Herstellung massiver metallischer Gläser aus kristallinen Gefügen durch lokales kleinvolumiges Umschmelzen

Metallic glasses, or the so‐called bulk metallic glasses (BMGs), have peculiar properties such as extreme strengths and hardness while their specific ferromagnetic properties can be controlled accurately by the alloy content which is due to their amorphous structure. This special properties combination makes them interesting for research and technology. In the current research work, the development of a novel method for the creation of amorphous structure via locally limited re‐melting of the crystalline Fe‐based pre‐alloys is presented. Two alloys, namely Fe₇₆Si₉B₁₀P₅ and Fe₄₃Co₇Cr₁₅Mo₁₄C₁₅B₆ (at.‐%), are produced by melting and slow solidification. The solidified dendritic, crystallographic bulk afterwards is locally heat treated by electron beam welding. Here, a high‐energy electron beam is focused onto the crystalline surface of the pre‐alloy, so that the material is melted rapidly at the surface for a short time and then re‐solidified very fast by self‐quenching. By this process technique both the surface and a relative big volume of the material is glazed. For the evaluation of the amorphous phase scanning electron microscopy coupled with energy dispersive X‐ray analysis (SEM/EDX) and high‐resolution electron diffraction based on transmission electron microscopy (HRTEM) were used. These methods are able to show the lack of structural order of the atoms and by that amorphous structures were evaluated [1].     

Electron beam welding of titanium aluminides

This paper gives an account of research which has been carried out on electron‐beam welded specimens made of high‐Nb γ/α₂‐titanium aluminides (in short: TiAl). The high niobium content of this alloy (5–8 %) has a positive effect on the strength and the creep resistance and also on the oxidation resistance. The standard welding parameters weld speed and beam current and also additional beam oscillation have been used for the determination of factors which will effect the solidification morphology and structural constitution since those, in return, exert influence on the high cracking susceptibility of the alloy. In order to reduce the critical cooling rate, preheating which has a positive effect on crack formation has, in addition, been applied. In a direct comparison of both alloys, micrographs and electron beam micro‐analyses of the developing weld structure and of the HAZ the effects of the beam parameters on both alloys have been established.     

Influence of welding parameters on lap joint between Al and Ti alloys using low power fiber laser

Fiber laser beam welding has always been a user‐friendly and flexible method to join dissimilar materials despite differences in thermal coefficient. Many industrial applications such as automotive has replaced the conventional joining methods towards this because of the flexibility and reduction in time consumption. In the present study, dissimilar titanium alloy; Ti6Al4 V and aluminum alloy; AA2024‐0 were laser welded through a lap joint technique using a low power Yb‐fiber laser without any additional filler. The influence of welding speed on weld morphology was investigated using optical microscopy (OM) and scanning electron microscope (SEM). The cross‐section of the joints revealed that the fusion zone (FZ) and heat affected zones (HAZ) are wider when welding speed decreases with lower laser power. This result shows that the low power fiber laser has sufficient energy to melt the base materials, forming a liquid bridge to facilitate the smooth flow of molten metal between the top and bottom layer. Therefore, at lower welding speeds with constant low laser power, it was shown that there are possibilities of laser welding between two non‐ferrous metals.     

Secondary‐Emission signal for weld formation monitoring and control in eletron beam welding (EBW)

The process of emission of term electrons from the zone of effect of the electron beam are analyzed. During the experiments, the samples of stainless steel and titanium alloy were welded. Experiments were conducted to examine the spectrum of oscillations of the secondary current at various values of the specific power of the electron beam. The conducted research showed that the signal spectrum of the secondary current in electron beam welding contains a characteristic high‐frequency (15…?25 kHz) component. It was established that the described frequency spectrum is not created by some control system in the electron beam machine and reflects the oscillations in the system – «keyhole‐plasma». Empirical density distribution of the high‐frequency signal was constructed in the amplitude range. It was shown that the parameters of the density distribution is closely linked with the nature of interaction between the beam with the metal and can be used for remote control of technology process.     

Elektronenstrahlschweißen an Atmosphäre – von der Entwicklung bis zum industriellen Einsatz

Non vacuum electron beam welding – from development to industrial application Attributable to the increasing degree of standardisation in many fields of industrial manufacturing, the saving of resources and thus the demand for light weight constructions and also the rapid development on the material sector have made joining tasks increasingly complex. This involves the joining method which must meet the metallurgical demands of the base materials to be welded and also the method’s profitability. In this connection, electron beam welding in atmosphere – NV‐EBW ‐ as a joining method is getting more and more important and is, from the side of the industry, becoming increasingly popular. NV‐EBW combines the many, well‐known advantages of electron beam welding in vacuum with the possibility to work under normal ambient pressure. With an equipment efficiency of more than 50 % and very high, achievable welding speeds of up to 60 m/min for aluminium materials, the electron beam in atmosphere is an efficient and profitable tool for welding. Under the direction of Professor U. Dilthey, the ISF has for many years and in close contact with industrial partners carried out research work in the field of the NV‐EBW technology. At that, elementary contribution to the development of rotationally‐symmetrical orifice assemblies and also to the testing and optimization of the method with regard to respective welding tasks has been carried out.     

