Research on hot cracking in laser welding of Al-contaminated CoCrFeMnNi high-entropy alloys.

To study the thermal cracking susceptibility of laser-welded CoCrFeMnNi high-entropy alloys, stainless steel and aluminum alloy plates were each used as backing for welding. The microstructure of the weld and morphology of the fracture were examined. In addition, the chemical compositions of the fractures, the interfacial tension between the CoCrFeMnNi high-entropy alloy and liquid aluminum alloy, and the linear expansion coefficient of the CoCrFeMnNi high-entropy alloy were determined. The results show that when stainless steel is used as the base plate, no cracking is apparent in the weld, and the microstructure is made up of dendrites and equiaxed crystals. Conversely, when an aluminum alloy plate is adopted, solidification cracks are seen at the center of the weld, and the microstructure consists of bright polygonal dendrites scattered in a dark gray matrix. In the later stage of solidification, the contact angle between the Al-dominated low-melt liquid metal and the CoCrFeMnNi high-entropy alloy is about 14.6°, which is distributed in the form of a liquid film between the dendrite of the CoCrFeMnNi high-entropy alloy weld, and the linear expansion coefficient of the high-entropy alloy is 23 × 10-6-25 × 10-6 K-1 in the temperature range of 900-1100 K, which is higher than the thermal expansion coefficient of austenitic stainless steel in this range, and the solidification temperature range is 1000-1400K. Therefore, thermal cracks tend to occur during the solidification process.

The SAM-Krom biomonitoring study shows occupational exposure to hexavalent chromium and increased genotoxicity in Denmark.

BACKGROUND: Hexavalent chromium (Cr(VI)) is a carcinogen. Exposure to Cr(VI) may occur in different industrial processes such as chrome plating and stainless steel welding. The aim of this study was to assess occupational exposure to Cr(VI) in Denmark. METHODS: This cross-sectional study included 28 workers and 8 apprentices with potential Cr(VI) exposure and 24 within company controls, all recruited from six companies and one vocational school. Use of occupational safety and health (OSH) risk prevention measures were assessed through triangulation of interviews, a questionnaire and systematic observations. Inhalable Cr(VI) and Cr-total were assessed by personal air exposure measurements on Cr(VI) exposed participants and stationary measurements. Cr concentrations were measured in urine and in red blood cells (RBC) (the latter reflecting Cr(VI)). Genotoxicity was assessed by measurement of micronuclei in peripheral blood reticulocytes (MNRET). RESULTS: At announced visits, a consistent high degree of compliance to OSH risk prevention measures were seen in 'chromium bath plating' for both technical devices (e.g. ventilation, plastic balls, sheet coverings) and in the use of personal protective equipment (e.g. gloves, respirators), yet a lesser degree of compliance was observed in 'stainless steel welding'. The geometric mean of the air concentration of Cr(VI) was 0.26 µg/m3 (95% confidence interval (CI): 0.12-0.57) for the Cr(VI)-exposed workers and 3.69 µg/m3 (95% CI: 1.47-9.25) for the Cr(VI)-exposed apprentices. Subdivided by company type, the exposure levels were 0.13 µg/m3 (95% CI: 0.04-0.41) for companies manufacturing and processing metal products, and 0.81 µg/m3 (95% CI: 0.46-1.40) for bath plating companies. Workers with occupational exposure to Cr(VI) had significantly higher median levels of urinary Cr (2.42 µg/L, 5th-95th percentile 0.28-58.39), Cr in RBC (0.89 µg/L, 0.54-4.92) and MNRET (1.59 ‰, 0.78-10.92) compared to the within company controls (urinary: 0.40 µg/L, 0.16-21.3, RBC: 0.60 µg/L, 0.50-0.93,MNRET: 1.06 ‰, 0.71-2.06). When sub-dividing by company type, urinary Cr (4.61 µg/L, 1.72-69.5), Cr in RBC (1.33 µg/L, 0.95-4.98) and MNRET (1.89 µg/L, 0.78-12.92) levels were increased for workers with potential Cr(VI) exposure in bath-plating companies, and when subdividing by work task, workers engaged in process operation had increased levels of urinary Cr (8.51 µg/L, 1.71-69.5), Cr in RBC (1.33 µg/L, 0.95-4.98) and MNRET (1.89 µg/L, 0.82-12.92) levels. CONCLUSION: This biomonitoring study shows that bath platers were highly exposed to Cr(VI), as suggested by relatively high levels of urinary Cr, Cr in RBC and increased levels of micronuclei. The urinary Cr concentrations were high when compared to the French biological limit value of 2.5 µg Cr/L, corresponding to the Danish occupational exposure limit of 1 µg/m3. This, in turn, indirectly suggests that additional exposure routes than via air may contribute to the exposure. For welders, no statistically significant increases compared to within company controls were observed, however, the observed urinary Cr levels were similar to the levels observed in a European study (HBM4EU), and were higher than the levels observed for welders in Sweden (SafeChrom). In spite of a high degree of self-reported and observed compliance to OSH risk prevention measures during announced visits, the biomarkers of exposure reflecting recent exposure (urinary Cr) or exposure during the last four months (Cr in RBC) may point to variation in compliance to OSH risk prevention measures in general. Reduced occupational exposure to Cr(VI) may be achieved by applying the hierarchy of controls in eliminating or substituting Cr(VI), and the use of more effective technical solutions (e.g. automation).

