Influence of heat input on the mechanical characteristics, corrosion and microstructure of ASTM A36 steel welded by GTAW technique.

The Gas Tungsten Arc Welding process weld for the 4 mm thickness of the ASTM A36 steel plate with varied heat input parameters of 0.608 kJ/mm, 0.900 kJ/mm and 1.466 kJ/mm, respectively. The effect of different heat inputs on microstructure, corrosion, and mechanical characteristics of developed weld joints are examined by three zones: heat-affected zone, welded zone, and base metal zone. The optical microscopic results of weld joints illustrate that fine grain structure leads to enhance welding strength. It is revealed that the increased heat input parameter on the weld joint shows a decreased tensile strength and hardness of the weld joint. The corrosion resistance of the weld joint is evaluated by Potentio-dynamic polarization. It facilitates that the corrosion rate of the weld joint is decreased with increasing heat input, which results indicate the best and worst corrosion micrograph of the polygonal ferrite and ferrite plus polygonal ferrite. However, the weld joint prepared with 0.900 kJ/mm heat input found maximum corrosion resistance.

Characterization of an energy efficient pulsed current TIG welding process on AISI 316 and 304 stainless steels.

This paper presents the characterization of a TIG welding process carried out by means of an arc welding power supply able to provide dc or pulsed current. The arc welding power supply is based on resonant power converters and an FPGA-based control circuit. Dc and multiple pulsed operations up to 1 kHz with different pulse widths have been tested. The operation of the proposed welding power supply has been compared to that of a high-quality commercial welding machine. Regarding performance, the investigated electrical parameters are: power factor, power conversion efficiency and the energy consumption of the process. The radiography and mechanical properties of the welds have been examined. The mechanical properties of the welded joints characterized through tensile tests are the yield stress, tensile strength and the strain under maximum stress. In addition, the impact properties of the joints were determined through Charpy tests and the curves relating energy absorbed and temperature were obtained. The results show an improved performance of the proposed arc welding power supply over the commercial counterpart, with higher efficiency and power factor, as well as lower energy consumption. The yield stress and tensile strength results indicate that the welded plates using pulsed modes with the proposed power supply are comparable to the reference weld performed with dc operation using the commercial welder. Remarkably, it was observed that the ductility of the welded plates using pulsed modes with the proposed power supply outperforms those of the reference weld carried out with dc arc using the commercial welder.

Solidification and Liquation Cracking in Welds of High Entropy CoCrFeNiCux Alloys.

High entropy CoCrFeNiCux alloys with a Cu molar ratio of x ≈ 0, 0.5, 1, 1.5 and 2 were arc welded. Solidification cracking occurred in the fusion zones of alloys with x ≈ 0.5, 1 and 1.5. Cu-rich material was observed around cracks, increasing in quantity with increasing Cu content. Liquation cracking occurred in the partially melted zone next to the fusion zone, and it propagated into the fusion zone as solidification cracking. A recently proposed index for the susceptibility to solidification cracking was tried, i.e., |dT/d(fS)1/2| near (fS)1/2 = 1, where T is temperature and fS the solid fraction. The index was higher in alloys with x ≈ 0.5, 1.0 and 1.5, consistent with the solidification cracking observed.

Enhancing Microstructural and Mechanical Properties of Ferrous Medium-Entropy Alloy through Cu Addition and Post-Weld Heat Treatment in Gas Tungsten Arc Welding.

