NMR-based metabolomics for investigating urinary profiles of metal carpentry workers exposed to welding fumes and volatile organic compounds.

Introduction: Metal carpentry includes a wide range of work activities such as welding and cutting metallic components, use of solvents and paints. Therefore, the employees in these types of activities are mainly exposed to welding fumes and volatile organic solvents. Here, we present an NMR-based metabolomic approach for assessing urinary profiles of workers in the same company that are exposed to two different risk factors. Methods: The study enrolled 40 male subjects exposed to welding fumes, 13 male subjects exposed to volatile organic compounds of a metal carpentry company, and 24 healthy volunteers. All samples were collected, in the middle of the working week at fast. Thirty-five urinary metabolites belonging to different chemical classes such as amino acids, organic acids and amines were identified and quantified. Results were processed by multivariate statistical analysis for identifying significant metabolites for each working group examined, compared to controls. Results: Workers exposed to welding fumes displayed urinary increase in glutamine, tyrosine, taurine, creatine, methylguanidine and pseudouridine associated to oxidative impairment, while workers exposed to volatile organic compounds showed higher urinary levels of branched chain aminoacids. Conclusion: Our work identified specific urinary profile related to each occupational exposure, even if it is below the threshold limit values.

Increased tensile strength induced by the precipitation of nanocrystals for welding joints of Zr-based amorphous alloys.

Zr-based amorphous alloys have attracted intensive attention for applications because of their excellent mechanical property. However, the welding process is inevitable for some special cases, such as the obtain of large size structure parts. It is significant to clarify the influence of introduced welding joints on mechanical properties in Zr-based amorphous alloys. Herein, the increased tensile strength of welding joints in Zr-based amorphous alloys is demonstrated by choosing a suitable initial temperature of Cu cooling fixtures for pulsed laser welding. It is found that an optimized tensile strength is observed when the initial temperature is -20 °C. With the decrease of the initial temperature from 10 to -30 °C, the tensile strength shows a trend of first increasing and then decreasing. Combined with the characterization of microstructures, it can be concluded that the increased tensile strength results from the precipitation of nanocrystals in the heat affected zone. Thus, our results provide a method to improve the mechanical property by controlling the microstructures of the heat affected zone in welding joints of Zr-based amorphous alloys.

Defect monitoring method for Al-CFRTP UFSW based on BWO-VMD-HHT and ResNet.

Underwater friction stir welding (UFSW) achieves reliable joining between dissimilar materials and meets the welding demand for function and properties in lightweight structures of modern engineering. A defect monitoring method based on Variational Mode Decomposition optimized by Beluga Whale Optimization and Hilbert-Huang Transform (BWO-VMD-HHT) is proposed to solve the unclear feature of AE signal in UFSW due to the aqueous medium. UFSW experiments on Al alloy and carbon fiber reinforced thermoplastic (CFRTP) are carried out with AE signals measured. The time-frequency domain features of AE signals are extracted by BWO-VMD-HHT. The experimental results show that the main frequency of the AE signal is 22.5 kHz, and surface crack defects, shallow hole defects, and deep hole defects are accompanied by the transfer phenomena of different frequency components. Then, the feature vectors are built by frequency components in the BWO-VMD-HHT spectrum and reduced by principal component analysis, including 22.5 kHz, 24 kHz, 20.6 kHz, 18.4 kHz, 17.3 kHz, and 15.6 kHz. The feature vectors are divided into the train and test sets, and the welding defect prediction model (ResNet18-attention) is built by ResNet18 and trained by feature vectors. In the test set, the ResNet18-attention is compared with the BP, SVM, and RBF. Test results show that the precision of models has improved by at least 10%, which are trained by BWO-VMD-HHT features vector. Also, ResNet18-attention has achieved an average precision of 0.906 and recognizes the category of weld defect accurately, and this method can be applied to the defect monitoring of UFSW.

Evolution of inclusions in DH36 grade ship plate steel during high heat input welding.

