrAl alloy, C35 M (Fe–13Cr–10Al–1Mo, at %), and its laser-fusion weldments were studied after neutron irradiation up to 1.8 dpa at 357 °C to evaluate the radiation damage and α'-precipitation kinetics. Results show that the densities of α' in the fusion zone (FZ) and the heat-affected zone (HAZ) were only a third of that in the base material, i.e., 2.3 × 10 24 m -3 . Here, density of dislocation loops in the FZ and HAZ were less than half of that in base material. The size of α' precipitates and the dislocation loops were found to be smaller in base material, compared to FZ and HAZ. The variances in microstructural response within the different regions were attributed to initial as-welded states of each region, indicating the impact of the pre-irradiation condition on radiation response in FeCrAl alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Friction stir welding and self-ion irradiation effects on microstructure and mechanical properties changes within oxide dispersion strengthened steel $\mathrm{MA956}$

We report the joining process for oxide dispersion strengthened (ODS) alloys remains a key challenge facing the nuclear community. The microstructure and mechanical properties were characterized in the base material and friction stir welded ODS MA956 irradiated with 5 MeV Fe 2+ ions from 400 to 500°C up to 25 dpa. Nanoindentation was performed to assess changes in hardness and yield stress, and the dispersed barrier hardening (DBH) model was applied to described results. A combination of scanning transmission electron microscopy (STEM) and atom probe tomography (APT) were used to assess evolution of the microstructure including dispersoids, network dislocations and dislocation loops, nanoclusters, and solid solution concentrations. Overall, softening was observed as a result of increased dose, which was exacerbated at 500°C. The formation and coarsening of new dispersoids was noted while nanoclusters tended to dissolve in the base material, and were not observed in the stir zone. Solute nanocluster evolution was identified as a primary driver of the changes in mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The significance of intermetallic compounds formed during interdiffusion in aluminum and magnesium dissimilar welds

Diffusion couples between Al-AA6111 and Mg-AZ31 have been used to perform a comprehensive review of the IMC phases that develop in this system, including; their growth kinetics, texture, residual stresses, and mechanical properties. The new observations made have been compared to data in the literature with the aim of providing an in-depth understanding of the detrimental effects of interfacial reaction in aluminum–magnesium dissimilar welding. Three Al–Mg binary IMC phases were identified, γ-Al{sub 12}Mg{sub 17} and β-Al{sub 3}Mg{sub 2}, as well as ε-Al{sub 30}Mg{sub 23}, which has not been previously reported in inter-diffusion studies. The β phase had the highest growth rate and became the dominant constituent of the IMC layer at longer reaction times. The ε-phase only appeared after extended heat treatment, via transformation at the Al{sub 12}Mg{sub 17}/Al{sub 3}Mg{sub 2} interface. Intrinsic diffusion coefficients of Al and Mg, calculated in the Al{sub 3}Mg{sub 2} phase, confirmed that Al is the faster diffusing species (by an order of magnitude) during IMC growth. Indentation techniques showed that all the IMC phases had extremely low toughness (1/2 ). FIB-assisted ring core milling revealed that both the β-Al{sub 3}Mg{sub 2} and γ-Al{sub 12}Mg{sub 17} phases contained large residual stresses. Their in-situ fracture toughness was consequently found to be asymmetric with lower values parallel to the joint interface. Greater tensile residual stress was measured in the β-Al{sub 3}Mg{sub 2} phase, which, combined with a lower toughness and more rapid growth kinetics, explains why it is generally the ‘weak link’ in Al–Mg dissimilar joints.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Precipitation behavior of stainless steel weld overlay cladding exposed to a long-term thermal aging

Highlights: • Silicide phase formation with G-phase was first time to be observed. • Precipitation behavior discrepancy existed at different locations of ferrite phase. • G-phase and silicide phase formed along dislocations and within ferrite matrix. • Heterogeneous distribution of elements induced silicide phase formation. - Abstract: Thermal aging behavior of stainless steel weld overlay cladding aged at 400 °C for 10,000 h was investigated. The results showed that the precipitates along the dislocation and within ferrite matrix contained the face-centered cubic structural G-phase and silicide phase. Silicide phase, supposed to be (Fe, Mn){sub 3}Si phase, preferred to form with G-phase along the dislocations and within ferrite matrix. Silicide phase showed a cube-on-cube relationship with ferrite phase and G-phase. Heterogeneous distribution of elements within Ni-Mn-Si clusters was responsible for silicide phase formation during thermal aging process, and the corresponding precipitation behavior discrepancy at different forming sites (dislocations, ferrite matrix and phase boundary) was discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of thermal aging on oxide film of stainless steel weld overlay cladding exposed to high temperature water

Highlights: • Oxide film of aged cladding material in high temperature water was studied. • Thermal aging contributed to high corrosion susceptibility of the ferrite phase. • Highly corrosion of aged ferrite phase was caused by spinodal decomposition. • Carbides along phase boundary facilitated the corrosion of the cladding material. - Abstract: Characteristics of the oxide film formed on stainless steel weld overlay cladding aged at 400 °C for different times in high temperature water were studied. The results showed that thermal aging showed no obvious effect on the volume fraction of ferrite phase but resulted in high corrosion susceptibility of the aged ferrite phase mainly. The oxide film formed on the unaged cladding material consisted of 100-nm-thick inner oxide layer (FeCr{sub 2}O{sub 4} and Cr{sub 2}O{sub 3}) and Fe-rich outer oxide particles (Fe{sub 3}O{sub 4}) with a size of 2 O4, Cr{sub 2}O{sub 3} and Fe{sub 3}O{sub 4}) and outer oxide particles (Fe{sub 3}O{sub 4} and FeCr{sub 2}O{sub 4}) with a size of <700 nm formed on the aged ferrite phase. Spinodal decomposition was considered as the main factor to promote the corrosion of the aged ferrite phase, and existence of carbides along phase boundary facilitated corrosion of the cladding material in high temperature water.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparison of microstructural and mechanical properties of friction stir spot welded ultra-high strength dual phase and complex phase steels

