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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Microstructure and Mechanical Properties of Three-Layer TIG-Welded 2219 Aluminum Alloys with Dissimilar Heat Treatments

2219-C10S and 2219-CYS aluminum alloys are 2219 aluminum alloys with different heat treatment processes, and they have been widely used in the aerospace industry. In the present study, 2219-C10S and 2219-CYS aluminum alloys were butt-welded by three-layer tungsten inert gas arc welding (with the welding center of the third layer shifted toward the CYS side), and the microstructure characteristics and mechanical properties of the welded joint were investigated. The lamellar θ′ phases, the bulk or rod θ phases, and the coarse rod-shaped or pancake-shaped Al-Cu-Fe-Mn phases coexisted in the two aluminum alloys. The Cu content of the α-Al matrix and the distribution of eutectic structures of different welding layers in the weld zone (WZ) were varied, implying that the segregation degrees of the Cu element were different due to the different welding thermal cycles in different welding layers. The microhardness values of the CYS side were much higher than those of the C10S side in each region on both sides of the joint. The tensile test deformation was concentrated mainly in the regions of WZ and the over aged zone (OAZ), where the microhardness values were relatively low. The main deformation concentrated region was transferred from the CYS side to the C10S side with the increase in the tensile load during the tensile test. The fracture behavior of the tensile test showed that the macroscopic crack initiated near the front weld toe had gone through the crack blunt region, the shear fracture region of the partially melted zone (PMZ), and the shear fracture region of OAZ. Meanwhile, the fracture characteristics gradually evolved from brittle to ductile. The concentrated stress and the dense eutectic structure in the region near the front weld toe of the C10S side contributed to the fracture of the joint. The shift of the welding center of the third layer to the CYS side resulted in two effects: (i) the microhardness values from the middle layer to the top layer in the PMZ of the CYS side were the most significantly increased and (ii) the distance between the front weld toe and the fusion line of the CYS side was significantly larger.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Atom probe tomography characterization of neutron irradiated surveillance samples from the R. E. Ginna reactor pressure vessel

Surveillance samples of a low copper (nominally 0.05 wt.% Cu) forging and a higher copper (0.23 wt.% Cu) submerged arc weld from the R. E. Ginna reactor pressure vessel have been characterized by atom probe tomography (APT) after exposure to three levels of neutron irradiation, i.e., fluences of 1.7, 3.6 and 5.8 × 10 23 n.m –2 (E > 1 MeV), and inlet temperatures of ~289 °C (~552 °F). As no copper-enriched precipitates were observed in the low copper forging, and the measured copper content in the ferrite matrix was 0.04± <0.01 at.% Cu, after neutron irradiation to a fluence of 1.7 × 10 23 n.m –3 , this copper level was below the solubility limit. A number density of 2 × 10 22 m –3 of Ni–, Mn– Si-enriched precipitates with an equivalent radius of gyration of 1.7 ± 0.4 nm were detected in the sample. However, Cu-, Ni-, Mn-enriched precipitates were observed in specimens cut from different surveillance specimens from the same forging material in which the overall measured copper level was 0.08± <0.01 at.% (fluence of 3.6 × 10 23 n.m –3 ) and 0.09± <0.01 at.% Cu (fluence of 5.8 × 10 23 n.m –3 ). Therefore, these slightly higher copper contents were above the solubility limit of Cu under these irradiation conditions. A best fit of all the composition data indicated that the size and number density of the Cu-enriched precipitates increased slightly in both size and number density by additional exposure to neutron irradiation. High number densities of Cu-enriched precipitates were observed in the higher Cu submerged arc weld for all irradiated conditions. The size and number density of the precipitates in the welds were higher than in the same fluence forgings. Some Cu-enriched precipitates were found to have Ni-, Mn- Si-, and P-enriched regions on their surfaces suggesting a preferential nucleation site. Furthermore, atom maps revealed P, Ni, and Mn segregation to, and preferential precipitation of, Cu-enriched precipitates over the surface of a grain boundary in the low fluence weld.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Weld Consumable Conditioning on the Diffusible Hydrogen and Subsequent Residual Stress and Flexural Strength of Multipass Welded P91 Steels