Microstructure and Properties of Mg-Gd-Y-Zn-Mn High-Strength Alloy Welded by Friction Stir Welding.

Mg-Gd-Y-Zn-Mn (MVWZ842) is a kind of high rare earth magnesium alloy with high strength, high toughness and multi-scale strengthening mechanisms. After heat treatment, the maximum tensile strength of MVWZ842 alloy is more than 550 MPa, and the elongation is more than 5%. Because of its great mechanical properties, MVWZ842 has broad application potential in aerospace and rail transit. However, the addition of high rare earth elements makes the deformation resistance of MVWZ842 alloy increase to some extent. This leads to the difficulty of direct plastic processing forming and large structural part shaping. Friction stir welding (FSW) is a convenient fast solid-state joining technology. When FSW is used to weld MVWZ842 alloy, small workpieces can be joined into a large one to avoid the problem that large workpieces are difficult to form. In this work, a high-quality joint of MVWZ842 alloy was achieved by FSW. The microstructure and properties of this high-strength magnesium alloy after friction stir welding were studied. There was a prominent onion ring characteristic in the nugget zone. After the base was welded, the stacking fault structure precipitated in the grain. There were a lot of broken long period stacking order (LPSO) phases on the retreating side of the nugget zone, which brought the effect of precipitation strengthening. Nano-α-Mn and the broken second phase dispersed in the matrix in the nugget zone, which made the grains refine. A relatively complete dynamic recrystallization occurred in the nugget zone, and the grains were refined. The welding coefficient of the welded joint exceeded 95%, and the hardness of the weld nugget zone was higher than that of the base. There were a series of strengthening mechanisms in the joint, mainly fine grain strengthening, second phase strengthening and solid solution strengthening.

Effect of Bias Arc on Microstructure and Corrosion Resistance of Q235/304 Dissimilar-Steel-Welded Joints.

To fully exploit the advantages of steel, the welding connection of dissimilar steels has been developed. In this work, the metallographic microstructures, elemental distributions, and electrochemical corrosion properties of the Q235 and 304 welds under different bias arcs were investigated. The arc bias caused the Q235-side heat-affected zone to widen, the microstructure consisted of ferrite and pearlite, and the ratio varied with decreasing distance from the fusion line. Elemental scans show that Cr and Ni concentration gradients exist near the fusion line. The 304-stainless-steel-side heat-affected zone was mainly composed of austenite grains, and the fusion zone was narrower but prone to cracking. Electrochemical tests revealed that 304 stainless steel had the best corrosion resistance, while Q235 had the worst corrosion resistance, and that the welded joints with an arc bias toward the 304 side had the best corrosion resistance. The samples' the passivation film which formed via electrochemical polarization had limited stability, but the over-passivation potential could be used as a reference for corrosion resistance. Overall, the arc bias and weld material properties significantly affected the microstructure and corrosion resistance of the joints.