In this paper, the solid solution and precipitation behavior of inclusions on the surface and 1/2 thickness of the tested steel plate under the condition of welding heat input of 400 kJ/cm is investigated by using laser confocal experiments with hot-rolled state DH36 ship plate steel as the research object, and the mechanism of the effect of inclusions on the phase transformation of an acicular ferrite is revealed. The results show that the inclusions of the tested steel are mainly composed of Oxide-MnS, MnS, Oxide, TiN, Spinel, etc. The amount of inclusions on the surface of the tested steel plate is significantly higher than that at the 1/2 thickness position. During the heating stage, the small inclusions on the surface immediately disappeared, and the large inclusions gradually solidified in the matrix; atomic diffusion occurred at the bond between the inclusions and the matrix; while the small inclusions at the 1/2 thickness position gradually disappeared at the beginning of the heating stage, and the inclusions began to precipitate and grow when the temperature was increased to 990 °C. The acicular ferrite preferentially nucleates and grows near the boundary of the inclusions during the post-weld cooling stage, and its growth ends when two acicular ferrites cross.

Nanolignin-Facilitated Robust Hydrogels.

Recently, certain challenges and accompanying drawbacks have emerged in the preparation of high-strength and tough polymer hydrogels. Insights from wood science highlight the role of the intertwined molecular structure of lignin and crystalline cellulose in contributing to wood's strength. Herein, we immersed prestretched poly(vinyl alcohol) (PVA) polymer hydrogels into a solution of nanosized lignosulfonate sodium (LS), a water-soluble anionic polyelectrolyte, to creatively reconstruct this similar structure at the molecular scale in hydrogels. The nanosized LS effectively fixed and bundled the prestretched PVA polymers while inducing the formation of dense crystalline domains within the polymer matrix. Consequently, the interwoven structure of crystalline PVA and LS conferred good strength to the composite hydrogels, exhibiting a tensile strength of up to ∼23 MPa, a fracture strain of ∼350%, Young's modulus of ∼17 MPa, toughness of ∼47 MJ/m3, and fracture energy of ∼42 kJ/m2. This hydrogel far outperformed previous hydrogels composed directly of lignin and PVA (tensile strength <1.5 MPa). Additionally, the composite hydrogels demonstrated excellent antifreezing properties (<-80 °C). Notably, the LS-assisted reconstruction technology offers opportunities for the secondary fixation of PVA hydrogel shapes and high-strength welding of hydrogel components. This work introduces an approach for the high-value utilization of LS, a green byproduct of pulp production. LS's profound biomimetic strategy will be applied in multifunctional hydrogel fields.

How difficult is titanium plate and screw implant removal? A retrospective case series.

INTRODUCTION: Titanium implants are commonly used for surgical fixation in orthopedic trauma, and have many benefits compared to stainless steel implants. Despite these benefits, some orthopedic surgeons remain hesitant to use titanium implants due to concerns of difficulty with future implant removal, given concerns with cold-welding and screw strippage. The objective of this study was to assess difficulties associated with titanium plate and screw implant removal. METHODS: This is a retrospective case series from a large hospital system. Patients were identified using Current Procedural Terminology (CPT) code 20,680 from 2017 to 2020. Patients were included if they had removal of titanium plate and screws from the upper or lower extremity, were at least18 years of age, and considered skeletally mature. The ease of titanium plate/screw removal was determined by assessing for implant cold-welding, broken screws, stripped screws, and the need for advanced tools (screw removal set, trephine, burr). RESULTS: 157 patients were identified, with a mean age of 54 years and 59 % female. In total 1274 screws were removed: 14 (1.1 %) were stripped, 8 (0.6 %) were cold-welded, 42 (3.3 %) were loose, and 13 (1.0 %) were broken. 183 plates were removed in total, and 15 (8.2 %) had bone overgrowth that required removal. 12 (7.6 %) procedures were complicated and required the use of advanced tools. Complicated implant removal operations occurred after significantly longer in vivo implant time (mean of 3.7 vs. 1.1 years, p = 0.036), were associated with a younger age, were more likely to occur in lower extremity procedures (p = 0.034), and took significantly longer time for removal (95 vs. 42 min, p < 0.001). CONCLUSIONS: Despite concerns with titanium implants, we found a low rate of screw strippage, breakage, and cold welding during the removal process. However, 7.6 % of the 157 surgeries required additional tools other than just a screwdriver, and needed additional operative time. This information allows treating surgeons to plan for implant removal when titanium implants have been used for fixation. LEVEL OF EVIDENCE: IV.