P91 steel weld joint was prepared using the shielded metal arc welding process and four different conditions of weld consumable that provide the different levels of diffusible hydrogen in deposited metal. In the present research, the effects of diffusible hydrogen content on the flexural strength, lower critical stress, and tensile strength of P91 steel welds were also determined with respect to different electrode conditions. To investigate the effect of diffusible hydrogen on multipass welding, top and root side flexural tests were performed. The residual stresses (axial stress and transverse stress) were also measured using the blind hole drilling method for different conditions of welding consumable. The peak value of residual stresses was measured at the center of the weld fusion zone. The maximum value of transverse stress was measured to be 355 MPa for case II (6.21 mL/100 g of diffusible hydrogen), while the maximum axial stress was about 218 MPa for case IV (12.43 mL/100 g of diffusible hydrogen). A three-dimensional finite element simulation was also performed to predict the residual stress distribution and thermal profile along the welded joint. The experimentally determined residual stresses correlated well with the numerically estimated residual stresses. The diffusible hydrogen content was not observed to have any significant effect on the residual stresses. The corrected residual stress values were also predicted by considering the plasticity-induced error. However, the flexural performance of the welded joint was affected by the diffusible hydrogen content. The top and root flexural strength was measured to be optimum for the low level of diffusible hydrogen content, and the values decreased with an increase in diffusible hydrogen content.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling of Keyhole-Induced Pore Formation in Laser-Arc Hybrid Welding of Aluminum Alloy with a Horizontal Fillet Joint

A three-dimensional transient model is proposed to investigate the weld pool dynamic behavior in laser + metal inert gas (MIG) hybrid fillet welding of aluminum alloy in the horizontal position, which allows for the joint configuration and coupling of the keyhole, droplet and weld pool as well as the heat and mass exchange between gas and liquid phases and is able to simulate the temperature distribution, fluid flow and formation process of a keyhole-induced pore in hybrid welding with a horizontal fillet joint. The weld porosity is also measured using x-ray nondestructive testing technology. Keyhole behavior and the formation mechanism of keyhole-induced porosity were analyzed. The calculated results are in generally good agreement with the experimental ones. A clockwise vortex always exists at the middle part of the weld pool. The formation and growth of the molten metal bulge on the keyhole wall are responsible for the occurrence of a gas bubble, which has a variation in size and shape and can be split during welding. The keyhole collapses easily at its middle or upper part in horizontal fillet welding, and the capture of the bubble by the upper molten pool boundary enhances the possibility of porosity formation to some degree. The keyhole-induced pore is mainly formed at the regions near the keyhole bottom and the upper fusion line of the weld pool.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Stability of zirconium hydride

This reports complete Milestone M2.2.1 Stability of zirconium hydride: Experimental investigation of the hydrogen concentration of encapsulated zirconium hydride before and after joining. In this milestone, we first report the successful fabrication of crack-free bulk zirconium hydride by using the ORNL static hydriding system. The fabricated hydride was characterized by using X-ray diffraction (XRD) and X-ray computed tomography (XCT). XRD results showed that the δ-phase zirconium hydride, α-zirconium, and ε-phase hydride were present. XCT confirmed the absence of the internal cracking. The hydrogen concentration was determined by the weight change before and after hydrogen loading, given the fact that the oxide phase was not found during XRD analysis. Two metallic cladding materials, i.e., molybdenum and FeCrAl, were selected to encapsulate the fabricated zirconium hydride pellets. Demonstration capsules were designed and machined. Mo crucible was successfully sealed by using a combination of electron beam welding and gas tungsten arc welding. Due to the undesired neutronics property of Mo, further investigation of this cladding material was not pursued. Electron beam welding and laser beam welding were employed to seal the FeCrAl capsules. XRD were performed on the zirconium hydride before and after the sealing. The results showed that the welding process has negligible impact on the hydrogen content in the FeCrAl-canned zirconium hydride. The presented work fulfilled the proposed work under this milestone and paves a pathway to fabricate single-phase zirconium hydride and to develop robust cladding materials to can bulk zirconium hydride.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rolling Behavior of Surface Tagged Aluminum 6061 using Photoluminescent Oxides

Physical tagging of nuclear fuel is potentially one way of tracking throughout the fuel lifecycle. The process of tagging can take many forms, but one promising method is to embed a small amount of photoluminescent particles in the surface of a material which are not detectable under normal illumination but are readily visible under excitation by ultraviolet light. The goal of this project was to explore the potential to tag simulated nuclear fuel cladding with small ceramic particles, via laser beam welding or gas tungsten arc welding, and measure the photoluminescent response. Surface tagging using this method has demonstrated viability and detectability throughout this project; work in FY24 focused on the survivability of these tags through subsequent deformation processing similar to what taggants in a fuel manufacturing environment would be subjected to. This work demonstrated that particles are readily visible in the as-welded state (i.e., before subsequent rolling treatment to represent mechanical processing of a fuel material), but visibility is reduced as the deformation is induced. Despite the reduction in photoluminescence, the taggants are still visible after rolling processes are performed, making this surface tagging technique a promising candidate for nuclear fuel cladding tagging. This work demonstrated, though, that targeted optimization work would be necessary to develop a robust taggant depending on the fidelity and luminescent properties required.

