The effect of tool rotational and traverse speed on friction stir weldability of AISI 430 ferritic stainless steels

In this study, the effects of tool rotational speed and traverse speed on welding of AISI 430 (X6Cr17, material number 1.4016) ferritic stainless steels by friction stir welding method are examined. Two specimens with dimension of 3 × 100 × 200 mm were joined in butt position. Tool rotational speeds were determined to be 560–1400 min⁻¹ and traverse speeds as 80–200 mm/min. During the studies, tool pressure force 3.5 kN and tool angle of 0° was kept constant. Hard metal carbide (WC-Co hard metal identified as K10) with equilateral triangle tip profile was used as the tool material. Determination of the tool advance speeds related to the tool rotation speeds giving the best-looking weld seals with acceptable values of mechanical properties was aimed.During welding of the specimens joined in butt position, the temperature change due to time and variation of the pressure force applied on welded specimens by the tool shoulder has been recorded. It has been observed that the best mechanical resistance values were obtained at tool rotational speed of 1120 min⁻¹ through five tool rotational speeds (560–1400). Also it has been observed that the best mechanical resistance values were obtained at traverse speed of 125 mm/min through five traverse speeds (80–200) with the constant tool pressure force of 3.5 kN and tool angle of 0°.     

Characterization of spatter in underwater wet welding by X-ray transmission method

The spatter forming mechanism of underwater flux-cored wire wet welding is characterized by using a self-developed X-ray transmission system. Three representative spatter modes, droplet repelled spatter, explosive spatter and molten pool shock spatter, forming during underwater wet welding have been observed. The generation of droplet repelled spatter is due to the excessive repulsive forces for metal transfer. The diameter of this type of spatter is largest relatively, which can reach about 4.5 mm. In addition, explosive spatter, with size about 2.5 mm, is changed from the droplet with high horizontal speed caused by a slight explosion occurs at the touching location of the droplet and molten surface. Moreover, the dimension of molten pool shock spatter is smallest potentially among the spatter types during underwater wet welding, and it is only about 0.8 mm. It is generated from ridgy liquid column on the molten pool surface because of the relatively severe concussion of the molten pool. The size, macroscopic pattern as well as chemical composition of these three types of spatters are different.     

Manipulation and welding of metal spheres above 10 μm using needle-like probe

A needle-like probe is the simplest tool to manipulate fine spheres. It catches fine spheres by adhesion forces without any holding device. Metallic spheres of 10–100 μm are difficult to manipulate with the needle-like probe, because the gravity rivals the adhesion forces in the dynamics of the spheres. Large and heavy spheres arranged on a substrate are easily disturbed because of the same reason. Here, a manipulator equipped with a direct power source, which applies voltage to the probe, is fabricated. Large and heavy spheres are adhered by the controllable electrostatic force. Besides the manipulation, the apparatus is designed to weld the spheres by using the probe as electrode for spot/arc welding. Experiments on the manipulation showed that the probe caught gold spheres of 40–80 μm by applying 20–50 V and released by putting them down after cutting the power off. Following to manipulation, welding experiments were carried out at various conditions. Two power sources, a high-voltage and low-current power source and a low-voltage and high-current power source, and two welding methods, arc welding and spot welding, are examined. The experiments showed that the gold spheres of 40–80 μm can be welded by the spot welding using the high-voltage and low-current power source, of which maximum power rating is 10 kV×1 mA. The probe is kept to touch the sphere and 4 kV or more is applied. Electric sparks are generated at the interface of the probe and the substrate, and the sphere is welded to the substrate. In both the manipulation and welding, the contact pressure must be very low. A tower of gold spheres is fabricated as an example of three-dimensional microstructures composed of fine spheres.     

