Welding in the World最新文献

{"title":"Investigation of stress corrosion cracking behavior of friction stir welded thick al 6061-t6 alloy plate","authors":"Imtiaz Ali Soomro,&nbsp;Adeel Hassan,&nbsp;Umair Aftab,&nbsp;Lun Zhao,&nbsp;Ali Arshad,&nbsp;Bilal Shahid","doi":"10.1007/s40194-024-01845-y","DOIUrl":"10.1007/s40194-024-01845-y","url":null,"abstract":"<div><p>In this study, the stress corrosion cracking (SCC) behavior of friction stir welded (FSWed) Al 6061-T6 alloy 10 mm thick plate is investigated. The general corrosion resistance of the base alloy and welded joint is evaluated using a potentiodynamic polarization test, electrochemical impedance spectroscopy (EIS), and immersion test in NaCl solution. SCC susceptibility is evaluated in 3.5% NaCl and 7.5% NaCl aqueous solution using a slow strain rate tensile (SSRT) test. Potentiodynamic polarization test results show that the FSWed joint experienced a higher corrosion rate (9.658 × 10⁻⁶ mmpy) compared to base metal (0.734 × 10⁻⁶ mmpy). EIS results show that the charge transfer resistance (<i>R</i>_ct) of the joint was higher (118 Ω) compared to base metal (242 Ω) which further confirms that the joint has a higher susceptibility to pitting corrosion. SEM results also show that the welded joint immersed for 168 h in a 3.5% chloride environment experienced higher pitting corrosion than the base metal, while EDX results confirm that the pitting occurred due to the anodic dissolution of Mg-Si particles within the Al matrix. SCC results show that FSWed joints tested in air, 3.5% and 7.5% NaCl environment, show maximum load vs. displacement of 23.5 kN vs. 23.5 mm, 20.9 kN vs. 20.9 mm, and 16.8 kN vs. 16.8 mm, respectively indicating a weakened SCC resistance to increasing chloride environment. Samples tested in a chloride environment during the SSRT test showed quasi-cleavage fracture, while samples tested in an air environment showed ductile-type fracture. The higher general corrosion rate and SCC susceptibility of FSWed joints are attributed to the inhomogeneous microstructure developed during welding and the anodic dissolution of intermetallic compounds.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 2","pages":"299 - 309"},"PeriodicalIF":2.4,"publicationDate":"2024-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108602","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":"Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy","authors":"A. A. C. Filho,&nbsp;C. R. L. Loayza,&nbsp;P. D. C. Assunção,&nbsp;E. M. Braga","doi":"10.1007/s40194-024-01844-z","DOIUrl":"10.1007/s40194-024-01844-z","url":null,"abstract":"<div><p>This study investigates the impact of travel speed on the weld quality of AA7075-T651 aluminum alloy using the cold wire pulsed gas metal arc welding (CW-PGMAW) process. By maintaining a constant heat input of 0.4 kJ/mm while varying travel speed between 90 and 100 cm/min, the study examines the process’s influence on microstructure, porosity, and liquation cracking. Results demonstrate that CW-PGMAW effectively refines microstructure and reduces defect formation compared to conventional GMAW. While mechanical properties showed improvement, further optimization is necessary to achieve base metal equivalent properties. The findings contribute to the understanding of CW-PGMAW for challenging aluminum alloys and provide a foundation for future process enhancements.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"68 12","pages":"3099 - 3113"},"PeriodicalIF":2.4,"publicationDate":"2024-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142645603","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":"Microstructure and properties of additive manufacturing by gas-shielded arc welding with hydrogen-resistant steel wires","authors":"Guo Chun,&nbsp;Zhang XinYu,&nbsp;Li WenQing,&nbsp;Li Yun,&nbsp;Chen YanYan,&nbsp;Huang GuangCan,&nbsp;Lin QingCheng","doi":"10.1007/s40194-024-01835-0","DOIUrl":"10.1007/s40194-024-01835-0","url":null,"abstract":"<div><p>The hydrogen steel gas-shielded welding wire was utilized in the WAAM technique, and the microstructure, crystal structure, and properties of the parts generated by layer-wise deposition were analyzed and evaluated. The study revealed that the components exhibit good quality, devoid of significant defects, and demonstrate robust internal metallurgical bonding. The metallographic structure mainly consists of pearlite and ferrite. The distribution of microhardness in the parts is fairly consistent, with mean microhardness values of 196.6 HV_0.1 (transverse) and 196.7 HV_0.1 (longitudinal). The parts exhibit exceptional mechanical properties, with a transverse yield strength of 406 MPa, an elongation rate of 14.2%, and a longitudinal yield strength of 380 MPa, an elongation rate of 18.9%. At − 30 °C, the average transverse Charpy impact value is 95.7 J, and the average longitudinal is 117 J.