The effect of pressure on the gas metal-arc welding of aluminum alloys.
Pressure effect on metal transfer and weld-bead shapes in arc welding of aluminum alloys in argon
ALUMINUM ALLOY↗
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Welding-base metal investigation Final report, 27 Jun. 1964 - 28 Jul. 1965
Weld defects associated with aluminum alloys - monitoring weld shielding gas purity
SHIELDING↗
A study of welded connections in cordwood electronic modules Final report
Fusion welding and weld strengths or ribbon and wires in cross-connections of cordwood electronic modules
ELECTRONIC MODULE↗
Structural analysis of bonded honeycomb welded joints.
Structural analysis of welded joints in composite welded panels using beam column concepts
WELDED STRUCTURE↗
Autogenous welding in airplane construction
Autogenous welding is discussed and various methods of testing those welds are presented.
TUBING, STEEL WELDED↗
Exploration Extravehicular Mobility Unit (xEMU): Electron Beam Welding of the Portable Life Support System (PLSS) Ti-6Al-4V Backplate with Integrated Cooling Channels
The Exploration Extravehicular Mobility Unit (xEMU) is the first clean sheet redesign of the astronaut spacesuit in approximately 40 years. NASA Langley Research Center’s electron beam welding team, of which the author is a member, is leading the development of the weld technology required to manufacture the backplate component of the Portable Life Support System (PLSS). This backplate will provide both structural support and integral cooling for the life support systems, communications, and other electronics inside the spacesuit.
electron beam welding↗
Friction Stir Processed Repair Welding of Dry Storage Canisters and Mitigation Strategies: Effect of Engineered Barrier Layer on Environmental Degradation
The proposed project aims to develop a friction sir based repair technique to heal cracks of stainless steel dry storage canisters (DSCs), created by the effect of stress corrosion cracking (SCC). In real service conditions, the welded parts of the canisters become prone to SCC under exposure to aggressive chemical environment. The focus of the project is on developing a mitigation strategy that can be implemented for countering SCC in DSCs following a two-pronged approach: (i) apply friction stir processing (FSP) as a crack repair technique while creating compressive residual stresses at the canister material surface, thus improving resistance against SCC; (ii) add molybdenum and/or nitrogen by friction stir based alloying process to create compositions that improve pitting resistance and thus enhance resistance against SCC. The specific project objectives are listed below: • Investigate FSW of 304L SS a potential repair welding technique of dry storage canisters; • Optimize the FSW parameters to introduce surface compressive stress profiles in the weldments; • Develop a FSP method to surface alloy the 304L with nitrogen and Mo by adding CrN and Mo powders; • Evaluate the surface compressive residual stress profile during FSW and FSP processes; • Evaluate the localized corrosion resistance of the FSW and FSP samples as a function of temperature, chloride concentration, and surface alloy composition; • Evaluate the SCC behavior of the FSW and FSP samples as a function of stress, chloride concentration, and temperature at different surface chemistries and induced residual stress profiles.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
THE ROLE OF FRACTURE PROPERTIES ON LAP JOINT STRENGTH OF FRICTION STIR WELDED AA7055-T6 SHEETS
Friction stir lap welded (FSLW) joints have weight-saving potential in aluminum-intensive automotive assembly. However, FSLW also modifies the material microstructure close to the joint. Optimizing the FSLW process requires understanding the relationship between the strength and the joint's microstructure. In previous studies, efforts have been dedicated to determining the effects of local softening, the shape of the oxide line, and porosity. However, the impact of changes to the fracture properties on the joint's strength has not been studied. In this work, strength testing, and simulations, aided by material characterization, were used to determine the role of fracture properties on the shear strength of a 3-sheet (aluminum alloys 7055-7055-6022) lap joint. Characterization involved testing for fracture properties in the weld region. This data was then implemented into finite element simulations. As a result, the joint strength was predicted with a deviation of less than 6% from the experimental value. Comparison with strength prediction using only the base metal properties indicates that fracture property in the nugget region determines the strength of AA7055 FSLW.