This study investigates the impact of a high-entropy alloy filler metal coated with copper (Cu) and post-weld heat treatment (PWHT) on the weldability of a ferrous medium-entropy alloy (MEA) in gas tungsten arc welding. The addition of 1-at% Cu had an insignificant effect on the microstructural behaviour, despite a positive mixing enthalpy with other elements. It was observed that a small amount of Cu was insufficient to induce phase separation into the Cu-rich phase and refine the microstructure of the as-welded specimen. However, with an increase in the PWHT temperature, the tensile strength remained mostly consistent, while the elongation significantly increased (elongation of as welded, PWHT700, PWHT800, and PWHT 900 were 19, 43, 55 and 68%, respectively). Notably, the PWHT temperature of 900 °C yielded the most desirable results by shifting the fracture location from the coarse-grained heat-affected zone (CGHAZ) to base metal (BM). This was due to significant recrystallisation and homogenised hardness of the cold-rolled BM during PWHT. However, the CGHAZ with coarse grains induced by the welding heat input remained invariant during the PWHT. This study proposes a viable PHWT temperature (900 °C) for enhancing the weldability of cold-rolled ferrous MEA without additional process.

A novel hybrid approach to develop bioresorbable material.

The need for bioresorbable implants that are able to dissolve within the body is rising, unlike their traditional counterparts. Bulk metallic glasses (BMGs) can perhaps serve this need, since they possess incredible properties, including high biocompatibility by virtue of their amorphous structure and absence of dislocations. However, the fabrication of BMGs is challenging, since, to achieve an amorphous structure, fast cooling is a pre-requisite which is very difficult to achieve for casting due to the fact that fast cooling rate and adequate rate of filling of the mold possess a trade-off relationship. Therefore, purpose of this work is to develop a simple novel hybrid approach that is cost effective and attempts to synthesize BMG based on Mg-Ca-Zn constituent. Synthesis of bioresorbable material was attempted by hybridizing friction stir processing (FSP) technique with gas tungsten arc welding (GTAW). FSP was performed with Magnesium as base material and Calcium granules as reinforcement. After FSP, GTAW process was performed by using Zn as filler material. The added Ca and Zn were found to effectively intermix with the Mg matrix in the FSP and GTAW steps, respectively. Especially, a relatively invariable distribution of Ca phases was observed in the stirred microstructure after FSP. Finally, a wide bead consisting of mixed dendritic and columnar cast structure was obtained. The current work is expected to alleviate the physiological issues pertaining to orthopaedic fixations and decrease the need for secondary surgeries in geriatric fractures.

Liquation Cracking Susceptibility and Mechanical Properties of 7075 Aluminum Alloy GTAW Joints.

In this work, aluminum alloy 7075-T651 was welded by using customized Al-Cu-Si and Al-Cu-Mg-Zn filler wire during gas tungsten arc welding. The liquation cracking susceptibility of the joints was tested under a circular-patch welding experiment. Besides, the temperature vs. solid fraction curves (T-fS) was calculated for different samples to reveal the formation mechanism of liquation cracking. The joint was susceptible to liquation cracking if (fS)weld > (fS)workpiece during the cooling stage. The results of the circular-patch welding experiment show that the liquation cracking susceptibility of the joint by using ER5356, Al-Cu1.5-Si4.5, Al-Cu3.0-Si2.5, Al-Cu4.5-Si1.5, Al-Cu2.3-Mg2.3-Zn6.6 and Al-Cu2.2-Mg2.0-Zn7.8 filler metal is 22.8%, 8.3%, 2.8%, 2.8%, 3.3% and 1.4%, respectively. The mechanical test shows that the data dispersion of the 7075 gas tungsten arc welding joint can be decreased by eliminating the liquation crack.

Study on the Weldability of Copper-304L Stainless Steel Dissimilar Joint Performed by Robotic Gas Tungsten Arc Welding.