Nutzung von Low‐Transformation‐Temperature‐Werkstoffen (LTT) zur Eigenspannungsreduzierung im Elektronenstrahlschweißprozess

Low‐Transformation‐Temperature materials (LTT) were designed to reduce delay as well as residual tensile stress in welds on carbon‐manganese steels. Using the volume expansion effect during a martensitic transformation these materials counteract the volume shrinkage during cooling. While this positive effects on residual stress relief by Low‐Transformation‐Temperature‐alloys has been proven in various studies, these alloys have always been used in large volumes as additional filler material in electric arc welding processes. Modular heat fields initiated by an electron‐beam‐welding‐process offers the potential of a time‐activated initiation of compressive stresses triggered by phase transformation of Low‐Transformation‐Temperature‐alloys. Developing a technology able to reduce residual stress and thus the deformation of complex welded components is the aim. The first approach of Low‐Transformation‐Temperature‐material used in the electron beam process and its behaviour is presented here.     

Development of directly and indirectly heated thermionic electron beam sources at EBSDL

The development of thermionic electron guns is of significant importance in electron beam technology. The paper is primarily concerned with the design, fabrication and experimentation of electron beam sources developed by our research group at electron beam sources development laboratory (EBSDL). This includes directly and indirectly heated thermionic electron beam sources as well as high power line source electron guns. The important features of optimized gun designs and performance characteristics are briefly outlined and their results are presented. These guns are currently being used for melting, welding and evaporation and heat treatment.     

钛合金搅拌摩擦焊搅拌头研究现状

搅拌摩擦焊在焊接钛合金这类高熔点金属方面具有很大优势,但是搅拌头的磨损一直是其一大难点。对钛合金搅拌摩擦焊中的搅拌头结构、材料选择进行了讨论,认为圆锥形搅拌针综合性能较好,而在材料选择方面,认为目前应用前景较好的是钨铼合金,但不同材料的组合可能更符合未来发展的方向。为了研究搅拌头的磨损机理及如何减小磨损,列举了几种辅助焊接工艺及目前应用较广的模拟仿真,指出辅助焊接工艺可减小搅拌头磨损,但目前工艺不完善等问题依然存在,需要进一步优化,包括模拟仿真在内,对于钛合金搅拌摩擦焊搅拌头结构、材料优化、磨损机理、辅助焊接工艺等研究均较少,限制了其研究进展及应用。     

Elektronenstrahlschweißen von massiven metallischen Gläsern

Electron‐Beam‐Welding of bulk metallic glasses Because of their excellent mechano‐technological properties bulk metallic glasses form a promising, relatively new class of materials. Due to their low thermal stability the weldability of bulk metallic glasses is subject to narrow limits, in case the joining zone shall be prevented from crystallization. The paper at hand describes the status‐quo of the research work on electron beam welding of beryllium‐free, zirconium‐based bulk metallic glasses (Zr_52,5Ti₅Cu_17,9Ni_14,6Al₁₀) carried out at the Welding and Joining Institute at RWTH Aachen University. So far, high quality joints free from defects could be produced, however, it has not beenaccomplished to avoid the crystallization of the joining zone completely. Further research is in progress.     

Relational analysis between parameters and defects for electron beam welding of AZ-series magnesium alloys

In the last half century, lightweight magnesium alloy has gradually shifted from military applications to civil applications. More noteworthy is that its low melting point, high thermal conductivity, and superior fluidity are good for weld pool flow and welding parameter research. This paper presents a novel approach to these characteristics, which analyzes the influences of electron beam welding parameters on weldment strength and defect formation by linking Taguchi's method with the grey relational analysis. Not only are the parameter contribution and the defect weight individually quantified, but also the relationship between welding parameters and defect dimensions can also be obtained this way.     

