Mechanical properties of friction stir welding and metal inert gas welding of Al-Zn aluminum alloy joints

In this work, an Al-Zn aluminum alloy was welded using friction stir welding (FSW) and metal inert gas (MIG) welding methods. The comparison between microstructure and mechanical properties of the two different joints was mainly discussed. Results showed that defect-free joints can be obtained using both the two welding methods. Due to much less heat input, grains of the stir zone (SZ) of the FSW joint are finer than those of the MIG joint, resulting into higher hardness. Tensile strength of the MIG and FSW joints respectively reaches 68.6 and 73.2% of the BM. The FSW joints own much better fatigue properties than the MIG joints and reach its infinite life at using 90 MPa. The FSW joint owns two cracks during the fatigue test.     

Assessment of the sulfide corrosion fatigue strength for a multi-pass welded A106 Gr B steel pipe below the low SSCC limit

In the area of heavy construction, welding processes are vital in the production and maintenance of pipelines and power plants. Welding processes happen to produce residual stresses and change the metal structure as a result of the large nonlinear thermal loading that is created by a moving heat source. The fusion welding process generates formidable welding residual stresses and metallurgical change, which increase the crack driving force and reduce the resistance to the brittle fracture as well as the environmental fracture. This is a serious problem with many alloys as well as the A106 Gr B steel pipe. This pipe that is used in petrochemical and heavy chemical plants either degrades due to corrosive environments, e.g., chlorides and sulfides, and/or become damaged during service due to the various corrosion damage mechanisms. Thus, in this study, after numerically and experimentally analyzing the welding residual stress of a multi-pass welded A106 Gr B steel pipe, the sulfide stress corrosion cracking (SSCC) characteristics were assessed in a 3.5 wt.% NaCl solution that was saturated with H₂S gas at room temperature on the basis of NACE TM 0177-90. The specimens used are of two kinds: un-notched and notched. Then, the sulfide corrosion fatigue (SCF) strength for the un-notched specimen was assessed below the low SSCC limit that was previously obtained from the SSCC tests for the notched specimen. From the results, in terms of the SSCC and SCF, all the specimens failed at the heat-affected zone, where a high welding residual stress is distributed. It was found that the low SSCC limit of un-notched specimens (σ_{SSCCun-notched}) was 46% (230 MPa) of the ultimate tensile strength (σ_U=502 MPa) of a multi-pass welded A106 Gr B steel pipe, and the notched specimens (σ_SSCCnotched) had 40% (200 MPa) of the ultimate tensile strength. Thus, it was determined that σ_{SSCCun-notched} was 13% lower than σ_SSCCnotched. Further, the sulfide corrosion fatigue limit (σ_{SCFun-notched}) was 32% (160 MPa) of the ultimate tensile strength of welded specimens. This σ_{SCF un-notched} was 20% lower than σ_SSCCnotched.     

A study on tensile and fatigue properties of aged NAS 254N stainless steel at elevated temperatures

The effects of aging on tensile properties and fatigue crack growth behaviors of NAS 254N stainless steel was studied. Yield strength and ultimate tensile strength of the aged specimens were almost the same as the as-received (as-rec.). The fracture strain, however, was decreased significantly by the aging, and the fracture surface of the aged at room temperature (RT) test was intergranular. As test temperature increased, yield strength, ultimate tensile strength and elongation decreased. And a type of serration was observed at 550-650°C As strain rate decreased, yield strength and ultimate tensile strength decreased, but elongation increased. It was observed that tensile strength and strain had a sudden change at one point. And this critical temperatureT _cr was 550°C. The effect of aging time on the tensile strength and strain was also investigated. Tensile strength and strain decreased significantly beyond 100hrs. Fatigue crack growth rate at RT was enhanced by the aging at high stress intensity factor range. This is due to the occurrence of the intergranular fracture in the aged specimen. At 650°C, the fatigue crack growth behavior was almost the same without intergranular fracture.     

CO2 laser welding of zinc-coated steel sheets

Welding of zinc-coated steel sheets for the automotive industry has been investigated experimentally and theoretically, using a continuous wave 2 kW CO₂ laser. The specimens of 0.8, 1.0 and 1.2 mm thickness were welded as butt joint and lap joint. Argon gas was shielded co-axially to reduce the plasma and to protect the molten, pool from atmosphere. The mechanical tests of specimens were carried out to investigate the ductility of welds in butt joint and lap joint, using the Erichsen test, ball punch test and tensile shear test. The value of transverse weld pattern is higher than others. The fatigue life of longitudinal weld is superior, but that of circular weld pattern is inferior due to the high tensile residual stresses in the weld. The maximum Erichsen value was obtained as 96% and the deformability of zinc coated steel butt-welded was found to be 80% in the ball punch test. The high pressure formed by vaporization of zinc with the low boiling temperature during laser lap-joint welding splattered the molten pool and created porosities in the weld. The optimum gap was calculated to be 0.1 mm in the lap joint welding of zinc-coated steel sheet which was a good agreement with the experimental result.     