Finite element analysis, Friction stir welding, ma↗
Evaluating the Electrochemical Behavior of Friction Stir-Welded AA2219-O Alloy Joint in 3.5% NaCl Solution
Single-pass friction stir welding of AA2219-O aluminum alloy was carried out at high rotation speed (1180 rpm), and transverse travel rate of 33.5 mm/min was selected. The microstructural, mechanical and electrochemical characteristics of the weldment are investigated in this study. The high rotational tool speed resulted in a less uniform distribution of the intermetallic θ-phase (CuAl{sub 2}) in the thermo-mechanically affected zone (TMAZ) than in the weld nugget zone (WNZ). The higher transfer coefficient and lower charge transfer resistance (R{sub ct} + R{sub θ}) were observed in case of TMAZ as evaluated from potentiodynamic polarization and impedance spectroscopy, respectively. These results confirmed that microstructural variations could deteriorate the electrochemical performance of the weldment. TMAZ provided the least corrosion resistance than the base metal (BM) and WNZ due to the high concentration of cathodic intermetallic particles and possibly due to the large mechanical distortion of the grain structure.
36 MATERIALS SCIENCE↗
Microstructure and Mechanical Properties of Rapidly Cooled Friction Stir Welded Ti-6Al-4V Alloys
Two mm-thick Ti-6Al-4V alloy plates were friction stir butt welded under natural- and rapid-cooling conditions. The microstructures and mechanical properties of joints were investigated and compared. The rapid cooling via spraying cooling liquid nitrogen on the plate top surface was beneficial to obtaining a narrower cross section and finer and more uniform grains in the stir zone than those obtained by natural cooling. Joint tensile strength of 1021 MPa and elongation of 1.88% under the rapid-cooling condition respectively reached 102.7 and 150.4% of those under the natural-cooling condition, respectively. The uniform-and-compact equiaxed grains led to equiaxed dimples on the fracture surface, which demonstrated a ductile fracture of the welding joints.
36 MATERIALS SCIENCE↗
Microstructures and Mechanical Properties of Resistance Spot-Welded Steel/Aluminum Alloy Joints with Process Tapes
The microstructure and mechanical property of resistance spot-welded joints of steel and aluminum were studied by using process tapes. The steel/aluminum joint consists mainly of aluminum nugget and interface zone. The liquid nugget solidification has an epitaxial growth characteristic, and the interface zone displays a double-layer structure, Fe{sub 2}Al{sub 5} layer at steel side and Fe{sub 4}Al{sub 13} layer at aluminum nugget side. Compared with joints without process tape, the joint nugget diameter and tensile shear load increased by 35.45 and 10.98%, respectively, and its indentation ratio decreased by 56.25% due to the process tapes increasing heat input, producing larger nugget diameter and continuous interface layer, and protecting against deep indentation. The joining area of intermetallic layer and aluminum nugget is weak link in the joint. It is favorable to use the process tapes for improving welding quality, raising joint strength, and energy saving.
36 MATERIALS SCIENCE↗
Effects of Rotation Speed on Microstructure and Mechanical Properties of 2060 Al-Cu-Li Alloy in Friction Stir Welding
Microstructural and mechanical properties of 2.0-mm-thick 2060 Al-Cu-Li alloy joints obtained at different rotation speeds were assessed in this study. The rotation speeds ranged from 400 to 1300 rpm, with welding speed kept at a constant value of 100 mm/min. With the increase in rotation speed, grain coarsening occurred while the density of precipitation decreased in the stir zone (SZ), and great amounts of the Al{sub 2}CuLi and Al{sub 2}Cu phases were dissolved while only small amounts of the Al{sub 3}Zr and Al{sub 3}Li phases remained. The lowest hardness was found at the interface between the heat-affected zone (HAZ) and thermo-mechanically affected zone (TMAZ); the average hardness value of SZ increased, while the lowest hardness moved in the direction away from the center of joints. The ultimate strength (UTS) of weld first increased rapidly and then slowly decreased as rotation speed increased, with a maximum value of 443 MPa obtained at a rotation speed of 600 rpm, reaching 83.58% of the base metal (BM) strength. Three fracture modes were established to illustrate the growth mechanism of the crack. Analysis of the fracture surface showed that insufficient materials flowed and coarsened secondary phases caused the joint fracture.