铝-钢爆炸焊接试验与分析

介绍了一种铝-钢复合板爆炸焊接工艺，包括所采用的炸药、复合板的性能和爆炸焊接材料的准备等。采用了金相技术、电子探钳和电子显微镜物相鉴定手段以及力学性能分析．结果显示．该复合板的结合区存在着金属强烈的塑性变形、熔化和原子间的相互扩散等冶金过程；铝-钢复合板是一种具有特殊使用性能的新型结构材料．具有很高的经济效益和广泛的应用前景。     

Melting and Glass Transformation of One‐Component Systems

Melting of solid chemical elements has recently been explained by electronic transitions. Due to such transitions into higher energy levels the wave‐functions and their local charge distributions are changed. Since the occupation of the electronic states and the corresponding charge distribution change at random with time, the core ions are continuously driven to new positions. If the forces are strong enough and the core ions relax to their new positions within the lifetime of the excited states, the changing arrangement of the core ions corresponds to a melt. These considerations are extended from elements to chemical compounds as one‐component systems. The melting entropy and the specific heat capacities near the melting temperature have been normalised to the number of atoms in the formula unit of the one‐component systems. The heat capacities exceed 3R, which is the value expected for vibrations, and accumulate surprisingly at special values as well as the melting entropies. This seems to support the idea of melting as an electronically induced effect. The distributions of the electronic energy levels in the molten state and in the crystalline solid are different. If the forces of the electronic distribution in the relaxed low energy states of the undercooled melt are too weak to attract the core ions to regular lattice positions, the disorder is frozen‐in during cooling and a glass transition takes place. Sufficiently strong directional bonds between neighbouring ions and low melting entropy per particle favour such a transition.     

A new generation of power supplies for electron beam welding machines

Widely used electron beam welding machines are equipped with heavy power supplies, located in a special oil tank and connected with an electron gun to a high-voltage cable. A special system detects electric discharges in the electron gun space, which may arise during welding and then it tries to switch off the high voltage to interrupt an electric arc. Such disadvantages have been eliminated with the novel power supply described here. The Q of resonance circuit of this supply is stabilized and as a result circulating power appears. During an electric discharge in the gun, power is not sent to the electron gun but circulates between the electronic parts of the resonance circuit without losses and “waits” for the break in the short circuit. The power supply is much smaller and lighter than supplies of similar rating used nowadays. It is connected directly to the electron gun chamber without a high-voltage cable. The first construction of the supply was designed for electron beam welding machine of 5 kW power and 60 kV accelerating voltage. Tests of the new power supply in laboratory and industrial conditions have shown its usefulness for electron beam welding.     

Verhalten geschweißter Magnesiumlegierungen unter mechanisch‐korrosiver Komplexbeanspruchung

Corrosion and corrosion fatigue of welded magnesium alloys In addition to the prevalent use of magnesium cast alloys a high potential for lightweight constructions is offered by magnesium‐wrought alloys, in particular in the automobile industry. The use of rolled and/or extruded magnesium alloys (profiles and sheet metals) requires suitable and economic join technologies like different welding procedures in order to join semi finished parts. Thus, the realization of lightweight constructions asks for high standards of materials‐ and joining‐technologies. In this context, the mechanical properties as well as the corrosion behaviour of the joints are of large interest. During welding of magnesium alloys, influences concerning the surface, the internal stresses and the microstructure occur. These influences particularly depend on the energy input and thus, on the welding procedure as well as the processing parameters, which all affect the corrosion behaviour of the joints. Sheets of magnesium alloys (AZ31, AZ61, AZ91) were joined with different welding procedures (plasma‐, laser beam‐ and electron‐beam welding in the vacuum and at atmosphere). The corrosion behaviour (with and without cyclic mechanical loading) of the welded joints was investigated by different methods such as corrosion tests, polarisation curves, scanning electron microscopy and metallography. Furthermore, substantial influencing variables on the corrosion behaviour of welded joints of magnesium alloys are pointed out and measures are presented, which contribute to the improvement of the corrosion behaviour.     

On selective laser melting of ultra high carbon steel: Effect of scan speed and post heat treatment

Selective laser melting is a laser‐based additive manufacturing process applying layer manufacturing technology and is used to produce dense parts from metallic powders. The application of selective laser melting on carbon steels is still limited due to difficulties arising from carbon content. This experimental investigation aims at gaining an understanding of the application of the process on ultra high carbon steel, which is a special alloy with remarkable structural properties suitable for different industrial applications. The feedstock ultra high carbon steel (2.1% C) powder, 20 μm to 106 μm was prepared by water atomizing technique. This powder was used for the selective laser melting to build specimens 10×10×40 mm in dimensions. To decrease the thermal stresses during layer by layer building, laser scanning was done through 5×5 mm random island patterns while layer thickness was 30 μm. Laser beam diameter, maximum power output, layer thickness and scan speed range were 0.2 mm, 100 W, 30 μm and 50–200 mm/s respectively. The process was done inside high purity nitrogen environment, with less than 0.5% oxygen content. The results illustrate the influence of scan speed from 50 to 200 mm/s on product geometry and dimensions, surface roughness, internal porosity and cracks, microstructure and surface hardness. The effect of post heat treatment by heating and holding for one hour (annealing) at different temperatures of 700°C, 750°C, 950°C is studied. The results indicate that selective laser melting is able to produce near to 95% density of ultra high carbon steel parts with acceptable geometry and surface quality. Porosity cracks, and microstructure formed during the process could be controlled through proper selection of process parameters and post heat treatment. Industrial ultra high carbon steel products can be rapidly fabricated by selective laser melting.     