焊后热处理对30CrMnSiNi2A钢电子束焊接件疲劳行为的影响

电子束局部热处理是一种新型的热处理方式，探讨其对电子束焊接接头组织和疲劳性能的影响规律具有十分重要的实际意义。文中采用CT(紧凑拉伸)试样，对30CrMnSiNi2A钢电子束焊接后焊态、焊后炉内整体热处理和电子束局部热处理三种焊接接头焊缝与母材的疲劳裂纹扩展速率进行试验研究；并测定上述两个部位的门槛值。结合金相组织分析，讨论焊后热处理对接头疲劳行为的影响。试验结果表明，电子束局部热处理和整体热处理都能够在一定程度上改善焊接接头的组织和近门槛值处抗疲劳裂纹扩展的能力。由于电子束局部热处理具有方便、省时、节省能源和提高生产率的优点，因而具有较大的应用潜力和研究价值。     

煤制天然气中氢对X80钢螺旋焊管力学性能的影响

近年来,我国多项煤制天然气示范工程投入运行,X80钢螺旋焊管常用于天然气长输管道建设,其与煤制天然气的相容性直接影响了长输管道的服役寿命和安全可靠性。为研究煤制天然气对国产X80钢螺旋焊管的力学性能影响,分别从埋弧螺旋焊管的母材和螺旋焊缝处取样,在总压为12 MPa,氢气分数为0,1vol%,2.2vol%,5vol%的模拟环境中分别进行慢应变速率拉伸试验和疲劳裂纹扩展速率试验。试验结果表明:含氢量5vol%以下时,煤制天然气对国产X80管线钢强度性能影响很小,但对塑性性能有一定影响,对疲劳裂纹扩展性能影响很大,煤制天然气中氢对母材的疲劳裂纹扩展性能劣化影响比螺旋焊缝严重。     

Experimental study on variations in charpy impact energies of low carbon steel,depending on welding and specimen cutting method

This paper presents an experimental study that examines variations of Charpy impact energy of a welded steel plate, depending upon the welding method and the method for obtaining the Charpy specimens. Flux cored arc welding (FCAW) and Gas tungsten arc welding (GTAW) were employed to weld an SA516 Gr. 70 steel plate. The methods of wire cutting and water-jet cutting were adopted to take samples from the welded plate. The samples were machined according to the recommendations of ASTM SEC. II SA370, in order to fit the specimen dimension that the Charpy impact test requires. An X-ray diffraction (XRD) method was used to measure the as-weld residual stress and its redistribution after the samples were cut. The Charpy impact energy of specimens was considerably dependent on the cutting methods and locations in the welded plate where the specimens were taken. The specimens that were cut by water jet followed by FCAW have the greatest resistance-to-fracture (Charpy impact energy). Regardless of which welding method was used, redistributed transverse residual stress becomes compressive when the specimens are prepared using water-jet cutting. Meanwhile, redistributed transverse residual stress becomes tensile when the specimens are prepared using wire cutting.     

Effect of single overload on fatigue behavior in the welded haz of low alloy steel

Room temperature fatigue crack growth behavior was obtained for 4140 parent steel, parent heat treated (same as PWHT), as-welded HAZ and PWHT HAZ material under R≈O constant amplitude loading and single tensile overloads with an over load ratio (OLR: P_over/P_max) of 2.5. Double pass automatic submerged arc welding with AWS EM2 electrode was used. PWHT was performed at 650°C for one hour. Constant amplitude fatigue crack growth behavior was very similar for all four material conditions in the log-log linear Paris region. All material conditions responded favorably to the single tensile overloads with fatigue crack growth retardation ranging from 2.5×10⁵ to 4.5×10⁵ cycles which corresponded to life increases of 250 to 400 percent. SEM analysis indicated many similarities on the fatigue fracture surfaces with predominant ductile quasi-striation morphology.     