Effect of metalloid silicon addition on densification,microstructure and thermal–physical properties of Al/diamond composites consolidated by spark plasma sintering

Aluminum matrix composites reinforced with diamond particles were consolidated by spark plasma sintering. Metalloid silicon was added (Al–Si/diamond composites) to investigate the effect. Silicon addition promotes the formation of molten metal during the sintering to facilitate the densification and enhance the interfacial bonding. Meanwhile, the alloying metal matrix precipitates the eutectic-Si on the diamond surfaces acting as the transitional part to protect the improved interface during the cooling stage. The improved interface and precipitating eutectic-Si phase are mutually responsible for the optimized properties of the composites. In this study, for the Al–Si/diamond composite with 55 vol.% diamonds of 75 μm diameter, the thermal conductivity increased from 200 to 412 Wm⁻¹ K⁻¹, and the coefficient of thermal expansion (CTE) decreased from 8.9 to 7.3 × 10⁻⁶ K⁻¹, compared to the Al/diamond composites. Accordingly, the residual plastic strain was 0.10 × 10⁻³ during the first cycle and rapidly became negligible during the second. Additionally, the measured CTE of the Al–Si/diamond composites was more conform to the Schapery’s model.     

A brief study of the force balance between a small iceberg,the ocean,sea ice,and atmosphere in the Weddell Sea

Icebergs are an important source of freshwater to the Weddell Sea. A unique set of oceanographic and other observations made during the Maud Rise Nonlinear Equation of State Study around one of the small icebergs, ubiquitous in the winter Weddell Sea, give us the opportunity to examine the dynamics of the interaction between an iceberg and the ocean. The iceberg was mapped using radar ranges and bearings from our ship, the research icebreaker Nathaniel Palmer, and found to be about 200 m wide above the water with a draft estimated to be 219 m. For this size, form drag dominates skin friction in both the atmosphere and ocean. Sea ice was ridged against the upwind side of the iceberg and thin sea ice and open water were on the downwind side. The iceberg was drifting 0.14 m s^− 1, or about 3% of the wind speed and 23° to the left. An automated CTD operating through the ship's moon-pool was used to measure temperature and salinity profiles upstream, downstream, and to the side of the iceberg. These profiles show a mixed upper layer 150 m deep upstream and 60 m deep downstream of the iceberg. The difference in density across the pycnocline was 0.05 kg m^− 3, which for the average pycnocline depth of 105 m and size of the iceberg corresponds to an interfacial internal wave speed equal to 0.166 m s^− 1. This and the upstream–downstream difference in pycnocline depth are consistent with a ± 45 m internal wave wake being generated by the motion of the iceberg. We estimate the contributions to total water drag from form drag and generation of the internal wake to be about equal. Consistent with theory, a qualitative argument using the observed pycnocline displacements suggests that internal wake drag should be a maximum when iceberg drafts are near the pycnocline depth. The drift rate of the iceberg (and sea ice) relative to wind speed was near the relative drift rate for the Weddell Sea ice we encountered during MaudNESS, but three times greater than what would result from a pure balance of atmospheric form drag against ocean form drag on the iceberg. Therefore, the force of sea ice on the iceberg, evidenced by ridging on the upwind side was dominant in moving the iceberg with the sea ice drift speed. The force transmitted through the sea ice required to drive the ice at the observed rate would be equivalent to the wind stress acting on an area of sea ice of 7.5 km². Maximum ridging forces in the 0.5 m thick sea ice should be adequate to drive the iceberg with this 219-m draft at 0.56 m s^− 1, much more than the observed drift rate but similar to the sea ice velocities during Weddell Sea storms.     

FEM simulation of Cu97Si3 filler metal droplets spreading under arc brazing

Abstract

The spreading behaviour of Cu₉₇Si₃ filler metal droplets under arc brazing is studied by finite element method (FEM) simulation using Surface Evolver software. The mathematical model of arc pressure force acceleration added to the droplet microelement as the form of gravity acceleration is used in numerical simulation. The 3D filler metal droplet profile for different welding currents is then simulated. Finally, the simulation results were compared with experimental results, showing good correspondence. It was seen that the spreading height decreases and the diameter increases with increase of the welding current in an approximate linear relation.     

