Welding in the World最新文献

{"title":"Detection of hot water boiler tubes inner surface damages at early stage of their development using the metal magnetic memory method","authors":"Anatoly Dubov,&nbsp;Alexander Dubov,&nbsp;Sergey Kolokolnikov,&nbsp;Artem Marchenkov","doi":"10.1007/s40194-025-01934-6","DOIUrl":"10.1007/s40194-025-01934-6","url":null,"abstract":"<div><p>Operational reliability of boilers and heat exchangers strongly depends on reliability of heating surface tubes. A wide range of non-destructive testing (NDT) technologies applied for their diagnostics includes various methods of eddy current testing, magnetic stray fields, an ultrasonic immersion echo method, laser optics, and visual inspection. However, all the above methods have limitations in their application. Moreover, conventional NDT methods are aimed at detecting only the existent defects. One of the solutions to prevent unexpected damages of heating surface tubes is the application of stress–strain state (SSS) control methods. This approach allows detecting the stress concentration zones (SCZs) as the main sources of the future defects initiation. Therefore, it becomes possible to identify defects at an early stage of their development, and monitor their propagation. The metal magnetic memory (MMM) method is a passive technique of magnetic testing. It is based on the self-magnetic stray field analysis that allows assessing the SSS of tested objects. The MMM method is used as a screening tool for diagnosis of impending failure of critical industrial equipment. The article discusses the MMM method application for the inspection of the inner surface of the boiler heat exchanger steel tubes. The examples of the SCZs detection and the identification of defects in these zones at an early stage of their development are presented. The influence of the revealed SCZs on the strength characteristics of the tube metal is shown. The relationship between the material strength characteristics and the magnetic characteristics of MMM testing is presented calculating the magnetic strain index <i>m</i>.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"727 - 738"},"PeriodicalIF":2.4,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396508","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"AI-driven autonomous adaptative feedback welding machine","authors":"Benedikt von Querfurth,&nbsp;Shems-Eddine Belhout,&nbsp;Christian Knaak,&nbsp;Stefan Mann,&nbsp;Peter Abels,&nbsp;Carlo Holly,&nbsp;Jonathan Tatman,&nbsp;Darren Barborak,&nbsp;Mitch Hargadine","doi":"10.1007/s40194-024-01898-z","DOIUrl":"10.1007/s40194-024-01898-z","url":null,"abstract":"<div><p>The gas tungsten arc welding (GTAW) is a primary method for nuclear component fabrication and repair. Recent advancements in monitoring and automation technologies have made the shift toward fully automated arc welding more feasible, reducing the necessity for continuous human oversight. Two artificial intelligence-based networks were developed that utilize sensor-based feedback on a mechanized GTAW head. We present an image-based semantic segmentation convolutional neural network that identifies crucial features such as the weld pool, groove, wire, and electrode based on which geometric measurements are derived. A separate novel neural network predicts the weld bead geometry for multi-pass welds and inconsistent groove geometries. The application of both neural networks is a pre-requisite that enables the autonomous planning and execution of multi-pass welds to fill a groove.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 5","pages":"1419 - 1426"},"PeriodicalIF":2.4,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01898-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835759","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Monitoring of DE-GMAW process in human–robot collaboration","authors":"Yue Cao,&nbsp;Heping Chen,&nbsp;YuMing Zhang","doi":"10.1007/s40194-025-01936-4","DOIUrl":"10.1007/s40194-025-01936-4","url":null,"abstract":"<div><p>Double-electrode gas metal arc welding (DE-GMAW) improves traditional GMAW by adding a non-consumable tungsten electrode, creating a bypass loop that decouples heat input and deposition rate. The bypass arc, critical for establishing the bypass loop, is affected by the bypass electrode position in both horizontal and vertical directions. However, the impact of the bypass electrode positioning has not been studied. This work focuses on monitoring human operations in DE-GMAW within a human–robot collaboration (HRC) setting, aiming to understand the process. Initially, the impact of bypass electrode position on arc morphology and metal transfer was studied, revealing the diversity of the process and the importance of precise electrode positioning. Subsequently, a convolutional neural network was trained using augmented data to accurately detect essential positional information from welding images, thereby determining the optimal operational positioning during human operation. Finally, the relationship between bypass arc voltage and position was quantified using Gaussian Process Regression (GPR), showing that this signal can effectively reflect the process state. This study advances the understanding of DE-GMAW and human operational intelligence, laying a foundational basis for automating the process.