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"68 12","pages":"3085 - 3097"},"PeriodicalIF":2.4,"publicationDate":"2024-10-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142645720","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":"Welding and analysis of Hastelloy X alloy butt joint made by CO2 laser","authors":"G. Sathishkumar,&nbsp;S. Senthil Murugan,&nbsp;P. Sathiya","doi":"10.1007/s40194-024-01846-x","DOIUrl":"10.1007/s40194-024-01846-x","url":null,"abstract":"<div><p>This study investigates the processing and analysis of laser-welded Hastelloy X (HX) alloy joints, which are widely used in high-temperature aerospace and nuclear applications. Laser beam welding (LBW) experiments were conducted on HX base metal using a CO₂ laser, following an L9 Orthogonal Array (OA) experimental matrix. Variables included laser power, focal length, and welding speed. ASTM-standard testing showed that weld bead characteristics and joint properties varied with parameters. The joint with 20 J/mm heat input achieved the highest tensile strength and ductility, with 93% efficiency. Microstructure and EBSD analyses revealed grain elongation and refinement in the weld zone (WZ). The corrosion behaviour of the joints was assessed using potentiostatic polarization, with corrosion rates ranging from 7.4 × 10⁻³ to 8.6 × 10⁻⁵ mm/year. The joint with 25 J/mm heat input exhibited the highest corrosion resistance. Consequently, a dry sliding wear test was conducted on that sample, varying applied load, sliding distance, and sliding velocity as per the L9 OA matrix. Results indicated that the wear test (30 N, 1.0 m/s, and 1000 m) had the highest coefficient of friction (COF), while the wear test (50 N, 2.0 m/s, and 1500 m) showed the greatest wear loss. Increased wear rate correlated with higher load and sliding distance, with weld speed affecting joint strength and laser power influencing corrosion and wear properties. Field emission scanning electron microscopy (FESEM) revealed grain boundary effects, corrosion pits from localized corrosion, and wear tracks with surface irregularities on the worn weld surfaces.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 2","pages":"311 - 325"},"PeriodicalIF":2.4,"publicationDate":"2024-10-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108675","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":"Effect of plasma gas composition on deposition characteristics in plasma arc directed energy deposition of Ti-6Al-4 V","authors":"Yipeng Wang,&nbsp;Jialuo Ding,&nbsp;Stewart Williams,&nbsp;Baoqiang Cong","doi":"10.1007/s40194-024-01843-0","DOIUrl":"10.1007/s40194-024-01843-0","url":null,"abstract":"<div><p>The increasing demand for high-efficiency and high-quality wire-based arc directed energy deposition processes presents a significant challenge to the plasma arc, which is greatly influenced by plasma gas composition. This paper introduced mixed gases of helium (He) and argon (Ar) into the plasma gas for the deposition of Ti-6Al-4 V. The effect of plasma gas composition on the deposition characteristics concerning arc electrical characteristics, keyhole formation, metal transfer, bead geometry, and surface waviness were investigated. Results demonstrate that the arc voltage and heat input exhibited a linearly increasing tendency with the increase of He in the plasma gas, attributed to a higher ionization potential and thermal conductivity. The threshold current value for keyhole formation was effectively increased by adding He to the plasma gas. The keyhole formation was completely suppressed as the He content was higher than 50% for the range of parameters tested. The metal transfer mode changed from surface tension transfer to droplet surface tension transfer and to free space droplet transfer, as the He content in the plasma gas increased. For the bead geometry, the bead height, aspect ratio, and contact angle showed a decreasing trend, while the bead width presented an increasing trend. The relative waviness and absolute waviness of the deposited single-pass multi-layer walls reduced remarkably with a higher He content. The results lay a solid foundation for an improved plasma arc DED process with high efficiency and good forming quality through plasma gas composition control.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"883 - 895"},"PeriodicalIF":2.4,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01843-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581070","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":"A comprehensive study on laser welding of stainless steel 301LN in lap joint configuration","authors":"Thierry Adrien,&nbsp;Shayan Dehghan,&nbsp;Asim Iltaf,&nbsp;Noureddine Barka","doi":"10.1007/s40194-024-01840-3","DOIUrl":"10.1007/s40194-024-01840-3","url":null,"abstract":"<div><p>Laser welding offers distinct advantages over traditional methods: less heat impact, no filler metal needed, and strong weld penetration. It is efficient and cost-effective, perfect for joining materials like the stainless steel 301LN, and ideal for industries addressing climate change. This study delves into the impact of various operating parameters on weld quality, specifically focusing on microstructure and microhardness. Using the Taguchi method, it is designed an experimental setup to systematically analyze these factors. The microstructure analysis shows a unique grain structure in the weld bead and a small heat-affected zone (HAZ), indicating precise welding control. Weld penetration measurements correlated with specific operating parameters using microstructure imaging. The microhardness analysis