The influence of various welding wires on microstructure, and mechanical characteristics of AA7075 Al-alloy welded by TIG process.

Owing to their exceptional mechanical properties, the various welding wires used to combine aluminum can meet the needs of many engineering applications that call for components with both good mechanical and lightweight capabilities. This study aims to produce high-quality welds made of AA7075 aluminum alloy using the GTAW technique and various welding wires, such as ER5356, ER4043, and ER4047. The microstructure, macrohardness, and other mechanical characteristics, such as tensile strength and impact toughness, were analyzed experimentally. To check the fracture surface of the AA7075 welded joints, the specimens were examined using optical and scanning electron microscopy (SEM). A close examination of the samples that were welded with ER5356 welding wire revealed a fine grain in the weld zone (WZ). In addition, the WZ of the ER4043 and ER4047 welded samples had a coarse grain structure. Because the hardness values of the welded samples were lower in the WZ than in the base metal (BM) and heat-affected zone (HAZ), the joints filled with ER5356 welding wire provided the highest hardness values compared to other filler metals. Additionally, the ER4047 filler metal yielded the lowest hardness in the weld zone. The welding wire of ER5356 produced the greatest results for ultimate tensile stress, yield stress, welding efficiency, and strain-hardening capacity (Hc), whereas the filler metal of ER4043 produced the highest percentage of elongation. In addition, the ER4047 fracture surface morphology revealed coarser and deeper dimples than the ER5356 fine dimples in the welded joints. Finally, the highest impact toughness was obtained at joints filled with the ER4047 filler metal, whereas the lowest impact toughness was obtained at the BM.

Effects of metal oxide inhalation on the transcription of some hormone receptors in the brain, examined in an in vivo mouse model.

Respirable metal oxide nanoparticles in welding fumes pose significant health risks upon inhalation, potentially leading to neurodegenerative diseases. While the exact mechanisms remain unclear, it is evident that metal oxide nanoparticles can disrupt cellular functions, including metabolism and inflammatory responses after crossing the blood-brain barrier (BBB). Our study investigates the impact of manual metal arc welding fumes on hormone receptor transcription in an in vivo mouse model. After collecting samples from six different brain regions at 24 and 96 h upon exposure, we focused on expression levels of estrogen receptors (ERs), thyroid hormone receptors (TRs), and peroxisome proliferator-activated receptors (PPARs) due to their roles in modulating neuroprotective responses and neuroinflammatory processes. Analysis revealed differential susceptibility of brain regions to hormonal disruption induced by welding fumes, with the hypothalamus (HT) and olfactory bulb (OB) showing prominent changes in receptor expression. Considering ERs, 24 h sampling showed an elevation in OB, with later increases in both ERα and ERß. HT showed significant ERß change only by 96 h. TRs mirrored ER patterns, with notable changes in OB and less in HT. PPARγ followed TR trends, with early upregulation in HT and downregulation elsewhere. These findings suggest a compensatory response within the CNS aimed at mitigating neuroinflammatory effects, as evidenced by the upregulation of ERß, TRα, and PPARγ. The coordinated increase in ERs, TRs, and PPARs in the hypothalamus and olfactory bulb also highlights their potential neuroprotective roles in response to welding fume exposure. Our results also support the theory of metal oxide penetration to the CNS via the lungs-blood-BBB pathway, making HT and OB more vulnerable to welding fume exposure.

Passive Vision Detection of Torch Pose in Swing Arc Narrow Gap Welding.

To enhance the synchronous detection of the horizontal and vertical positions of the torch in swing arc narrow gap welding, a torch pose detection (TPD) method is proposed. This approach utilizes passive visual sensing to capture images of the arc on the groove sidewall, using advanced image processing methods to extract and fit the arc contour. The coordinates of the arc contour center point and the highest point are determined through the arc contour fitting line. The torch center position is calculated from the average horizontal coordinates of the arc contour centers in adjacent welding images, while the height position is determined from the vertical coordinate of the arc's highest point. Experimental validation in both variable and constant groove welding conditions demonstrated the TPD method's accuracy within 0.32 mm for detecting the torch center position. This method eliminates the need to construct the wire centerline, which was a requirement in previous approaches, thereby reducing the impact of wire straightness on detection accuracy. The proposed TPD method successfully achieves simultaneous detection of the torch center and height positions, laying the foundation for intelligent detection and adaptive control in swing arc narrow gap welding.