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 5","pages":"1427 - 1435"},"PeriodicalIF":2.4,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835692","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-power ultrasonic spot welding of copper to type 304L austenitic stainless steel","authors":"Mohamed Wahba,&nbsp;Sami M. Ibn Shamsah,&nbsp;Mohamed A. H. Gepreel,&nbsp;Macoto Takahashi","doi":"10.1007/s40194-024-01905-3","DOIUrl":"10.1007/s40194-024-01905-3","url":null,"abstract":"<div><p>The demand for a robust welding technique capable of joining copper and steel is driven by their extensive application across various industrial sectors. Addressing the limitations of current welding methods, this study explores the effectiveness of ultrasonic welding in joining commercially pure copper to type 304L stainless steel. The effects of different welding parameters on the characteristics of the welded joints were investigated. The results demonstrate the successful welding of the two metals without inserting an interlayer despite the metallurgical immiscibility of copper and iron. The interfacial bond density and the joint strength were found to increase with the applied welding energy. A joint strength of approximately 80% of the base copper strength was obtained. Transmission electron microscopy (TEM) analysis unveiled a well-bonded interface with excellent continuity between the two metals. A diffusion layer containing nano-sized chromium-rich oxide or intermetallic compound particles was observed. It was noticed that copper penetrated the partially disrupted chromium-rich oxide layer reaching and developing intimate contact with the newly uncoated stainless steel surface. A synergy of mechanical interlocking and solid-state metallurgical adhesion was revealed for the bonding mechanism in addition to potential metallurgical interactions at the interface.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 2","pages":"555 - 569"},"PeriodicalIF":2.4,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01905-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108417","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigating the effect of varying powder size range on particulate matter emission and mechanical properties of in situ micropowder alloyed WAAM depositions","authors":"Adarsh Prakash,&nbsp;Rubal Dhiman,&nbsp;Anirudha Ambekar,&nbsp;Thaseem Thajudeen,&nbsp;Sachin Dnyandeo Kore","doi":"10.1007/s40194-024-01922-2","DOIUrl":"10.1007/s40194-024-01922-2","url":null,"abstract":"<div><p>Wire Arc Additive Manufacturing (WAAM) fabricates 3D products by laying molten filler wire in layers, resulting in final products with properties similar to the parent filler wire. In situ micro powder alloying during WAAM can modify the deposited material without changing the parent filler material to enhance its mechanical properties. This study investigates the effects of adding titanium (Ti) and copper (Cu) micro powders in different size ranges (&lt; 25 µm, 25–45 µm, and 45–95 µm), within the layers of carbon steel in multilayered vertical walls during WAAM. The analysis of the variations in the mechanical and metallurgical properties of WAAM deposited samples is also done along with the dynamics of fine and ultrafine particle (UFP) emissions resulting from WAAM depositions, with and without the incorporation of CuTi powder. Real-time data acquisition of particulate matter (PM) concentration was carried out with a combination of low-cost particulate matter sensors (LCS) and scanning mobility particle sizer (SMPS). The incorporation of CuTi powder in various sizes has been observed to improve the mechanical properties, with the most significant enhancement noted in samples containing CuTi powder with sizes ranging from 25 to 45 µm. This improvement is likely attributable to the superior adhesion and uniform distribution of these particles across the surface compared with samples containing CuTi powder of finer size ranges. Variations in PM and UFP levels across different sizes of CuTi powder revealed that smaller-sized CuTi particles (less than 25 µm or 25–45 µm) demonstrate superior combustion compared with larger particles (45–95 µm). Consequently, larger particles contribute to higher PM and UFP emissions. The importance of micro powder size on mechanical properties enhancement is studied in detail along with the emission characteristics of CuTi micropowder added WAAM depositions, to understand the potential for identifying an optimized size range of micropowders.