further underlined the control over HAZ thickness, crucial for ensuring the integrity of the welded joint. Through analysis of variance (ANOVA), it is identified significant factors affecting physical properties, help to construct a mathematical model to quantify parameter influences accurately. Findings suggest that minimizing the focal spot diameter is key to optimizing weld penetration, albeit in a delicate balance with welding speed and laser power settings. Adjusting these parameters can also influence the chemical composition match between the weld bead and base material, crucial for structural integrity. For achieving the desired hardness close to the base material, specific parameter ranges are recommended: a beam oscillation amplitude of 1.45 mm, a beam oscillation amplitude between 2.82 and 2.97 kW, and a focal spot diameter above 0.34 mm. Findings offer practical insights for improving weld quality and efficiency in industrial applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"68 12","pages":"3141 - 3168"},"PeriodicalIF":2.4,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142645409","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":"Research on the differences of mechanical properties between horizontal and vertical in al-cu alloy deposits fabricated by wire + arc additive manufacturing","authors":"Shuai Wang,&nbsp;Lingling Ren,&nbsp;Lan Yang,&nbsp;Zhu Ming,&nbsp;Chengde Li,&nbsp;Wei Wang","doi":"10.1007/s40194-024-01842-1","DOIUrl":"10.1007/s40194-024-01842-1","url":null,"abstract":"<div><p>Al-Cu alloy made by arc fuse additive has excellent microstructure and properties, but the difference between transverse and longitudinal is the key factor limiting its application. In this experiment, Al-Cu alloy deposits with different Cu contents were formed by the wire + arc additive manufacturing (WAAM) process using Al-Cu welding wire with different Cu content. The microstructure and properties of the deposits, both intralayer and interlayer, were analyzed using metallography, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and tensile tests. The results showed that the interlayer content of Cu is higher than that in the intralayer. When Cu content in the deposit was 6.3% in the as-deposited state, there was an enhanced θ (Al₂Cu) precipitate phase in the interlayer position. After T4 treatment, there were still θ phases with a size larger than 20 μm, which were linearly distributed parallel to the accumulation layer. These θ phases led to lower mechanical properties in the vertical direction than in the horizontal direction, with a brittle fracture mode. When the Cu content of the deposit was reduced to 5.6% after T4 treatment, there were no large θ phases in the interlayer position. Furthermore, the mechanical properties of horizontal and vertical directions were consistent, and they had a ductile fracture mode. The Cu content in the deposit was the primary reason for the difference in mechanical properties between horizontal and vertical directions. Al-Cu alloy deposits with uniform mechanical properties in the horizontal and vertical directions can be obtained by controlling the Cu content, which has an important role in the application of this process.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"871 - 881"},"PeriodicalIF":2.4,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143580934","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":"Round robin study on the determination of weld geometry parameters - Part A: analysis of a reference specimen","authors":"Matthias Jung,&nbsp;Moritz Braun,&nbsp;Jan Schubnell,&nbsp;Heikki Remes","doi":"10.1007/s40194-024-01829-y","DOIUrl":"10.1007/s40194-024-01829-y","url":null,"abstract":"<div><p>The weld toe is known to be a critical point of fatigue failure in many welded constructions. Especially for research purposes but also for improving fatigue life predictions, the weld toes geometry is often described by a set of parameters, including the weld toe radius and the flank angle. There is no universal agreement on the definition of the geometry parameters as well as on measuring routines. To get an overview over used techniques and comparability between research labs, a comprehensive round robin study was conducted over the past years. Two measuring tasks were given to the participants. Part A: A machined specimen with well known geometry inspired by a cruciform joint was analyzed and the results were compared with the actual dimensions of the specimen. Part B: Welded specimens with unknown geometry were measured by the participants and the results were bench-marked against each other. The present study summarizes the findings of Part A. The study gives an overview over used measuring techniques, the influence of measuring equipment and the comparability of the results in the scientific community. Most of the participants achieved good results with their respective measuring methods for radii larger than 1 mm. Smaller radii tend to be overestimated.