Mechanical and Fatigue Properties of Welded Fe-Mn-Si Shape Memory Alloys.

This paper presents the experimental results of a study evaluating the mechanical and fatigue performance of welded Fe-Mn-Si SMA. For the experimental study, welded and welded-and-heat-treated Fe-Mn-Si SMA specimens were fabricated, and fatigue tests were performed at various stress amplitudes. In addition, direct tensile tests and recovery stress tests were also performed to evaluate the material properties of Fe-Mn-Si SMAs. The elastic modulus, yield strength, and tensile strength of the welded specimens were reduced by 35.4%, 12.1%, and 8.6%, respectively, compared to the values of the non-welded specimens. On the other hand, the elastic modulus, yield strength, and tensile strength of the welded-and-heat-treated Fe-Mn-Si SMA specimens were increased by 18.6%, 4.9%, and 1.3%, respectively, compared to the values of the welded specimens. Both welded and welded-and-heat-treated Fe-Mn-Si SMAs failed at lower cycles than the conventional Fe-Mn-Si SMAs at the same stress amplitude. High-cycle fatigue failure, characterized by cycles exceeding 104, typically occurs at relatively low stress levels within the elastic region, whereas low-cycle fatigue failure, generally occurring within cycles below 104, involves high stress levels that encompass both elastic and plastic deformation. Regardless of the welding condition, the stress amplitude at which Fe-Mn-Si SMA transitions from high-cycle to low-cycle failure exceeded the yield strength.

Study on Laser Transmission Welding Technology of TC4 Titanium Alloy and High-Borosilicate Glass.

As the demand for high-performance dissimilar material joining continues to increase in fields such as aerospace, biomedical engineering, and electronics, the welding technology of dissimilar materials has become a focus of research. However, due to the differences in material properties, particularly in the welding between metals and non-metals, numerous challenges arise. The formation and quality of the weld seam are strongly influenced by laser process parameters. In this study, successful welding of high-borosilicate glass to a TC4 titanium alloy, which was treated with high-temperature oxidation, was achieved using a millisecond pulsed laser. A series of process parameter comparison experiments were designed, and the laser welding behavior of the titanium alloy and glass under different process parameters was investigated using scanning electron microscopy (SEM) and a universal testing machine as the primary analysis and testing equipment. The results revealed that changes in process parameters significantly affect the energy input and accumulation during the welding process. The maximum joint strength of 60.67 N was obtained at a laser power of 180 W, a welding speed of 3 mm/s, a defocus distance of 0 mm, and a frequency of 10 Hz. Under the action of the laser, the two materials mixed and penetrated into the molten pool, thus achieving a connection. A phase, Ti5Si3, was detected at the fracture site, indicating that both mechanical bonding and chemical bonding reactions occurred between the high-borosilicate glass and the TC4 titanium alloy during the laser welding process.

A Review on Metallurgical Issues in the Production and Welding Processes of Clad Steels.

Carbon and low-alloy steel plates clad with stainless steel or other metals are a good choice to meet the demand for cost-effective materials to be used in many corrosive environments. Numerous technical solutions are developed for the production of clad steel plates, as well as for their joining by fusion welding. For thick plates, a careful strategy is required in carrying out the multiple passes and in choosing the most suitable filler metals, having to take into account the composition of the base metal and the cladding layer. The specificity of the different processes and materials involved requires an adequate approach in the study of the metallurgical characteristics of clad steel, thus arousing the interest of researchers. Focusing mainly on ferritic steel plates clad with austenitic steel, this article aims to review the scientific literature of recent years which deals with both the production and the fusion welding processes. The metallurgical issues concerning the interfaces and the effects of microstructural characteristics on mechanical behaviour and corrosion resistance will be addressed; in particular, the effects on the fusion and thermally affected zones that form during the fusion welding and weld overlay processes will be analysed and discussed.

