New developments in aluminum welding.
Aluminum welding, examining internal defects such as porosity and metallurgical changes in heat effected zone
METAL-METAL BONDING↗
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Hybrid Ultrasonic TOFD Imaging of Weld Flaws Using Wavelet Transforms and Image Registration
Ultrasonic time of flight diffraction (TOFD) is an effective weld crack inspection technique. Due to the intensity of diffraction wave is rather weak compared with the lateral wave and the bottom echo wave, thus the signal-to-ratio (SNR) of TOFD image is low. A new dichotomous method is comprised of two steps that contains wavelet shrinkage and image registration is proposed in this paper to reduce the noise and improve the resolution of TOFD images as well. In order to evaluate the reliability of our proposed method in this paper, we have established the experiment system, and sampled a number of TOFD data with random distribution of noise characteristics. We adopted one-dimension wavelet transform and two-dimension wavelet transform in the very beginning of the first step of the proposed algorithm respectively. The SNR of the result obtained in this step is improved significantly compared with the classic algorithms. Next, the image registration is applied. After the registered images have been added to form a new one, then it comes to the final result that shows not only the SNR but also the definition of the image is enhanced effectively.
42 ENGINEERING↗
Dissolution of Nb(C,N) and (Ti,V)N in the Coarse-Grained Heat-Affected Zone of Electric Resistance Welded X65 Line Pipe
Nb-rich and Ti/V-rich precipitates were introduced into the X65 linepipe via thermomechanical controlled processing. Their dissolution kinetics were investigated in the coarse-grained heat-affected zone after electric resistance welding. Nb-rich precipitates were found to dissolve completely, whereas Ti/V-rich precipitates were found to dissolve partially, because of slower dissolution kinetics. In conclusion, a complete dissolution of Nb-rich precipitates was associated with significant austenite grain coarsening, which promoted bainite as a quench product, which might have reduced the impact toughness.
microstructure↗
Friction Stir Welding of Al-B{sub 4}C Composite Fabricated by Accumulative Roll Bonding: Evaluation of Microstructure and Mechanical Behavior
In this investigation, friction stir welding (FSW) of Al-B{sub 4}C composite fabricated by 10 cycles accumulative roll bonding was conducted. In order to investigate the influences of pin geometry on microstructure and mechanical properties, four different pin geometries (cylindrical, square, triangular and hexagonal) were selected. It was found that FSW parameters had a major effect on the fragmentation and distribution of reinforcement particles in stir zone. When the tool travel speed was increased, the distribution of B{sub 4}C particles was become gradually uniform in the aluminum matrix. The effect of tool rotational speed on the peak temperature was determined to be greater than the tool travel speed. The attained data of tensile properties and microhardness tests showed that the tool travel speed had bilateral effect on the tensile strength. The maximum tensile joint efficiency was obtained as 238% for FSWed of Al-2%B{sub 4}C composite to annealed base Al sheet.
36 MATERIALS SCIENCE↗
Process Parameter Optimization in Refill Friction Spot Welding of 6061 Aluminum Alloys Using Response Surface Methodology
6061-T6 aluminum alloy joint was fabricated by refill friction stir spot welding (RFSSW) on which three process parameters of tool rotation speed, sleeve moving rate, and plunge depth make an important effect. The response surface methodology (RSM) was applied to establish a mathematical model to study the effect of process parameters on lap shear fracture load (LSFL) of the RFSSWed joints which were performed in Box–Behnken designs with three factors, three levels and 15 runs. Analysis of variance used to check the adequacy of the developed model indicates that the mathematical model is significant. LSFL increases with the increase in tool rotation speed, sleeve plunge depth, and sleeve moving rate to maximum and then decreases. Sleeve plunge depth makes the most effect on LSFL in all process parameters. The RFSSW process parameters were also optimized using RSM to predict maximize LSFL. The joint produced using a tool rotational speed of 1506 rpm, sleeve moving rate of 1.01 mm/s and sleeve plunge depth of 2.46 mm displays higher LSFL.