Failure analysis of a radio-activated accelerator component

A double-walled, hemispherical metal beam exit window made of alloy 718, used at the Los Alamos Neutron Science Center (LANSCE), developed a crack during service, leading to leakage of coolant. The window had been exposed to radiation damage from 800 MeV protons and a cyclic stress from 600 MPa tensile to near zero induced by numerous temperature cycles calculated to be from 400 to 30 °C. The window was activated to > 200 Sv/h. It was determined, through analysis using remote handling techniques and hot cells, that the crack initiated near a spot weld used to affix thermocouples to the window surface. In addition to analysis of the crack, some of the irradiated material from the window was used to measure mechanical properties. Hot cell techniques for preparation of samples and testing have been developed at both Forschungszentrum Juelich (FZJ) and Los Alamos National Laboratory (LANL). Important and useful data on radiation effects can be obtained from components used in service because they have experienced true operating conditions of radiation, strain, and temperature. (retired)     

Ti2AlNb合金电子束焊接头残余应力及变形的数值模拟

目的 研究平板对接电子束焊接过程中Ti2AlNb合金接头的残余应力及变形规律。方法 采用高斯圆柱体和高斯面组合热源模型模拟了6.6 mm厚的Ti2AlNb合金平板对接电子束焊过程,对比研究了高焊速高束流和低焊速低束流2种工艺参数下焊接接头的残余应力和变形分布规律,并用小孔法测量了焊缝中心及距焊缝中心10 mm位置的残余应力值。结果 在高焊速高束流参数下,获得了熔池体积小、熔池宽度窄(为3.62 mm)、深宽比高的焊缝;在该参数下焊缝横截面上的高应力集中区(应力在900 MPa以上)尺寸较小,其宽度仅为低焊速低束流参数下的89%;同时,在高焊速高束流参数下,焊缝法向变形最大值为0.79 mm,低于低焊速低束流参数下的0.82 mm;模拟计算所得残余应力与实测值的误差在5.64%以内。结论 高束流高焊速工艺具有热输入小、热量集中、加工效率高的特点,有助于获得高应力集中区域小、深宽比高、变形小的焊缝,比低束流低焊速工艺更具优势。     

等离子-MIG焊在有色金属焊接中的应用研究现状及展望

随着复合焊接成为焊接领域的热点,等离子-MIG焊作为一种高能量束流的焊接方法得到了广泛的研究,等离子-MIG焊具备阴极雾化的功能,有利于清理金属表面的氧化膜,对有色金属焊接有独特的优势。介绍了同轴式和旁轴式等离子-MIG焊的工作原理及优缺点,从数值模拟、控制与监测方法、工艺参数研究3个方面对等离子-MIG焊在有色金属焊接中的应用研究现状进行了分析。分析结果表明,等离子-MIG焊在铝合金材料焊接中研究进展显著,已经能够实现高质量的焊接,并开展了在镁、铜等其他有色金属焊接方面的研究,取得了一定的效果。最后对等离子-MIG焊的应用前景和发展方向进行了展望,等离子MIG焊在双电弧耦合机理、多物理场的协同工作、系统稳定性等方面还有待深入研究。     

Thermal conductivity issues of EB‐PVD thermal barrier coatings

The thermal conductivity of electron‐beam physical vapor deposited (EB‐PVD) thermal barrier coatings (TBCs) was investigated by the Laser Flash technique. Sample type and methodology of data analyses as well as atmosphere during the measurement have some influence on the data. A large variation of the thermal conductivity was found by changes in TBC microstructure. Exposure at high temperature caused sintering of the porous microstructure that finally increased thermal conductivity up to 30 %. EB‐PVD TBCs show a distinct thickness dependence of the thermal conductivity due to the anisotropic microstructure in thickness direction. Thin TBCs had a 20 % lower thermal conductivity than thick coatings. New compositions of the ceramic top layer offer the largest potential to lower thermal conductivity. Values down to 0.8W/(mK) have been already demonstrated with virgin coatings of pyrochlore compositions.     

电子束技术在高温合金中的应用

作为近年发展起来的先进加工技术,电子束技术具有高能量密度、高真空度、可实现精确控制等优点,其在高温合金中的应用已受到广泛关注。本文对电子束技术在高温合金的制备以及加工领域的研究与应用进行了综述,包括高温合金的电子束成型制造、高温合金的电子束精炼、电子束焊接、表面改性以及高温合金的电子束物理气相沉积,指出了目前电子束技术面临的挑战,并对电子束技术在高温合金领域的发展前景进行了展望。