36 MATERIALS SCIENCE↗
NASA NTRS1969

Gas Metal Arc /GMA/ weld torch proximity control

Adjustable transducer probe, which is attached to a welding torch and maintains a preset touch-to-work distance, accurately follows irregular surfaces, is less sensitive to heat and static interference, and has more positive response because of electro-mechanical control.

Hawkes, E. D.↗
NASA NTRS1972

State-of-technology for joining TD-NiCr sheet

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.

Holko, K. H.↗
NASA NTRS1989

Ground-Sensing Circuit For Arc Welders

Ground-sensing circuit for arc-welding power supply prevents arc burns at loose ground connections on workpiece. Used with ac supply or dc supply of either polarity. Includes oscillator/detector pairs normally shorted out by ground connections to workpiece. When one or more of these four connections broken, one or more oscillator signals applied across power diodes and detected. Detected oscillator signal trips shutoff relay.

Burley, Richard K.↗
DOE OSTI2013

Towards Real Time Diagnostics of Hybrid Welding Laser/GMAW

Methods are currently being developed towards a more robust system real time feedback in the high throughput process combining laser welding with gas metal arc welding. A combination of ultrasonic, eddy current, electronic monitoring, and visual techniques are being applied to the welding process. Initial simulation and bench top evaluation of proposed real time techniques on weld samples are presented along with the concepts to apply the techniques concurrently to the weld process. Consideration for the eventual code acceptance of the methods and system are also being researched as a component of this project. The goal is to detect defects or precursors to defects and correct when possible during the weld process.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Welding wire pressure sensor assembly

The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

Morris, Timothy B.↗
DOE OSTI2024

Enhancing NDE Reliability for Grade 91 Steel Welds: Ultrasonic Imaging and Microstructural Correlations

Ensuring the integrity of Grade 91 (9Cr-1Mo-V) steel welds is vital for the safe and reliable operation of fossil fuel–fired and nuclear power plants. Here, this study applies an imaging technique for the ultrasonic characterization of two Grade 91 steel welds created with cold metal transfer and flux-cored arc welding processes. Ultrasonic immersion testing in the through-transmission configuration was employed to generate shear waves, which helped identify the weld metal, heat-affected zone, and base metal regions. These weld microstructures were also correlated to their ultrasonic images using metallography, ultrasonic amplitude, hardness measurements, and grain size. The findings from this study can assist practitioners in developing new nondestructive evaluation technologies, improving the inspection reliability of creep strength–enhanced ferritic steel welds by potentially identifying weld microstructure regions susceptible to creep-type failures.

Grade 91 steel↗
NASA NTRS1993

Measuring Weld Parameters By Spectroscopy

Optical-emission spectrometric apparatus used to monitor variable-polarity plasma arc welding of aluminum alloys. Spectrometer incorporated into control system to ensure quality of weld because in keyhole, arc fully penetrates weld joint and impurities flushed out. Apparatus helps ensure high quality of weld by monitoring such contaminants as oxygen and hydrogen in shield gas, detecting inadequate flow of shield gas, and sensing changes in temperature of arc with changes in arc current and voltage.

Nunes, Arthur↗
DOE OSTI2019

Microstructure and Mechanical Characterization of Incoloy 925 Welds in the As-Welded and Direct Aged Conditions

The joints of Incoloy 925 obtained from gas tungsten arc welding (GTAW) with pulsating current utilizing ERNiCrMo-3 and ERNiCrMo-10 were investigated under as-welded and direct aged conditions. The microstructure showed the microsegregation of Nb-Mo-, Ti-rich phases in the weld zone of ERNiCrMo-3 in the as-welded condition. Post-weld heat treatment (PWHT) involving direct aging was carried out on the weldments at 732 °C for 4 h followed by air cooling. On direct aging, the tensile strength of the base metal increases by 40% when compared to the as-received ones. The failures were experienced in the parent metal of Incoloy 925 upon tension testing in as-welded conditions. Although the tensile strength was improved considerably, the failures occurred at the fusion zones, for both the fillers in the direct aged conditions. The joint efficiencies of Incoloy 925 welds employing ERNiCrMo-3 and ERNiCrMo-10 were reported as 95 and 86%, respectively. The impact toughness of the weldments in both the as-welded and PWHT conditions was considerably greater compared to that of the candidate metal.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Phase structures and morphologies of tempered CA6NM stainless steel welded by hybrid laser-arc process