Thickness Effect of 2195 Al-Li Alloy Friction Stir Weld Fracture Toughness.

For damage tolerance design in engineering components, the fracture toughness value, KIC, of the material is essential. However, obtaining specimens of sufficient thickness from stir friction welded plates is challenging, and often, the experimental test values do not meet the necessary criteria, preventing the experimental fracture toughness, Kq, from being recognized as plane strain fracture toughness KIC. The fracture toughness Kq of 2195 Al-Li alloy welding seams with different thicknesses was measured on the forward and backward sides. Microstructure characterization was conducted by scanning electron microscope (SEM). The results indicated minimal significant differences in grain size between the advancing and retreating sides of the weld nugget zone. In specimens of the same thickness, fracture toughness measurements along the normal direction of the joint cross-section showed a high similarity between the advancing and retreating sides of the weld nugget zone. Utilizing the quantitative relationships between fracture toughness and sample thickness derived from both the fracture K and G criteria, it is possible to predict the fracture toughness of thick plates using thin plates. This study employs these relationships to calculate the fracture toughness KIC of 2195 aluminum-lithium alloy friction stir welds. The KIC values obtained are 41.65 MPa·m1/2 from the fracture K criterion and 43.54 MPa·m1/2 from the fracture G criterion.

Ultrasonic Welding of Acrylonitrile-Butadiene-Styrene Thermoplastics without Energy Directors.

Ultrasonic welding (USW) of thermoplastics plays a significant role in the automobile industry. In this study, the effect of the welding time on the joint strength of ultrasonically welded acrylonitrile-butadiene-styrene (ABS) and the weld formation mechanism were investigated. The results showed that the peak load firstly increased to a maximum value of 3.4 kN and then dropped with further extension of the welding time, whereas the weld area increased continuously until reaching a plateau. The optimal welding variables for the USW of ABS were a welding time of 1.3 s with a welding pressure of 0.13 MPa. Interfacial failure and workpiece breakage were the main failure modes of the joints. The application of real-time horn displacement into a finite element model could improve the simulation accuracy of weld formation. The simulated results were close to the experimental results, and the welding process of the USW of ABS made with a 1.7 s welding time can be divided into five phases based on the amplitude and horn displacement change: weld initiation (Phase I), horn retraction (Phase II), melt-and-flow equilibrium (Phase III), horn indentation and squeeze out (Phase IV) and weld solidification (Phase V). Obvious pores emerged during Phase IV, owing to the thermal decomposition of the ABS. This study yielded a fundamental understanding of the USW of ABS and provides a theoretical basis and technological support for further application and promotion of other ultrasonically welded thermoplastic composites.

Prediction of Welding Deformation Using the Thermal Elastic-Plastic Finite Element Method by Considering Welding Interpass Temperature.

In this study, we propose a method for predicting welding deformation caused by multi-pass welding using the thermal elastic-plastic finite element method (TEP-FEM) by considering the interpass temperature. This method increases the interpass temperature, which has not been considered in the existing TEP-FEM, from 200 °C to 1000 °C, and simultaneously performs thermal and mechanical analyses. In addition, this method can also evaluate temperature history and the time it takes to weld. By predicting the welding deformation using this method, angular distortion prediction was reduced from 16.75 mm to 10.9 mm compared to the case where the interpass temperature was cooled to room temperature. Additionally, the deformation error was significantly reduced from 6.14% to 2.92% compared to that of the strain as directed boundary method used in a previous study. Additionally, our research demonstrated that interpass temperatures above 800 °C can result in increased deformation errors. In conclusion, it is essential to select an appropriate temperature to minimize deformation error.

Assessing the Performance of a Dual-Speed Tool When Friction Stir Welding Cast Mg AZ91 with Wrought Al 6082.