Effect of boron content and welding current on the mechanical properties of electrical resistance spot welds in complex-phase steels

When complex phase steel where tensile strength is more than 1 GPa grade is joined by resistance spot welding (RSW) optimum boron (B) content should be chosen to satisfy weldability and mechanical properties. Therefore, in this study, the effect of the B content (0–40 ppm) on the tensile-shear strength of the RSW were investigated. As the resistivity of the base metal was independent on the B content it did not affect to nugget diameter. Regardless of the B content the specimens under 5t^1/2 (t = sheet thickness) were fractured at interfacial failure mode. In the low welding current condition (lower than 6.4 kA), measured nugget diameters were smaller than calculated critical nugget diameter regardless of the amount of B addition so that fracture mode was interfacial failure. Pull out failure occurred at the softened zone which was boundary between the base metal and the heat affected zone. Tensile-shear load of the specimen failure at the pull-out mode was increased as the fractured diameter and hardness of the softened zone were increased. Shear load was only dependent on the fractured diameter. The equations to calculate the shear and tensile-shear load were suggested for the specimens fractured at interfacial and pull-out failure modes respectively. Correlation coefficients between measured and calculated values of shear and tensile-shear load were 0.98 and 0.97, respectively. Therefore, shear and tensile-shear load of advanced high strength steel joined by RSW could be predicted successfully using the suggested equation.     

Effect of Ti on hot cracking and mechanical performance in the gas tungsten arc welds of copper thick plates

The new welding material – ERCuTi alloys filler metals were developed for gas tungsten arc welding (GTAW) of copper. The cracking susceptibility of the welds with ERCuTi and ERCu separately in GTAW of 10 mm copper thick plates was investigated. The formation causes of hot cracking was researched by using ERCu and the suppression mechanism of hot cracking when using ERCuTi alloy filler was proposed. It has been found that, when element Ti is added into the welding pool, the Ti will combine with O preferentially rather than Cu to generate TiO₂, which process can suppress the formation of Cu₂O. The hot cracking force and the hot ductility of the welds in brittle temperature range (BTR) could be improved effectively by adding Ti in filler metal compared with that of the welds without Ti. But the degree of addition of Ti (2–4 wt%) is critical when the susceptibility of cracking is to be suppressed. If the level is allowed to exceed 4 wt%, more low-melting point eutectics (β-TiCu₄ and TiCu₂) will be formed in the welds, and cracking susceptibility will be increased again. Results of mechanical properties tests show that although adding Ti increases the hardness and strength of the weld compared to the base metal, the impact ductility and the plastic properties are not decreased significantly.     

The effect of thermal ageing on low cycle fatigue behaviour of 316 stainless steel welds

It is well known that welds are the weak links in any structure. Therefore, it is of out most importance to characterize the mechanical properties of welds. Moreover, the changes in the microstructure that occur in welds on exposure to high temperatures affect the mechanical properties and must be studied by ageing the welds at high temperature. In this paper the low cycle fatigue behaviour of thermally aged 316 stainless steel weld metal is presented. Weld pads with single V configuration were prepared by the shielded metal arc welding process using 316 electrodes. Thermal ageing was done for 10,000 h at 823 and 873 K. Total strain controlled low cycle fatigue tests were conducted at a constant strain rate of 3 × 10^?3 s^?1 with strain amplitudes in the range ±0.25% to ±0.6% at 823 and 873 K. Weld metal exhibited initial hardening followed by cyclic softening prior to failure. The aged samples exhibited higher stress response as compared to the unaged samples. At both the temperatures and all strain amplitudes fatigue life was inferior to that of unaged samples. The metallography of the aged and tested material was studied through optical, scanning and transmission electron microscopy. The effect of transformation of δ-ferrite to sigma phase and carbides in the weld metal on low cycle fatigue behaviour was evaluated.     