The welding process of dissimilar metals, with distinct chemical, physical, thermal, and structural properties, needs to be studied and treated with special attention. The main objectives of this research were to investigate the weldability of the dissimilar joint made between the 99.95% Cu pipe and the 304L stainless steel plate by robotic Gas Tungsten Arc Welding (GTAW), without filler metal and without preheating of materials, and to find the optimum welding regime. Based on repeated adjustments of the main process parameters-welding speed, oscillation frequency, pulse frequency, main welding current, pulse current, and decrease time of welding current at the process end-it was determined the optimum process and, further, it was possible to carry out joints free of cracks and porosity, with full penetration, proper compactness, and sealing properties, that ensure safety in operating conditions. The microstructure analysis revealed the fusion zone as a multi-element alloy with preponderant participation of Cu that has resulted from mixing the non-ferrous elements and iron. Globular Cu- or Fe-rich compounds were developed during welding, being detected by Scanning Electron Microscope (SEM). Moreover, the Energy Dispersive X-ray Analysis (EDAX) recorded the existence of a narrow double mixing zone formed at the interface between the fusion zone and the 304L stainless steel that contains about 66 wt.% Fe, 18 wt.% Cr, 8 wt.% Cu, and 4 wt.% Ni. Due to the formation of Fe-, Cr-, and Ni-rich compounds, a hardness increase up to 127 HV0.2 was noticed in the fusion zone, in comparison with the copper material, where the average measured microhardness was 82 HV0.2. The optimization of the robotic welding regime was carried out sequentially, by adjusting the parameters values, and, further, by analyzing the effects of welding on the geometry and on the appearance of the weld bead. Finally, employing the optimum welding regime-14 cm/min welding speed, 125 A main current, 100 A pulse current, 2.84 Hz oscillation frequency, and 5 Hz pulse frequency-appropriate dissimilar joints, without imperfections, were achieved.

Experimental Investigation and Parametric Optimization of the Tungsten Inert Gas Welding Process Parameters of Dissimilar Metals.

Special attention is required when joining two materials with distinct chemical, physical and thermal properties in order to make the joint bond robust and rigid. The goal of this study was to see how significantly different tungsten inert gas (TIG) welding process parameters (welding current, gas flow rate, root gap, and filler materials) affect mechanical properties (tensile, hardness, and flexural strength), as well as the bead width and microstructural properties, of dissimilar welds In comparison to SS 316 and AISI 1020 low-carbon steel. TIG welding parameters were optimized in this study using a Taguchi-based desirability function analysis (DFA). From the experimental results, it was observed that welded samples employing ER-309L filler wires had a microstructure consisting of a delta ferrite network in an austenite matrix. The tensile strength experimental results revealed that welding current, followed by GFR, was a highly influential parameter on tensile strength. Weld metals had higher hardness and flexural strength than stainless steel and carbon steel base metals. This was supported by the fact that the results of our tests had hardness ratings greater than a base for the FZ and HAZ, and that no crack was observed in the weld metal following U-shape flexural bending. Welding current has a significant impact on the bead width of welded specimens, followed by root gap. Furthermore, the dissimilar welded sample responses were optimized with a composite desirability percentage improvement of 22.90% by using a parametric setting of (A2B4C4D2). Finally, the validation of the experiment was validated by our confirmation test results, which agreed with the predictive optimum parameter settings.

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding.

This work investigates the feasibility of using friction stir welding (FSW) process as a groove filling welding technique to weld duplex stainless steel (DSS) that is extensively used by petroleum service companies and marine industries. For the FSW experiments, three different groove geometries without root gap were designed and machined in a DSS plates 6.5 mm thick. FSW were carried out to produce butt-joints at a constant tool rotation rate of 300 rpm, traverse welding speed of 25 mm/min, and tilt angle of 3o using tungsten carbide (WC) tool. For comparison, the same DSS plates were welded using gas tungsten arc welding (GTAW). The produced joints were evaluated and characterized using radiographic inspection, optical microscopy, and hardness and tensile testing. Electron back scattering diffraction (EBSD) was used to examine the grain structure and phases before and after FSW. The initial results indicate that FSW were used successfully to weld DSS joints with different groove designs with defect-free joints produced using the 60° V-shape groove with a 2 mm root face without root gap. This friction stir welded (FSWed) joint was further investigated and compared with the GTAW joint. The FSWed joint microstructure mainly consists of α and γ with significant grain refining; the GTWA weld contains different austenitic-phase (γ) morphologies such as grain boundary austenite (GBA), intragranular austenite precipitates (IGA), and Widmanstätten austenite (WA) besides the ferrite phase (α) in the weld zone (WZ) due to the used high heat input and 2209 filler rod. The yield strength, ultimate tensile strength, and elongation of the FSWed joint are enhanced over the GTAW weldment by 21%, 41%, and 66% and over the BM by 65%, 33%, and 54%, respectively. EBSD investigation showed a significant grain refining after FSW with grain size average of 1.88 µm for austenite and 2.2 µm for ferrite.