Highlights: • The microstructure and mechanical properties of FSSW of ultra high strength DP and CP steels are compared. • The stir zone (SZ) of CP steel mainly consists of bainite and martensite; no bainite is identified in the SZ of DP steel. • The cooling was not fast enough for the CP steel to suppress the effect of chemical composition on phase transformation. - Abstract: The microstructure and mechanical properties of friction stir spot welding of ultrahigh strength dual phase (DP) and complex phase (DP) steels are compared based on the experimental results. For both DP and CP steels, FSSW joints are successfully fabricated using the same process parameter set. While the microstructure of joints are characterized in detail using scanning electron microscopy, electron back scattered diffraction, and transmission electron microscopy, the mechanical property of joints are evaluated by shear tensile tests. The result of the microstructural analysis shows that the stir zone (SZ) of CP steel mainly consists of bainite and martensite, while no bainite is identified in the SZ of DP steel. The existence of bainite in the SZ of CP steel suggests that the cooling rate, which is nearly identical for both CP and DP steels, was not fast enough to suppress the effect of the alloying composition, particularly that of Mn, on the phase transformation. The result of the present study contributes to the development of solid state joining process of the ultrahigh strength steels.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of grain boundary character distribution on weld heat-affected zone liquation cracking behavior of AISI 316Ti austenitic stainless steel

Highlights: • Grain boundary engineered AISI 316 was produced through thermomechanical processing. • Grain boundary engineering resulted in random high angle boundary network disruption. • Liquation cracks are arrested at triple junctions having one or more CSL boundaries. • Grain boundary engineering resulted in improvement in liquation cracking resistance. - Abstract: In this work, the role of grain boundary engineering (GBE) on the weld heat-affected-zone (HAZ) liquation cracking resistance of austenitic stainless steel AISI 316Ti was investigated. Standard wrought-processed alloy 316Ti was cold rolled to 5% strain and subsequently annealed at 1373 K for 30 min to achieve the optimum grain boundary character distribution (GBCD). The GBE samples were found to consist of a significantly higher fraction (72%) of low Ʃ coincident site lattice (CSL) boundaries as compared to the as received (AR) samples (45%). To study the liquation cracking behavior, single-track longitudinal varestraint tests was performed on AR and GBE samples. Microstructural examination revealed that the grain coarsening and the liquation events were less prominent in the GBE samples as compared to the AR samples. It is believed that the reduced segregation of impurities to the special boundaries (coherent Ʃ3 twins, in particular) present in the GBE samples is responsible for the observed improvement in the HAZ liquation cracking resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of tailored martensitic transformation in a thick weld: Residual stresses mitigation, heterogeneous microstructure, and mechanical properties

The residual stresses, microstructural heterogeneities, and mechanical properties were extensively examined in a 25 mm thick weld consisting of two regions which respectively undergo phase transformation at relatively low (100 °C) temperature (LTT) and high (670 °C) temperature (HTT) during cooling. Due to the LTT martensitic transformation, which features a transformation strain of ~4000 με, large compressive residual stress (−510 MPa) was generated as confirmed by neutron diffraction and contour method. Meanwhile, significant heterogeneities were observed in terms of the chemical composition, yield strength, and microhardness across the interface between the LTT and HTT regions. The dependency of martensitic transformation starting temperature (M{sub s}) on chemical composition is empirically formulated, and it reveals that the dependency of M{sub s} on the Ni and Cr compositions becomes stronger when the temperature is lower than 200 °C. The maximum change of residual stresses (σ{sub x}{sup max}) exponentially decreases as M{sub s} decreases in the manner of σ{sub x}{sup max} = 97.5 exp(M{sub s}/227)-649. The fracture behavior was found highly dependent upon the volume fraction of retained austenite influenced by M{sub s}. While a ductile fracture mode was found in the cellular LTT region containing relatively higher amount of retained austenite (~10%), the interface shows transgranular brittle fracture features and sub-cracking due to the relatively small amount of retained austenite and the predominant martensite constituent.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Deformation and fracture of explosion-welded Ti/Al plates: A synchrotron-based study

Here, explosion-welded Ti/Al plates are characterized with energy dispersive spectroscopy and x-ray computed tomography, and exhibit smooth, well-jointed, interface. We perform dynamic and quasi-static uniaxial tension experiments on Ti/Al with the loading direction either perpendicular or parallel to the Ti/Al interface, using a mini split Hopkinson tension bar and a material testing system in conjunction with time-resolved synchrotron x-ray imaging. X-ray imaging and strain-field mapping reveal different deformation mechanisms responsible for anisotropic bulk-scale responses, including yield strength, ductility and rate sensitivity. Deformation and fracture are achieved predominantly in Al layer for perpendicular loading, but both Ti and Al layers as well as the interface play a role for parallel loading. The rate sensitivity of Ti/Al follows those of the constituent metals. For perpendicular loading, single deformation band develops in Al layer under quasi-static loading, while multiple deformation bands nucleate simultaneously under dynamic loading, leading to a higher dynamic fracture strain. For parallel loading, the interface impedes the growth of deformation and results in increased ductility of Ti/Al under quasi-static loading, while interface fracture occurs under dynamic loading due to the disparity in Poisson's contraction.

36 MATERIALS SCIENCE↗