A novel dual-speed tool for which the shoulder and pin rotation speeds are separately established was utilized to friction stir weld cast magnesium AZ91 with wrought aluminum 6082-T6. To assess the performance and efficacy of the dual-speed tool, baseline dissimilar welds were also fabricated using a conventional FSW tool. Optical microscopy characterized the weld microstructures, and a numerical simulation enhanced the understanding of the temperature and material flow behaviors. For both tool types, regions of the welds contained significant amounts of the AZ91 primary eutectic phase, Al12Mg17, indicating that weld zone temperatures exceeded the solidus temperature of α-Mg (470 °C). Liquation, therefore, occurred during processing with subsequent eutectic formation upon cooling below the primary eutectic temperature (437 °C). The brittle character of the eutectic phase promoted cracking in the fusion zone, and the "process window" for quality welds was narrow. For the conventional tool, offsetting to the aluminum side (advancing side) mitigated eutectic formation and improved weld quality. For the dual-speed tool, experimental trials demonstrated that separate rotation speeds for the shoulder and pin could mitigate eutectic formation and produce quality welds without an offset at relatively higher weld speeds than the conventional tool. Exploration of various weld parameters coupled with the simulation identified the bounds of a process window based on the percentage of weld cross-section exceeding the eutectic temperature and on the material flow rate at the tool trailing edge. For the dual-speed tool, a minimum flow rate of 26.0 cm3/s and a maximum percentage of the weld cross-section above the eutectic temperature of 35% produced a defect-free weld.

Influence of Laser Welding Modes along a Curved Path on the Mechanical Properties and Heterogeneity of the Microstructure of 316L Steel Plates.

The results of experimental studies in the manufacture of components of the supporting structure of the first wall panel, carried out as part of the manufacture of a model of the International Thermonuclear Experimental Reactor (ITER) using laser welding technology, are presented. The influence of laser welding modes on the quality of formation, microstructure characteristics, and mechanical properties of a welded joint made of 10 mm thick 316L steel was studied. A coaxial nozzle was designed and manufactured to protect the weld pool with a curved trajectory. The mechanical properties of the welded joint are 98-100% that of the base metal, and the microhardness of the welded joint and base metal is in the range of 180-230 HV. It was established that the lower part of the weld metal on the fusion line has transcrystalline grains and differs in δ-ferrite content; due to a high welding speed, the ratio of the depth to the width of the welding seam is 14 times. The width of the rectilinear part of the seam is 15-20% larger than its curved part.

Grain Structure and Texture Evolution in the Bottom Zone of Dissimilar Friction-Stir-Welded AA2024-T351 and AA7075-T651 Joints.

High-strength dissimilar aluminum alloys are difficult to connect by fusion welding, while they can be successfully joined by friction stir welding (FSW). However, the asymmetrical deformation and heat input that occur during FSW result in the formation of a heterogeneous microstructure in their welded zone. In this work, the grain structure and texture evolution in the bottom zones of dissimilar FSW AA2024-T351 and AA7075-T651 joints at different welding speeds (feeding speeds) were quantitatively investigated. The results indicated that dynamic recrystallization occurs in the bottom zones of dissimilar FSW joints, and equiaxed grains with low grain sizes are formed at the welding speed of 60-240 mm/min. A high fraction of the recrystallized grains were generated in the bottom zones of the joints at a low welding speed, while a high fraction of the substructured grains are produced at a high welding speed. Different types of shear textures are produced in the bottom zones of the joints; the number fraction of shear texture types depends on different welding speeds. This study helps to understand the mechanism of microstructure homogenization in dissimilar FSW joints and provides a basis for further improving the microstructure of the welded zone for engineering applications.

Influence of Post-Weld Heat Treatment on Mechanical Properties and Microstructure of Plasma Arc-Welded 316 Stainless Steel.

This study investigates the effects of post-weld heat treatment (PWHT) on the microstructures and mechanical properties of plasma arc-welded 316 stainless steel. The experimental parameters included the solid solution temperatures of 650 °C and 1050 °C, solid solution durations of 1 h and 4 h, and quenching media of water and air. The mechanical properties were evaluated using Vickers hardness testing, tensile testing, scanning electron microscopy (SEM), and optical microscopy (OM). The highest ultimate tensile strength (UTS) of 693.93 MPa and Vickers hardness of 196.4 in the welded zone were achieved by heat-treating at 650 °C for one hour, quenching in water, and aging at 500 °C for 24 h. Heat-treating at 650 °C for one hour, followed by quenching in water and aging at 500 °C for 24 h results in larger dendritic δ grains and contains more σ phase compared to the other conditions, resulting in increased strength and hardness. Additionally, it shows wider and shallower dimple structures, which account for its reduced impact toughness.