[Bioaccessibility characteristics of metals in welding fume and its application in exposure assessment].

Objective: To explore the bioaccessibility of the main metal components in welding fume welding fume in simulated lung fluid, and to evaluate the exposure level of each metal component in combination with the EPA inhalation exposure risk assessment model. Methods: In November 2022, the microscopic morphology characteristics of welding fumes were analyzed by scanning electron microscopy, the bioaccessibility of each metal component in lung fluid simulated normal and lung inflammatory states was analyzed by in vitro simulation method, and the exposure level of each metal component was calculated in combination with the EPA inhalation exposure risk assessment model. Results: The main metal components in carbon dioxide gas shielded welding fumes were Fe, Mn, Zn, Ti, Al, Cu, Cr, Cd, Ni and As, and the bioaccessibility in simulated normal lung interstitial fluid was 0.82%-1.84%, 5.07%-9.41%, 4.52%-7.23%, 5.10%-8.67%, 20.48%-29.60%, 5.27%-9.83%, 4.80%-7.56%, 0.07%-1.08%, 6.48%-13.84% and 33.02%-42.81%. The bioaccessibility of the above metal components in the lung fluid under simulated lung inflammation was 14.79%-27.45%, 34.53%-46.11%, 35.31%-59.13%, 16.45%-22.51%, 60.78%-76.51%, 26.58%-34.12%, 15.32%-25.87%, 2.0%-5.7%, 34.77%-43.33% and 71.34%-88.36%, respectively. Compared with the simulated lurg interstitial fluid, the bioaccessibility of metal components in the lung fluid under the simulated inflammatory state was increased, and the difference was statistically significant (P<0.05). The average daily exposure dose Mn in the two simulated lung fluids exceeded the inhalation reference limit (>50 times), and the average daily exposure dose Ti and Cr in the simulated lung inflammation exceeded the reference limit (>1.3 times) . Conclusion: Attention should be paid to the bioaccessibility characteristics of metal components in the exposure level and hazard assessment of welding fumes.

Comparative corrosion behavior of three titanium alloy base materials and their welds in a simulated chimney environment.

This study investigates the corrosion behavior of titanium alloys (TA2, TC4, TB6) in a 3 % sulfuric acid flue gas environment using electrochemical tests and microscopic analyses (SEM/EDS, XRD, metallographic microscopy). Results show that TA2 base metal has lower corrosion resistance compared to its weld metal, while TC4 and TB6 exhibit opposite trends. Specifically, TC4 and TB6 base metals have lower corrosion current densities (0.9 and 0.5 µA/cm2) and higher corrosion potentials then their weld metals (1.93 and 2 µA/cm2). In contrast, TA2 base metal showed higher corrosion current density (2 µA/cm2) than its weld metal (0.35 µA/cm2) and HAZ metal (0.16 µA/cm2). Microscopic analyses reveal ß phase transitions in TC4 and TB6 weld areas, leading to larger grain sizes and reduced corrosion resistance. Conversely, TA2 retains finer grains post-welding, enhancing its corrosion resistance. These insights clarify weld corrosion effects and provide valuable guidance for industrial applications of titanium alloys, particularly in designing and maintaining titanium alloy chimneys.

Enhanced strength of ultrasonically-welded austenitic stainless steels joints by introducing dynamic recrystallization of interlayers.