The post-weld tempered microstructure of hybrid laser-arc welded CA6NM, a cast low carbon martensitic stainless steel, was investigated. The microstructural evolutions from the fusion zone to the base metal were characterized in detail using optical microscopy, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), X-ray diffraction (XRD) and microhardness techniques. The fusion zone, in its post-weld tempered condition, consisted of tempered lath martensite, residual delta-ferrite with various morphologies, reversed austenite and chromium carbides. The reversed austenite, which can be detected through both EBSD and XRD techniques, was found to be finely dispersed along the martensite lath boundaries, particularly at triple junctions. Based on the EBSD analysis, the orientation relationship between the reversed austenite and the adjacent martensite laths seemed to follow the Kurdjumov-Sachs (K-S) model. The results also revealed the presence of the reversed austenite in the different regions of the heat affected zone after post-weld tempering. The microindentation hardness distribution was measured, and correlated to the evolution of the corresponding microstructure across the welds. - Highlights: •The EBSD analysis was performed on hybrid laser-arc welded CA6NM. •The FZ consisted of tempered lath martensite, reversed austenite, carbides and δ ferrite after tempering. •The reversed γ was formed along the α′ lath boundaries, particularly at triple junctions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Assessment of Weld Microstructure Through Sound Velocity Measurements for Power Plant Applications

Here, this research study employed an immersion-based micro-resolution ultrasonic velocity measurement technique (MUVT) to evaluate Grade 91 (9Cr-1Mo-V) steel welds. This process utilized a 20 MHz focused ultrasonic beam with a spot size of 250 µm, a 6 µm laser vibrometer spot size for detection, and an automated 3-axis raster scanner to accurately collect ultrasonic velocity data from two Grade 91 steel welds fabricated using cold metal transfer (CMT) and flux-cored arc welding (FCAW) processes. By analyzing the MUVT data, the Poisson’s ratio (υ) and modulus of elasticity (E), which are important mechanical properties for weldments, were calculated. The correlation between mechanical properties and ultrasonic velocity was examined. The results indicated that longitudinal ultrasonic velocity could effectively identify base metal, heat-affected zone (HAZ), and weld metal areas, showing a strong correlation with hardness. In particular, the distinctive V-shaped dip in velocity and hardness data across the HAZ areas of both samples highlighted changes in the microstructure of creep strength–enhanced ferritic steel welds. Importantly, the immersion-based MUVT demonstrated high accuracy in small sections of the weld, surpassing the conventional contact ultrasonic testing method in spatial resolution detection.

arc welding↗
DOE OSTI2018

Alternative PWHT to Improve High-Temperature Mechanical Properties of Advanced 9Cr Steel Welds

Creep-resistant 9Cr steels are extremely important in thermal power generation industry due to their marked resistance to creep and corrosion. The weldability of these alloys is critical since they are used in welded construction equipment. The required mechanical properties are achieved after post-weld heat treatment. This study examined the effect of different post-weld heat treatments on microstructure and mechanical properties of creep strength-enhanced 9Cr steel welding deposits. It was obtained with an experimental flux-cored arc welding wire used under protective gas (Ar-20% CO{sub 2}). The heat treatments used were: (1) tempering (760 °C × 2 h), (2) solubilizing (1050 °C × 1 h) + tempering (760 °C × 2 h) and (3) solubilizing (1150 °C × 1 h) + first tempering (660 °C × 3 h) + second tempering (660 °C × 3 h). All-weld metal chemical composition was analyzed, and hot tensile tests were carried out at different temperatures. Charpy-V impact tests and Vickers microhardness measurements were also performed. Microstructures were studied using x-ray diffraction and optical and scanning electron microscopy. In all cases, a martensitic matrix with intergranular and intra-granular precipitates was detected. In the as-welded condition, δ-ferrite was also found. Microhardness dropped, and the impact energy increased with post-weld heat treatments. The highest hot tensile strength result was achieved with samples submitted to austenization at 1150 °C and double tempering at 660 °C.

36 MATERIALS SCIENCE↗