Heating and Strain Sensing Elements Based on Segregated Polyethylene/Carbon Black Composites in Polymer Welded Joints.

The development of easy and direct real-time monitoring of welded joint quality instead of surface damage analysis is crucial to improve the quality of industrial products. This work presents the results of high-density polyethylene (HDPE)-based composites with various carbon black (CB) content (from 20 to 30 vol.%) for use as a heating element and strain sensor in electrofusion-welded polymer joints. The pyroresistive heating process was used to determine the effect of generated Joule heat during welding on the structure and sensor properties of polymer-carbon composites. It is shown that the generation of Joule heat depends on the nanocarbon content and affects the crystallinity of the polymer matrix. The partial disruption of the conductive path of carbon black particles was observed and, as a result, a decrease in electrical conductivity for composites with lower CB content after welding was found. For the highest CB amount, conductivity increased, which is caused by smaller particle-to-particle distance for filler paths. Therefore, the best balance between pyroresistive and sensor properties was found.

Considerations for Tungsten Carbide as Tooling in RFSSW.

Tool wear is a key issue for the manufacturing performance of refill friction stir spot welding in high-volume manufacturing environments. As such, the aim of this study is to examine conditions in which tungsten carbide with a cobalt binder can succeed as a tool material in the spot welding of 2029 aluminum for a sustained lifetime. Critical factors are shown herein to include cleanliness and thermal management. The life of a WC-Co toolset is demonstrated to be approximately 2998 welds, which is of the same scale as conventional steel tooling. With a WC-Co shoulder and probe, the H13 clamp showed the only significant wear.

Finite Element Simulation and Microstructural Analysis of Roll Forming for DP590 High-Strength Dual-Phase Steel Wheel Rims.

In this study, finite element (FE) simulation by the software Abaqus was relied on to investigate the roll forming process of a wheel rim made of an innovative dual-phase steel, i.e., DP590, after flash butt welding (FBW). In the simulation, an FE model was generated, including the design of the dies for flaring, three-roll forming, and expansion, and detailed key processing parameters based on practical production of the selected DP590. Combined with the microstructures and properties of the weld zone (WZ) and heat-affected zones (HAZs) after FBW, the distribution of stress/strain and the change in thickness of the base metal (BM), WZ and HAZs were analyzed, and compared in the important stages of roll forming. Theoretically, the variation in the microstructure and the corresponding stress-strain behaviors of the BM, WZ, and HAZs after FBW have led to the thickness reduction of DP590 that originated from softening behaviors occurring at the region of subcritical HAZs (SCHAZs), and a small amount of tempered martensite has evidently reduced the hardness and strength of the SCHAZ. Meanwhile, the distribution of stress/strain has been influenced to some extent. Further, the study includes the influence of the friction coefficient on the forming quality of the wheel rim to guarantee the simulation accuracy in practical applications. In sum, the dual-phase steel has to be carefully applied to the wheel rim, which needs to experience the processes of FBW and roll forming, focusing on the performance of SCHAZs.

A Comparative Study on the Performance and Microstructure of 304NG Stainless Steel in Underwater and Air Laser Welding.

In order to facilitate the application of underwater laser welding technology in in situ repairs of nuclear power plants, this study conducted comparative experiments between local dry underwater laser welding and laser welding in air on 304NG nitrogen-controlled stainless steel. The aim was to explore its microstructural evolution and mechanical properties in underwater environments. It was found that, near the fusion line of laser welding in air, columnar dendrites gradually evolved into cellular dendrites toward the weld center, eventually disappearing, resulting in a skeletal ferrite and serrated austenite structure. The underwater laser welding joints exhibited similar characteristics yet with more pronounced alternation between columnar and cellular dendrites. Additionally, the size of cellular dendrites decreased significantly, and needle-like ferrite was observed at the weld center. The hardness of underwater laser welded joints was slightly higher than that of in-air laser welded joints. Compared to laser welding in air, the strength of underwater laser welding joints increased from 443 MPa to 471 MPa, and the displacement increased from 2.95 mm to 3.45 mm, both types of welded joints exhibited a mixed mode fracture characterized by plasticity and brittleness.