铝合金点焊拉剪接头疲劳性能及寿命分析

研究了铝合金AA5754点焊拉剪接头的疲劳性能,获得了不同厚度试件的载荷寿命曲线。研究了铝合金焊点的疲劳失效模式,讨论了焊点疲劳裂纹的扩展形式,并测量了裂纹扩展路径与点焊熔核界面之间的角度。分析了点焊拉剪试件在同时承受I型和II型载荷时,疲劳裂纹的扩展方向,并与测量值进行了比较。利用疲劳破坏后沿铝板厚度方向的实际裂纹长度修正了裂纹尖端的局部应力强度因子,提出了评价焊点寿命的疲劳参量K(i),并对试验数据进行了分析比较。结果证明K(i)可以有效关联试件尺寸效应和焊点疲劳寿命,能够用于预测焊点疲劳寿命。     

9%Ni钢用国产镍基焊丝的焊接试验研究

针对镍基焊丝的热裂纹敏感性试验,研制出FISCO热裂纹试验装置,利用该装置对研制的ERNiCrMo-3镍基焊丝进行焊接热裂纹敏感性试验,结果表明,研制焊丝的热裂纹敏感性与进口焊丝相当,均具有较低的热裂纹敏感性。采用研制焊丝焊接9%Ni钢的工艺试验结果表明,焊接接头各项力学性能优良,焊缝组织为纯奥氏体组织,析出相很少,可以满足大型LNG储罐的设计要求。     

Effect of constraint on fracture behavior of welded 17mn4 and aisi304 steels

In this study, 17Mn4 (P295GH) pressure vessels steel and AISI304 stainless steel were welded with ER309L austenitic consumable. In experimental part of the study, tensile tests were conducted on welded plates and variation of hardness values along specimen was measured. J-integral fracture toughness values were investigated for different crack locations. In order to determine the regions where plastic deformation did not take place due to constraint, uni-axial tensile test was performed on welded tensile specimen after attaching strain gauges. In numerical part of the study, finite element (FE) analyses were conducted by fixing 2-D models precracked on different locations by using ANSYS software. In these models, stress triaxiality and plastic deformation characteristics around crack tip were determined for each crack locations after stress — strain analyses. The limitation on the extension of plastic deformation at diffusion line causes extra increase in stress triaxiality at crack tip.     

Influences of post weld heat treatment on fatigue crack growth behavior of TIG welding of 6013 T4 aluminum alloy joint (Part 1. Fatigue crack growth across the weld metal)

The present study evaluates the influences of PWHT on FCG behavior and tensile properties of TIG butt welded Al 6013-T4 sheets. Crack propagation tests were carried out on compact tension (CT) specimens. The T82 heat treatment was varied in three artificial aging times (soaking) of 6, 18 and 24 hours. The results of T82 heat treatment with artificial aging variations were tested for their fatigue crack growth rates at the main metal zone, the heat-affected zone (HAZ), and the welded metal zone. It has been observed that the various agings in heat treatment T82 are sensitive to the mechanical properties (fatigue crack growth rate test, tensile test). The results show that PWHT-T82 for 18 hours aging is the highest fatigue resistance, while the aging 18 hours provided the highest tensile test result.     

HG80钢及其焊接接头的疲劳裂纹扩展

为适应大型工程机械焊接用钢需要，对低合金高强度钢HG80及其焊接接头的疲劳裂纹扩展速率进行了研究。结果表明，疲劳裂纹扩展速率对钢板的轧制方向不敏感，焊缝及热影响区疲劳裂纹扩展速率明显低于基材。在排除焊接残余应力导致的裂纹闭合效应后，焊缝及热影响区疲劳裂纹扩展速率与基材相当。     

Effect of specimen thickness on the statistical properties of fatigue crack growth resistance in BS4360 steel

In this paper the effect of specimen thickness on fatigue crack growth with the spatial distribution of material properties is presented. Basically, the material resistance to fatigue crack growth is treated as a spatial stochastic process, which varies randomly on the crack surface. The theoretical autocorrelation functions of fatigue crack growth resistance with specimen thickness are discussed for several correlation lengths. Constant ΔK fatigue crack growth tests were also performed on CT type specimens with three different thicknesses of BS 4360 steel. Applying the proposed stochastic model and statistical analysis procedure, the experimental data were analyzed for different specimen thicknesses for determining the autocorrelation functions and probability distributions of the fatigue crack growth resistance.     

Growth behavior of short surface fatigue cracks in 2 1/4 Cr-1 Mo steel

Fatigue tests by axial loading (R-0.05) were carried out to investigate short fatigue crack growth behavior in 2 1/4 Cr-1 Mo steel at room temperature using smooth and a small notched flat specimen. All the data of the fatigue crack growth rate in the present tests were analyzed as a function of the stress intensity factor equation in conjunction with crack closure behavior. Analysis was performed accounting for the relation of surface effective stress range,Ua and depth effective stress range,Ub. In the case of isotropic crack growth properties,Ub=(ΔK_ta/ΔK_tb) ·Ua. By use ofUb obtained from the analysis, crack growth rates to surface direction coincide with those of depth direction.     