Research on fatigue behavior of welded joint spraying fused by low transformation temperature alloy powder

Modification of spraying fused (MSF) of plasma arc as heat source was used to improve the fatigue performance of welded joint, which both fundamentally reduced stress concentration at weld toe and achieved metallurgical bond between spraying fused coating and welding. The low transformation temperature alloy powder was applied to the method of MSF. After spraying fusion, especially spraying fused joint by low transformation temperature alloy powder, the distribution of residual stress is more difficult to be obtained. Finite element (FE) simulation as an important tool was used to determine the stress field and temperature field of spraying fused joint. Simulated results show that as-welded joint and welded joint spraying fused by conventional nickel base alloy powder (Conventional-joint) present tensile stress. The stress of welded joint spraying fused by low transformation temperature alloy powder (LTT-joint) is compressive stress. Fatigue test results indicated that under the condition of 2 × 10⁶ cycles, the fatigue strength of as-welded joint is 135 MPa, while that of Conventional-joint and LTT-joint is 218 MPa and 235 MPa, respectively. The fatigue strength of Conventional-joint increases by 61.48%, and fatigue strength of LTT-joint increases by 74.07%.     

Effect of impact force on Ti–10Mo alloy powder compaction by high velocity compaction technique

Ti–10Mo alloy powder were compressed by high velocity compaction (HVC) in a cylinderical form of height/diameter (h/d) in die 0.56 (sample A) and 0.8 (sample B). Compactions were conducted to determine the effect of impact force per unit area of powder filled in die for densification and mechanical properties of Ti–10Mo samples. The micro structural characterization of samples were performed by scanning electron microscope (SEM). The mechanical properties of the compressed samples such as Vickers hardness, bending strength, and tensile strength were measured. Experimental results showed that the density and mechanical properties of sample A and sample B increased gradually with an increase in impact force and decreased with an increase in height/diameter ratio. The relative green density for sample A reached up to 90.86% at impact force per unit area 1615 N mm⁻². For sample B, it reached 79.71% at impact force per unit area 1131 N mm⁻². The sintered sample A exhibited a maximum relative density of 99.14%, Vickers hardness of 387 HV, bending strength of 2090.72 MPa, and tensile strength of 749.82 MPa. Sample B revealed a maximum relative sintered density of 97.73%, Vickers hardness of 376 HV, bending strength 1259.94 MPa and tensile strength 450.25 MPa. The spring back of the samples decreased with an increase in impact force.     

Detailed design and transport properties of a helium droplet nozzle from 5 to 50 K

This paper reports our efforts to engineer a robust, user-friendly, and broadly tunable helium droplet nozzle, and to quantitatively measure its thermal and mass transport performance. In addition to describing the physical design in detail, we report helium throughput measurements for a 6.4 μm diameter nozzle over stagnation conditions ranging from 5 to 50 K and 10 to 100 bar. The measured flow rates were in excellent agreement with those predicted by a simple effusive flow model for nozzle temperatures above 20 K, but were systematically lower for both sub-critical and super-critical jets as the temperature was lowered. The helium flow through a 500 μm skimmer was also measured, and the skimmed fraction was found to vary by two orders of magnitude over the range of stagnation conditions investigated. These results indicate a substantial narrowing of the total jet angle spread from ～90° to 5° at temperatures below 10 K. Efforts to image the low temperature jet with Schlieren and shadowgraph techniques were unsuccessful. These details combined with previously reported theory and experiments on the droplet size distributions provide the necessary foundation to predict cluster production rates and to customize nozzle/pump designs for specific applications.     

The effect of repeated repair welding on mechanical and corrosion properties of stainless steel 316L

The purpose of this study is to evaluate changes in the mechanical, micro structural and the corrosion properties of stainless steel 316L under repeated repair welding. The welding and the repair welding were conducted by shielded metal arc welding (SMAW). The SMAW welding process was performed using E316L filler metals. Specimen of the base metal and different conditions of shielded metal arc welding repairs were studied by looking in the micro structural changes, the chemical composition of the phases, the grain size (in the heat affected zone) and the effect on the mechanical and corrosion properties. The microstructure was investigated using optical microscopy (OM) and scanning electron microscopy (SEM). The chemical composition of the phases was determined using energy dispersive spectrometry (EDS). The corrosion behavior in 1 M H₂SO₄ + 3.5% NaCl solution was evaluated using a potentiodynamic polarization method. Tensile tests, Charpy-V impact resistance and Brinell hardness tests were conducted. Hardness of the heat affected zone decreased as the number of repairs increased. Generally an increase in the yield strength (YS) and the ultimate tensile strength (UTS) occurred with welding. After the first repair, a gradual decrease in YS and UTS occurred but the values of YS and UTS were not less than values of the base metal. Significant reduction in Charpy-V impact resistance with the number of weld repairs were observed when the notch location was in the HAZ. The HAZ of welding repair specimen is more sensitive to pitting corrosion. The sensitivity of HAZ to pitting corrosion was increased by increasing the number of welding repair.     