Modeling of Melt Flow and Heat Transfer in Stationary Gas Tungsten Arc Welding with Vertical and Tilted Torches.

A 3D numerical simulation was conducted to study the transient development of temperature distribution in stationary gas tungsten arc welding with filler wire. Heat transfer to the filler wire and the workpiece was investigated with vertical (90°) and titled (70°) torches. Heat flux, current flux, and gas drag force were calculated from the steady-state simulation of the arc. The temperature in the filler wire was determined at three different time intervals: 0.12 s, 0.24 s, and 0.36 s. The filler wire was assumed not to deform during this short time, and was therefore simulated as solid. The temperature in the workpiece was calculated at the same intervals using heat flux, current flux, gas drag force, Marangoni convection, and buoyancy. It should be noted that heat transfer to the filler wire was faster with the titled torch compared to the vertical torch. Heat flux to the workpiece was asymmetrical with both the vertical and tilted torches when the filler wire was fully inserted into the arc. It was found that the overall trends of temperature contours for both the arc and the workpiece were in good agreement. It was also observed that more heat was transferred to the filler wire with the 70° torch compared with the 90° torch. The melted volume of the filler wire (volume above 1750 °K) was 12 mm3 with the 70° torch, compared to 9.2 mm3 with the 90° torch.

Exploring infrared sensoring for real time welding defects monitoring in GTAW.

This paper presents an evaluation of an infrared sensor for monitoring the welding pool temperature in a Gas Tungsten Arc Welding (GTAW) process. The purpose of the study is to develop a real time system control. It is known that the arc welding pool temperature is related to the weld penetration depth; therefore, by monitoring the temperature, the arc pool temperature and penetration depth are also monitored. Various experiments were performed; in some of them the current was varied and the temperature changes were registered, in others, defects were induced throughout the path of the weld bead for a fixed current. These simulated defects resulted in abrupt changes in the average temperature values, thus providing an indication of the presence of a defect. The data has been registered with an acquisition card. To identify defects in the samples under infrared emissions, the timing series were analyzed through graphics and statistic methods. The selection of this technique demonstrates the potential for infrared emission as a welding monitoring parameter sensor.

Microsegregation Model Including Convection and Tip Undercooling: Application to Directional Solidification and Welding.

The microsegregation behavior of alloy filler metal 52 (FM 52) was studied using microprobe analysis on two different solidification processes. First, microsegregation was characterized in samples manufactured by directional solidification, and then by gas tungsten arc welding (GTAW). The experimental results were compared with Thermo-Calc calculations to verify their accuracy. It was confirmed that the thermodynamic database predicts most alloying elements well. Once this data had been determined, several tip undercooling calculations were carried out for different solidification conditions in terms of fluid flow and thermal gradient values. These calculations allowed the authors to develop a parametrization card for the constants of the microsegregation model, according to the process parameters (e.g., convection in melt pool, thermal gradient, and growth velocity). A new model of microsegregation, including convection and tip undercooling, is also proposed. The Tong⁻Beckermann microsegregation model was used individually and coupled with a modified Kurz-Giovanola-Trivedi (KGT) tip undercooling model, in order to take into account the convection in the fluid flow at the dendrite tip. Model predictions were compared to experimental results and showed the microsegregation evolution accurately.