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1171 - 1190"},"PeriodicalIF":2.4,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581139","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The influence of weld start reentrant angle on fatigue life determined through analysis and physical testing","authors":"D. Bradley Cook,&nbsp;Christy Lee,&nbsp;Donald Stickel","doi":"10.1007/s40194-024-01906-2","DOIUrl":"10.1007/s40194-024-01906-2","url":null,"abstract":"<div><p>The influence of acute toe reentrant angle on fatigue life at a robotic weld start location was investigated both analytically using linear elastic fracture mechanics (LEFM) and through physical testing. 2D LEFM results show no significant change in stress intensity factor (SIF) within a toe reentrant angle range of 60 degrees (acute) to 120 degrees (obtuse). 3D LEFM was used to compare crack growth rates for idealized 60- and 90-degree weld start geometry. Crack propagation was identical for these two cases. Physical fatigue test specimens were created with two distinct toe reentrant angle groups averaging 68 and 103 degrees at the weld start locations. Fatigue failure cycles at three stress ranges for the two groups produced similar stress-life trends. The study concludes that local weld start acute toe reentrant angle change between 60 and 90 degrees does not significantly influence the joint fatigue life under axial loading.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"633 - 642"},"PeriodicalIF":2.4,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396462","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fatigue assessment of as-welded and HFMI-treated high-strength steel joints under variable amplitude loading using local approaches","authors":"Antti Ahola,&nbsp;Martin Leitner,&nbsp;Kiia Grönlund,&nbsp;Peter Brunnhofer,&nbsp;Christian Buzzi,&nbsp;Masoud Moshtaghi,&nbsp;Timo Björk","doi":"10.1007/s40194-024-01919-x","DOIUrl":"10.1007/s40194-024-01919-x","url":null,"abstract":"<div><p>Among various post-weld treatment techniques, the high-frequency mechanical impact (HFMI) treatment is a robust technique to introduce an enhancement in the fatigue strength of welded high-strength steel joints. In engineering applications, however, structures usually undergo fluctuating cyclic load conditions resulting in variable amplitude load (VAL) conditions. The objective of this work is to validate the use of local notch stress approaches to assess the fatigue strength of as-welded (AW) and HFMI-treated joints made of high-strength and ultra-high-strength steels under VAL conditions. The 4R method is applied as an effective stress-based concept considering mean stress correction via four parameters, i.e., material strength <i>R</i>_m, applied stress ratio <i>R</i>, residual stresses <i>σ</i>_res, and weld toe radius <i>r</i>_true. To validate the 4R method, the study extracts and re-analyzes fatigue test data of published literature on CAL and VAL studies. Finite element analyses are carried out to determine effective notch stresses (ENS) for the evaluation of the data using the ENS concept and 4R method. The results of the re-evaluation conducted using the ENS method showed that the existing design curves provide conservative assessments. However, applying equivalent stress concept for VAL data, the experimental data showed damage parameters of <i>D</i> &gt; 1.0 for joints in the AW conditions with respect to the CAL data. The fatigue data was analyzed with the 4R Master Curve, which obtained conservative assessments for both joints in the AW and HFMI-treated conditions, as well as CAL and VAL data and, thus applicability of the 4R method for the fatigue assessments of welded joints was thus further validated by the experimental data.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"687 - 700"},"PeriodicalIF":2.4,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01919-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of microstructure and mechanical properties of diffusion brazed boron carbide ceramics with Ni–Cr-Si-Fe-B-C filler alloy","authors":"A. Amirnasiri,&nbsp;S. E. Mirsalehi","doi":"10.1007/s40194-024-01912-4","DOIUrl":"10.1007/s40194-024-01912-4","url":null,"abstract":"<div><p>This study investigates the mechanical properties and microstructure of boron carbide ceramic joints with Ni–Cr-Si-Fe-B-C filler, using vacuum diffusion brazing at temperatures from 1363 to 1423 K. The results of shear strength tests showed a 43.8% increase (from 39.44 to 56.73 MPa) as the temperature rose from 1363 to 1383 K, a 22.8% increase (from 56.73 to 69.56 MPa) from 1383 to 1403 K, and a 10.9% decrease (from 