Improving mechanical and electrical properties of oriented polymer-free multi-walled carbon nanotube paper by spraying while winding

In this study, a new method is introduced for fabricating carbon nanotube (CNT) paper, in which the solvent is sprayed on the CNT sheet while it is wound on a rotating mandrel. As the solvent evaporated, the capillary force pulls CNT closer together, resulting in a CNT paper with a high degree of alignment and a high packing density. Three batches of multi-walled CNTs with different wall thicknesses, tube diameters and lengths are utilized for synthesizing highly oriented CNT papers. It is found that CNTs with smallest diameter of 8 nm form strongest CNT paper with a tensile strength of 563 MPa and a tensile modulus of 15 GPa, while that made with CNTs of 10 nm diameter shows the highest electrical conductivity of 5.5 × 10⁴ S/m.     

Laser,tungsten inert gas,and metal active gas welding of DP780 steel: Comparison of hardness,tensile properties and fatigue resistance

The microstructural characteristics, tensile properties and low-cycle fatigue properties of a dual-phase steel (DP780) were investigated following its joining by three methods: laser welding, tungsten inert gas (TIG) welding, and metal active gas (MAG) welding. Through this, it was found that the size of the welded zone increases with greater heat input (MAG > TIG > laser), whereas the hardness of the weld metal (WM) and heat-affected zone (HAZ) increases with cooling rate (laser > TIG > MAG). Consequently, laser- and TIG-welded steels exhibit higher yield strength than the base metal due to a substantially harder WM. In contrast, the strength of MAG-welded steel is reduced by a broad and soft WM and HAZ. The fatigue life of laser-and TIG-welded steel was similar, with both being greater than that of MAG-welded steel; however, the fatigue resistance of all welds was inferior to that of the non-welded base metal. Finally, crack initiation sites were found to differ depending on the microstructural characteristics of the welded zone, as well as the tensile and cyclic loading.     

Self-assembled InN quantum dots grown on AlN/Si(111) and GaN/Al2O3(0001) by plasma-assisted molecular-beam epitaxy under Stranski–Krastanow mode

We demonstrate that InN quantum dots (QDs) can be spontaneously formed on AlN and GaN surfaces by plasma-assisted molecular-beam epitaxy under the Stranski–Krastanow (S–K) mode. Both Si(111) wafers and metal–organic chemical vapor deposition grown GaN/Al₂O₃(0001) templates were used as substrates in this work. Silicon is particularly interesting as a substrate for InN QD applications because of its electrical conductivity and transparency in the near-infrared. By using reflection high-energy electron diffraction (RHEED), the formation process of InN QDs can be monitored in situ. We observed the 2D–3D transition of S–K growth mode and the lattice constant varied dramatically at the 2D–3D transition point from AlN to InN lattice constant. Furthermore, from the ex situ atomic force microscopy and scanning electron microscopy measurements, we directly imaged InN QDs on the AlN surface with an average diameter of ∼ 14 nm and high areal density of ∼ 1.6 × 10¹¹ cm^− 2.     

Nonlinear optical response of silica doped with copper nanoclusters under 1064 nm laser excitation

Metal nanocluster composite glass was formed by Cu ion implantation into silica using metal vapor vacuum arc (MEVVA) ion source. The microstructural properties of the nanoclusters were analyzed by optical absorption spectra and transmission electron microscopy (TEM). Third-order nonlinear optical properties of the nanoclusters were measured at 1064 nm excitations using Z-scan technique. The nonlinear refraction index, nonlinear absorption coefficient, and the real and imaginary parts of the third-order nonlinear susceptibility were deduced. The mechanisms responsible for the nonlinear response were discussed. Third-order nonlinear susceptibility χ⁽³⁾ of this kind of sample was determined to be (4.2 ± 1.0) × 10⁻⁸ esu.     