36 MATERIALS SCIENCE↗
Influence of Annealing on the Properties of Explosively Welded Titanium Grade 1—AW7075 Aluminum Alloy Bimetals
Explosive welding of titanium Grade 1 to AW7075 aluminum alloy arranged in parallel setup was performed. The annealing of produced bimetals at the temperatures of 450, 500 and 550 °C for times ranging from 20 to 100 h was carried out after explosive welding. The produced bimetal was characteristic by its wavy interface typical for that bonding process. Increase in the microhardness at the interface was recorded due to work hardening. Delamination of titanium Grade 1 flyer sheet was firstly observed when annealing temperature of 500 °C for 40 h was carried out. Annealing at 550 °C also resulted in delamination of upper sheet. The intermetallic compound (IMC) layer was observed at the interface after annealing of bimetals. The higher the annealing temperature and time, the higher the thickness of continuous IMC layer. The maximum measured thickness of IMC layer averaged 13 µm. Energy dispersive x-ray spectroscopy (EDS) and x-ray diffraction (XRD) analyses revealed that the interface layer is consisted of Al{sub 18}Ti{sub 2}Mg{sub 3} IMC. Microhardness at the interface increased dramatically up to 439 HV0.1 after annealing of bimetal due to the presence of above-mentioned IMC.
36 MATERIALS SCIENCE↗
Microstructure and Mechanical Properties of Exothermic-Reaction-Assisted Friction-Stir-Welded Nickel-Aluminum Bronze Alloy
In the present work, nickel-aluminum bronze alloy is joined using conventional friction stir welding (CFSW) and thermite heat-assisted friction stir welding (THAFSW). In this experiment, preheating technology was utilized using the thermite reaction of Al-CuO powder. A substantial rise in temperature was observed during THAFSW which is beneficial to the eliminations of tunnel defect. In THAFSW, a large amount of α-phase was observed from the top to the center in stir zone as a result of the rise in temperature. Transverse tensile strength of the THAFSW and CFSW was improved by 27 and 14%, respectively, in comparison with base metal tensile strength. A higher microhardness values observed at the bottom of the stir zone in the THAFSW, while this was seen higher in the surface zone and the center zone in the case of CFSW. Tool wear was reduced during the THAFSW process.
36 MATERIALS SCIENCE↗
Numerical Simulation of Residual Stresses in Multipass Gas Metal Arc-Welded Joints of Thick Aluminum Alloy Plates
Numerical simulation was utilized to investigate the residual stresses in the multipass gas metal arc-welded joints of high-strength Al-Zn-Mg alloy plates. In order to elevate the reliability of numerical simulation, the heat source model, parameters characterizing the thermal and mechanical properties, boundary conditions, material constitutive model and finite element meshing were discussed in detail. As a novelty of this paper, the modified Arrhenius constitutive equation of the base material and the filled material was obtained according to the results of high-temperature tensile tests. Distributions of stress on the upper and bottom surface of the joint were obtained based on numerical simulation. Special attention was paid to the evolutions of local residual stress on the bottom surface of the joint, and it’s found that residual stresses on the bottom surface of the joint were almost unchanged after the weld seam approached a certain thickness. Blind-hole method and x-ray method were adopted to detect the residual stresses on the surfaces to verify the accuracy of the results obtained by numerical simulation.