36 MATERIALS SCIENCE↗
Microstructure and Wear Resistance of FeCrBSi Plasma-Sprayed Coating Remelted by Gas Tungsten Arc Welding Process
Herein, an FeCrBSi coating was fabricated via plasma spray on AISI1045 steel, and subsequently, a gas tungsten arc welding (GTA) process was employed to remelt the coating. The microstructure, microhardness, fracture toughness and surface roughness of the coating before and after remelting were investigated, as well as the wear resistance was tested by a UMT-3-type sliding wear apparatus. The results showed that, upon remelting, most defects in the as-sprayed coating were effectively eliminated, the surface roughness decreased by 43%, and the coating–substrate interface bonding changed from mechanical to metallurgical. The phase composition of the as-sprayed coating was primarily α-Fe and a small amount of hard Fe{sub 3}B phase, while the remelted coating consisted of α-Fe and (Fe,Cr){sub 23}C{sub 6} and a small quantity of CrB. In addition, remelting the coating was found to induce a 287.6% increase in the fracture toughness, a 33.4% increase in the average microhardness, and a 47.5% decrease in the wear volume, while the failure mechanism changed from abrasive wear to fatigue wear upon remelting. Therefore, GTA remelting of plasma-sprayed coating was found to be a feasible method to obtain a coating with good wear resistance.
36 MATERIALS SCIENCE↗
Residual Stresses in Explosively Welded Plates Made of Titanium Grade 12 and Steel with Interlayer
Distributions of residual stress components in explosively welded three-layer plate composed of titanium Grade 12, titanium Grade 1 and SA516 Grade 70 steel are investigated in this paper. The study applied the sectioning and the hole-drilling strain gage methods for residual stress measurement. The results have shown an inhomogeneous residual stress distribution, approximated by fourth-order polynomial along the thickness of a three-layer plate. Biaxial compressive residual stress state is observed in titanium Grade 12 and Grade 1 layers which change to tensile type in the vicinity of the interface between titanium Grade 1 and steel. Microstructure observation reveals the presence of the adiabatic shear bands in titanium Grade 12 layer at the interface with titanium Grade 1 interlayer. The observed distribution of residual stress components is justified by the occurrence of the shock wave phenomena.
36 MATERIALS SCIENCE↗
High Wear-Resistant Aluminum Matrix Composite Layer Fabricated by MIG Welding with Lateral B{sub 4}C Powder Injection
In this work, a low-cost technique combining MIG welding and lateral powder injection was developed to fabricate B{sub 4}C particles-reinforced aluminum matrix composite (AMC) layer on a T6 heat-treated 7075 aluminum alloy (AA7075-T6) substrate. The AMC layer was 6-7 mm thick and well bonded to the substrate. The B{sub 4}C particles were dispersed throughout the AMC layer with an average content of approximately 7 vol.%. No significant reaction products existed either at the particle–matrix interface or in the Al-matrix. In pin-on-disk dry sliding wear tests against Al{sub 2}O{sub 3} grinding wheels, the AMC layer exhibited excellent wear resistance with volume wear rate approximately 1/10-3/10 that of the quenched AISI 1045 steel and only approximately 2-7% that of the AA7075-T6 alloy under the same wear conditions. A small addition of ceramic particles can greatly improve wear resistance, suggesting that this technique has good prospects for a wide variety of applications.
36 MATERIALS SCIENCE↗
Variation in Morphology and Kinetics of Granular Bainite with Welding Thermal Cycles in High-Nb Fire-Resistant Steel: Experiments and Theoretical Calculations
The microstructure and kinetics of granular bainite (GB) were investigated in novel fire-resistant steel containing high niobium and subjected to simulated welding thermal cycles. The dilatometric data were analyzed to determine the activation energy and Avrami exponents. It was observed that austenite transformed to GB over a wide range cooling rates of 0.5-100 K/s. Theoretical calculations indicated that Avrami exponent (n) decreased with increased transformed volume fraction (f{sub b}) and cooling rate. At a moderate cooling rate of 20-6 K/s, bainitic ferrite as sheaves formed from austenite and the corresponding Avrami exponent was 2 < n < 3. Martensite in martensite/austenite constituent formed with Avrami exponent n ~ 1. At the fastest cooling rate of 50 K/s, lath bainitic ferrite and film-like retained austenite (RA) were obtained with the corresponding Avrami exponent n ~ 1. At lower cooling of 1 and 0.5 K/s, plate-like bainitic ferrite and block-like microphase composed of lamellar RA and ferrite were obtained with Avrami exponent n > 3. The local activation energy for austenite transformation to bainitic ferrite decreased from ~ 198 to ~ 182 kJ/mol with increasing f{sub b} from 0.05 to 0.95, while the local activation energy for austenite transformation to martensite decreased from ~ 80 to ~ 71 kJ/mol with increasing f{sub b} from 0.05 to 0.95.
36 MATERIALS SCIENCE↗
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↗
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↗
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↗
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↗
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↗
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↗
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↗
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↗
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↗