Effect of oxygen partial pressure on microstructural and optical properties of titanium oxide thin films prepared by pulsed laser deposition

Nanocrystalline titanium oxide (TiO₂) thin films were deposited on silicon (1 0 0) and quartz substrates at various oxygen partial pressures (1 × 10⁻⁵ to 3.5 × 10⁻¹ mbar) with a substrate temperature of 973 K by pulsed laser deposition. The microstructural and optical properties were characterized using Grazing incidence X-ray diffraction, atomic force microscopy, UV–visible spectroscopy and photoluminescence. The X-ray diffraction studies indicated the formation of mixed phases (anatase and rutile) at higher oxygen partial pressures (3.5 × 10⁻² to 3.5 × 10⁻¹ mbar) and strong rutile phase at lower oxygen partial pressures (1 × 10⁻⁵ to 3.5 × 10⁻³ mbar). The atomic force microscopy studies showed the dense and uniform distribution of nanocrystallites. The root mean square surface roughness of the films increased with increasing oxygen partial pressures. The UV–visible studies showed that the bandgap of the films increased from 3.20 eV to 3.60 eV with the increase of oxygen partial pressures. The refractive index was found to decrease from 2.73 to 2.06 (at 550 nm) as the oxygen partial pressure increased from 1.5 × 10⁻⁴ mbar to 3.5 × 10⁻¹ mbar. The photoluminescence peaks were fitted to Gaussian function and the bandgap was found to be in the range ∼3.28–3.40 eV for anatase and 2.98–3.13 eV for rutile phases with increasing oxygen partial pressure from 1 × 10⁻⁵ to 3.5 × 10⁻¹ mbar.     

Fatigue in laser welded titanium tubes intended for use in aircraft pneumatic systems

The pneumatic system conducts the pressurized hot air from the engine to the environmental systems of the aircrafts. In-service failures of arc-welded pneumatic parts have driven further developments of laser beam welding as an alternative method. Here, a fiber laser with 2 kW power had been employed to weld commercial purity titanium tubes with 0.5 mm wall thickness and 50 mm diameter. For comparison purposes, semiautomatic TIG welding was realized. The chosen parameters speed and laser power for laser welding were 200 W–2 m/min and 250 W–3 m/min. The laser welded tubes presented 1 mm wide weld beads composed by partially twinned α-Ti grains. The TIG welded tubes showed 5 mm wide beads composed by acicular α-grains. These observed differences had been associated with the cooling rates, which are ten times higher in the laser case. Both laser and TIG welded tubes were cycled 44,000 times in a pneumatic bench at 350 °C without failures or cracks that could release the internal pressure. After the pressurization tests, the tubes were tested for tensile and fatigue resistance. The yield stresses, tensile strengths and total elongation did not change comparing base material, TIG welded and laser welded cases. The condition 200 W–2 m/min presented superior fatigue resistance values compared to other welding conditions, and could be considered similar to the tubes in the unwelded condition. The microstructural and mechanical results had shown that the current laser technology can replace, with advantages, the arc welding for the joining of the titanium tubes.     

Pressure drop and heat transfer during two-phase flow vaporization of propane in horizontal smooth minichannels

This study examined the two-phase flow boiling pressure drop and heat transfer for propane, as a long term alternative refrigerant, in horizontal minichannels. The pressure drop and local heat transfer coefficients were obtained for heat fluxes ranging from 5–20 kW m^?2, mass fluxes ranging from 50–400 kg m^?2 s^?1, saturation temperatures of 10, 5 and 0 °C, and quality up to 1.0. The test section was made of stainless steel tubes with inner diameters of 1.5 mm and 3.0 mm, and lengths of 1000 mm and 2000 mm, respectively. The present study showed the effect of mass flux, heat flux, inner tube diameter and saturation temperature on pressure drop and heat transfer coefficient. The experimental results were compared against several existing pressure drop and heat transfer coefficient prediction methods. Because the study on evaporation with propane in minichannels was limited, new correlations of pressure drop and boiling heat transfer coefficient were developed in this present study.