36 MATERIALS SCIENCE↗
Numerical Simulation of Residual Stress for Laser Welding of Ti-6Al-4V Alloy Considering Solid-State Phase Transformation
In the present work, a thermal-metallurgical-mechanical model which considered the influence of phase transformation was used to predict the residual stress field of Ti-6Al-4V after laser welding. In this model, the Johnson–Mehl–Avrami equation was used to predict diffusional solid-state phase transformations: α phase to β phase during heating and β phase to α phase during cooling. The Koistinen–Marburger equation was used to predict diffusionless solid-state phase transformation of β phase to martensite during cooling. The properties of material were obtained using a mixing rule based on the phase fraction and the property of each pure phase. By applying this model, the effect of solid-state phase transformations of Ti-6Al-4V alloy on temperature field and stress field during laser welding was considered in the simulation. In addition, experiments were carried out for comparison, which significantly verified the accuracy of the applied model.
36 MATERIALS SCIENCE↗
Butt Laser Welding–Brazing of AZ31 Mg to Nickel-Coated Ti-6Al-4V
Mg and Ti alloy are hard to be bonded due to their huge discrepancy in physical and metallurgical characteristics. As an intermediate element, Ni is feasible for joining of Mg and Ti. The interfacial microstructure and mechanical properties of laser-welded–brazed AZ31 Mg/Ti-6Al-4V joints in butt configuration were investigated with different thicknesses of electrodeposited Ni interlayer. The interfacial reaction products evolved from an ultra-thin Ti{sub 3}Al layer to Ti{sub 2}Ni layer mingled with Ti{sub 3}Al, and more Mg{sub 3}AlNi{sub 2} compounds were produced in the fusion zone (FZ) as Ni coating thickness increased. Slag inclusions and cracks were observed in interfacial layer when coating thickness exceeded 2.5 μm. The quantity of Mg{sub 3}AlNi{sub 2} and the thickness of interfacial layer decreased from the top to bottom of groove of the same joint owing to high thermal gradient during laser welding. The chemical potential of Al and Ni indicated that Al-Ti reaction product was produced more easily than Ni-Ti in 0.001Mg-(Ni-Al-Ti) system. The thermodynamic calculation results of Gibbs free energy suggested the preferential formation Ti-Al phase and Ti-Ni phase along the interface while the Mg-Al-Ni ternary phase in the FZ. Fracture loads of joints increased first followed by a decline with the increase in coating thickness. The joint fractured at the Mg base metal, reaching a maximum value of 3900 N with the Ni coating thickness of 1.5 μm. In the case of using thinner or thicker Ni coating, crack propagated along the interface due to the insufficient metallurgical bonding or defects existed in the interfacial layer. The characteristic of fracture surface changed from the tear ridges and terraces to river pattern when interfacial failure occurred.
36 MATERIALS SCIENCE↗
Effect of a Zinc Interlayer on a Cu/Al Lap Joint in Ultrasound-Assisted Friction Stir Welding
This study proposes a welding process, ultrasound-assisted friction stir welding of dissimilar Al/Cu metals. Zinc foil is melted using the heat generated by a pinless stirring tool, and the molten intermediate layer is stirred by ultrasonic cavitation to achieve an effective connection. The metallurgical reaction behavior of the joint under the action of the sound field was studied, and the effects of different microstructures on the joint performance were analyzed. Specifically, the following observations were reported in this study: (1) When ultrasound assistance was used, the cavitation effect changed the brittle intermetallic compounds of Al{sub 2}Cu from a continuous distribution to a block distribution, and the mechanical properties of the joint were greatly improved; (2) the effects of the thickness of the zinc were also determined. The results showed that the highest shear tensile force was obtained when the thickness of the zinc foil was 0.2 mm. When the thickness was 0.3 mm, the ultrasound effect was weakened. The copper-side interface generated a zigzag-shaped Al{sub 4.2}Cu{sub 3.2}Zn{sub 0.7} layer with a thickness of 3.4 μm and had a continuous distribution. Increasing the thickness of the zinc to 0.5 mm, however, drastically decreased the mechanical properties of the joint due to incomplete melting of the zinc layer.
36 MATERIALS SCIENCE↗