钣金件焊接性能试验研究

为了提高产品钣金件的抗拉强度和防腐蚀性能,并选择合适的焊接方法,文中分别采用2种胶焊方法(透胶胶焊、毛细作用胶焊)和传统点焊方法对3种材料(St12钢板、5A05铝板、2A12铝板)进行了试验。采用3种方法对试验件做盐雾试验、拉伸试验后再对所得数据进行对比分析。试验结果表明:对于St12钢板,点焊件抗拉强度最高,而毛细作用胶焊的抗腐蚀性能最好;对于5A05和2A12铝板,毛细作用胶焊的抗拉强度和抗腐蚀性能都最好。由此可见,毛细作用胶焊方法是一种较为适合的钣金件连接方式。     

The study of MIG weldability of heat-treated aluminum alloys

In this article, Metal Inert Gas (MIG) weldability of commercially received and aged samples of 6061-T₆ and 7075-T₆₅₁ aluminum alloys was investigated. The welding joints were prepared in ten different combinations. Microstructure, microhardness, EDX, energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) analyses were used in order to evaluate the effect of aged heat treatment on the performance of welded joints. In addition, the mechanical properties of welding joints were characterized using the tensile and microhardness tests. In conclusion, it was shown that prewelding aging heat treatment improves the mechanical properties of welding joints.     

Investigation of welding residual stress of high tensile steel by finite element method and experiment

Due to varying temperature distribution of welding area during welding process, thermal stress is generated. It is known that the thermal stress forms residual stress. The welding residual stress has an important effect on welding deformation, embrittlement fracture, fatigue fracture, etc. In this paper, residual stress due to welding was numerically investigated by finite element method. To verify the results of numerical analysis, the residual stress of high tensile steel was measured by the hole-drilling method. Temperature change experimentally measured at the location of 3-mm-off-weld-bead, in addition, was compared with the numerical analysis. The above methodologies were applied to H-plate with 13.5mm thickness through MIG welding process. The distributions of the residual stress and the temperature distributions from the experimental and the numerical analyses were confirmed to be close.     

Virgo104 铸钢及焊接接头力学性能研究

对Virgo104钢的力学性能进行了检验,并研究了与之匹配的两种气保焊焊丝及一种焊条的焊接接头力学性能.试验结果表明,Virgo104钢中心与表面的力学性能基本一致,具有良好的强度与塑性匹配,而且具有优良的低温冲击韧度,特别是其高的Wp/Wi(约3.0)及高的侧向膨胀率(约15%),表明该钢具有优良的抗脆性断裂性能.焊缝金属及焊接接头具有良好的力学性能,其中HS367L焊丝的焊缝金属,在焊态下具有较高的塑性,预示出较高的抗焊接裂纹性能.     

Effects of laser shock processing on mechanical properties of laser welded ANSI 304 stainless steel joint

With the rapid development of engineering component with integration,high-speed and multi-parameter,traditional techniques haven’t met practical needs in extreme service environment.Laser welding,a new welding technology,has been widely used.However,it would generate the drop of mechanical properties for laser welded joint due to its thermal effect.Laser shock processing(LSP) is one of the most effective methods to improve the mechanical properties of laser welded ANSI 304 stainless steel joint.In this paper,the effects of LSP on the mechanical properties of laser welded ANSI 304 stainless steel joint have been investigated.The welded joint on the front of the tensile samples is treated by LSP impacts,and the overlapping rate of the laser spot is 50%.The tensile test of the laser welded joint with and without LSP impacts is carried out,and the fracture morphology of the tensile samples is analyzed by scanning electron microscope(SEM).Compared with the yield strength of 11.70 kN,the tensile strength of 37.66 kN,the yield-to-tensile strength ratio of 0.310 7,the elongation of 25.20%,the area reduction of 32.68% and the elastic modulus of 13 063.876 MPa,the corresponding values after LSP impacts are 14.25 kN,38.74 kN,0.367 8,26.58%,42.29% and 14 754.394 MPa,respectively.Through LSP impacts,the increasing ratio of the yield strength and tensile strength are 121.79% and 102.87%,respectively;the elongation and area reduction are improved by 5.48% and 29.38%,respectively.By comparing with coarse fracture surface of the welded joint,the delamination splitting with some cracks in the sharp corner of the welded joint and asymmetric dimples,LSP can cause brighter fracture surface,and finer and more uniform dimples.Finally,the schematic illustration of dimple formation with LSP is clearly described.The proposed research ensures that the LSP technology can clearly improve the yield strength,tensile strength,yield-to-tensile strength ratio,elongation,area reduction and elastic modulus of the welded joint.The enhancement mechanism of LSP on laser welded ANSI 304 stainless steel joint is mainly due to the fact that the refined and uniform dimples effectively delay the fracture of laser welded joints.