69.56 to 61.92 MPa) from 1403 to 1423 K. The sample brazed at 1403 K for 30 min showed the highest shear strength of 69.56 MPa. This increased strength is due to the higher fluidity of the molten filler alloy and enhanced interactions in the ceramic–metal system at elevated temperatures. The joint interface, interfacial phenomena, fracture surface, hardness, microstructure, and phases in different samples were analyzed. Fractography results indicate that shear strengths correlate with the ratio of removed areas from the ceramic on the fracture surface. The boron carbide part exhibited a mixed mode of brittle fracture. Successful joining and good strength at low temperatures are attributed to compounds like Fe₂B, SiC, and Ni₄B₃. Higher temperature samples showed stronger peaks of these compounds and chromium borides, contributing to the higher strength observed. The study also reveals consistent results in the diffusion pattern of elements, elemental analyses, hardness values, and phases formed at the fracture surface.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1645 - 1662"},"PeriodicalIF":2.4,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925574","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of process prediction models for hot-wire laser metal deposition using transfer learning strategies based on simulation datasets","authors":"Chunkai Li,&nbsp;Yu Pan,&nbsp;Yu Shi,&nbsp;Wenkai Wang","doi":"10.1007/s40194-024-01921-3","DOIUrl":"10.1007/s40194-024-01921-3","url":null,"abstract":"<div><p>This study addresses the challenge of predicting and controlling melt pool behavior in Hot-Wire Laser Metal Deposition (HW-LMD) technology by proposing a transfer learning strategy based on simulation datasets for melt pool information prediction. First, a large amount of simulated data was generated using a numerical model to pre-train a deep neural network (DNN). Then, transfer learning was applied by incorporating actual experimental data to enhance the model’s accuracy in predicting melt pool size information. The experimental results demonstrate that this method significantly reduces the demand for experimental data and lowers prediction errors. The model trained with traditional methods exhibited an error rate of 21.16%, whereas the error was significantly reduced to 2.03% after optimization using the transfer learning strategy based on the simulation dataset. The findings offer a novel approach to process optimization and quality control in the field of additive manufacturing.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 5","pages":"1193 - 1205"},"PeriodicalIF":2.4,"publicationDate":"2025-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835590","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanized HFMI for improved fatigue life in complex weld shapes","authors":"T. Stenberg,&nbsp;G. Hultgren,&nbsp;Y. Banno,&nbsp;Z. Barsoum","doi":"10.1007/s40194-024-01907-1","DOIUrl":"10.1007/s40194-024-01907-1","url":null,"abstract":"<div><p>This study investigates the implementation of mechanized high-frequency mechanical impact (HFMI) treatments to enhance the fatigue life of complex welded structures. Digital visual inspection and path planning are utilized through digital laser scanning system to automate the HFMI process for more complex weld shapes in S355 steel grade, such as circular weld seams, which are more challenging to treat consistently. The mechanized HFMI setup was calibrated to ensure precise alignment and consistent application of the HFMI tool along the weld toe line. Finite element analysis was used to simulate the HFMI process, focusing on the effects of multi-pass HFMI treatments and optimizing treatment parameters. The simulations identified fatigue initiation sites which were confirmed with the mechanized HFMI treated specimens. Fatigue testing of both as-welded and HFMI-treated samples was conducted, revealing significant improvements in fatigue strength for the HFMI-treated specimens, which is in line with IIW recommendations. The fatigue test results were also compared with previous testing of manually treated samples. It was concluded that the fatigue life scatter, expressed in log C (load capacity), resulted in a smaller standard deviation for the mechanically HFMI-treated samples than the manually treated samples. Geometric measurements from laser scanning post-HFMI treatment also indicated reduced scatter in weld toe radius and HFMI groove depth compared to manual treatments, demonstrating the robustness and consistency of the mechanized process.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"643 - 655"},"PeriodicalIF":2.4,"publicationDate":"2025-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01907-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396456","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}