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 1","pages":"169 - 176"},"PeriodicalIF":2.4,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01829-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142844972","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":"Simulation-based assessment of railhead repair welding process parameters","authors":"Björn Andersson,&nbsp;Erika Steyn,&nbsp;Magnus Ekh,&nbsp;Lennart Josefson","doi":"10.1007/s40194-024-01837-y","DOIUrl":"10.1007/s40194-024-01837-y","url":null,"abstract":"<div><p>This study uses a finite element method based simulation methodology for in-situ railhead repair welding to investigate how welding process parameters impact the repaired rail quality. The methodology includes material modeling with cyclic plasticity, phase transformations, transformation-induced plasticity, and multi-phase homogenization. The weld process modeling includes a 3D heat transfer analysis and a 2D Generalized Plane Strain (GPS) mechanical analysis. The Heat source model used in the thermal simulation is calibrated using measurements from a repair welding experiment. To assess the performance of the repaired rail, mechanical rolling contact simulations are performed to estimate the risk of fatigue crack initiation. The process parameter study is based on the Swedish stick-welding railhead repair procedure and focuses on factors affecting the repair quality, such as preheating and operation temperature conditions as well as variations in repair geometry. Significant findings highlight both the inherent robustness of the process and regions susceptible to parameter variations. Specifically, the powerful final zig-zag weld passes provide effective resilience against variations in additional heating, and the start and end stretches of the repair welding are the most susceptible to parameter variations. Chamfered and deeper cutout repair geometries are found to be effective in mitigating adverse effects. In agreement with field observations, the simulations identify the fusion zone of the base and weld filler material as the critical region of the repaired rail in operation. This is attributed to the integrated effects of unfavorable microstructures, longitudinal tensile residual stresses from repair welding, and tensile stresses during operational traffic loads.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 1","pages":"177 - 197"},"PeriodicalIF":2.4,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01837-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142844971","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 the gas metal arc additive manufacturing process using unsupervised machine learning","authors":"Giulio Mattera,&nbsp;Joseph Polden,&nbsp;John Norrish","doi":"10.1007/s40194-024-01836-z","DOIUrl":"10.1007/s40194-024-01836-z","url":null,"abstract":"<div><p>The study aimed to assess the performance of several unsupervised machine learning (ML) techniques in online anomaly (The term “anomaly” is used here to indicate a departure from expected process behavior which may indicate a quality issue which requires further investigation. The term “defect detection” has often been used previously but the specific imperfection is often indirectly inferred.) detection during surface tension transfer (STT)-based wire arc additive manufacturing. Recent advancements in quality monitoring for wire arc manufacturing were reviewed, followed by a comparison of unsupervised ML techniques using welding current and welding voltage data collected during a defect-free deposition process. Both time domain and frequency domain feature extraction techniques were applied and compared. Three analysis methodologies were adopted: ML algorithms such as isolation forest, local outlier factor, and one-class support vector machine. The results highlight that incorporating frequency analysis, such as fast Fourier transform (FFT) and discrete wavelet transform (DWT), for feature extraction based on general frequency response and defined bandwidth frequency response, significantly improves performance, reflected in a 14% increase in F2 score, compared with time-domain features extraction. Additionally, a deep learning approach employing a convolutional autoencoder (CAE) demonstrated superior performance by processing time-frequency domain data stored as spectrograms obtained through short-time Fourier transform (STFT) analysis. The CAE method outperformed frequency domain analysis and traditional ML approaches, achieving an additional 5% improvement in F2-score. Notably, the F2-score (The F2 score is the weighted harmonic mean of the precision and recall (given a threshold value). Unlike the F1 score, which gives equal weight to precision and recall, the F2 score gives more weight to recall than to precision.) increased significantly from 0.78 in time domain analysis to 0.895 in time-frequency analysis. The study emphasizes the potential of utilizing low-cost sensors to develop anomaly detection modules with enhanced accuracy. These findings underscore the importance of incorporating advanced data processing techniques in wire arc additive manufacturing for improved quality control and process optimization.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"68 11","pages":"2853 - 2867"},"PeriodicalIF":2.4,"publicationDate":"2024-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01836-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142438768","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}