This study investigated the role of interfacial deformability in bond integrity and strength, particularly in the production of robust joints between harder austenitic stainless steels (SS) during ultrasonic welding. The specimen without the interlayer experienced limited strength enhancement owing to internal cracking from continuous sliding at interfacial temperatures below 0.6 times the melting point (Tm), which is attributed to the limited deformability of the austenitic SS. In contrast, introducing Fe and Ni interlayers between the substrates resulted in a notable increase in the interfacial strength, surpassing 2500 N in the peak load within a reduced welding duration. The correlation between the interfacial strength and the peak temperature suggests that a substantial decrease in hardness below 0.4 Tm is sufficient for extensive bond formation. Moreover, dynamic recrystallization (DRX) led to grain refinement in the Fe interlayer owing to shorter weld durations, whereas grain growth was observed in the Ni interlayer due to higher peak temperatures. Both the Fe and Ni interlayers significantly improved the bonding integrity by accommodating plasticity through the above phenomena without severe damage to the substrates, leading to increase of interfacial strength by 24% (2050 N to 2500 N) and reduction of weld duration by 40% (1.5 s in Fe interlayer). In addition, the fracture position after the lap shear test shifted from the edge of the weld area to the SS substrate.

Effect of welding parameters on microstructure and mechanical properties of dissimilar AISI 304/ductile cast iron fusion welded joints.

Problems associated with dissimilar fusion welding are mainly originated from the differences in melting points, coefficients of thermal conductivity and thermal expansion, …etc., and carbon content when welding dissimilar ferrous materials. In this study, the problems associated with dissimilar fusion welding of stainless steel AISI304 with ductile cast iron DCI grade A536 were investigated. Using shielded metal arc welding (SMAW) process, various welding parameters were studied to investigate the successful/accepted dissimilar welded joint(s). Welding electrodes and welding techniques were the main studied parameters. Microstructural and mechanical investigations were carried out for welded joints under different welding parameters. Tensile, impact and hardness tests coupled with optical and scanning electron microscopic examinations with EDX analysis were made for metallurgical and mechanical evaluations of welded joints. This extensive study could solve the problem of dissimilar welding between ductile cast iron and 304 stainless steel. The main results showed that joints welded by ENiCrFe-3 electrode in root pass and ENiFe-CI in filling passes were the successful dissimilar welded joints with 422 MPa tensile strength which represents 104% of annealed DCI base metal and without any changes in toughness properties, where toughness at HAZ of DCI was 18 J. High Ni content in weld metal increased the strength, ductility and reduced the weld metal dilution.

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.

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.

Pulsed directed energy deposition-arc technology for depositing stainless steel 309L: Microstructural, elements distribution, and mechanical characteristics.

In recent years, additive manufacturing has increased in prominence as a primary method of manufacturing around the globe. Modern metal additive manufacturing presents an innovative approach to manufacturing complex structures for the aerospace, energy, and construction sectors, due to technological advancements. In the present study, the austenitic stainless steel 309L (SS-309L) thick wall component was manufactured employing pulsed current gas tungsten arc welding (PC-GTAW) WAAM technology. The metallurgical characteristics of the as-deposited SS-309L thick wall part were evaluated. The investigation of material characteristics in the manufactured areas encompasses a study of cross-sectional (CS) and transverse-sectional (TS) regional portions, specifically the upper, middle, and lower regions. The microstructures of the CS and TS planes showed austenite, columnar, and delta ferrite dendrites in the upper, middle, and lower regions, respectively. The CS sample reveals the greatest grain size at 159.4 µm, following the EBSD investigation. The average size of the grains across the TS is 127.09 µm. The thermal cycles in multi-layer production result in changes in grain size. The microhardness in the transverse sectional regions is higher than in the CS regions, measuring average values of 257 HV, 253 HV, and 251 HV for the upper, middle, and lower sections, respectively. The ultimate tensile strengths (UTS) in the cross-sectional parts are 656 MPa, whereas in the transverse regions it was 661 MPa for the topmost regions. This study investigates the correlation among the mechanical and metallurgical properties of wire arc additively fabricated SS-309L austenite steel material.

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.

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.

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.