Theoretical investigation of penetration characteristics in gas metal-arc welding using finite element method

In the modeling of the gas metal-arc (GMA) welding process, heat inputs to the workpiece by the arc and the metal transfers have been considered separately. The heat energy delivered due to the metal transfer has been approximated in the form of a cylindrical volumetric heat source, whose dimensions of the radius and the height are dependent on the molten metal droplet characteristics. The pinch instability theory (PIT) and the static force balance theory (SFBT) of drop detachment have independently been used to obtain the expressions for various characteristics of the drop,i.e., the drop radius, the drop velocity, and the drop frequency at various welding parameters. The occurrence or the nonoccurrence of finger penetration, routinely found in the GMA welding at high welding currents, has been satisfactorily explained by the cylindrical heat source model. The effect of various welding parameters,e.g., the welding current, the wire radiusetc., on the weld bead penetration characteristics has been investigated. In this modeling effort, the heat conduction equation has been solved in three dimensions.     

Transition metal joints for steam generators—An overview

The transition metal joint (TMJ) between an austenitic stainless steel and a chromium-molybdenum (Cr-Mo) ferritic steel used widely in steam generators of power plants has for a long time presented problems relating to premature failures in service. The direct (bimetallic) TMJ presently in use is designed for a service life of about 200,000 h; but such TMJs with iron-base weld metals have been failing in service within about one-third of their design lifetime, while their counterparts with nickel-base weld metals fail within about one-half of their design lifetime. The causes for such premature service failures of these TMJs are discussed in detail, leading to the development of improved TMJs. One of the improved TMJs with a trimetallic configuration of austenitic stainless steel/Alloy 800/Cr-Mo ferritic steel is discussed in detail, covering its development, characterisation and evaluation. Accelerated performance tests in the laboratory have indicated a four-fold improvement in the service life of the TMJ with this trimetallic configuration compared to the bimetallic configuration. The metallurgical details of these studies are also discussed in this paper.     

Characterization of tempered martensite embrittlement using hardness measurement

A series of experiments were carried out on three commercial steels to explore the possibility for characterizing tempered martensite embrittlement (TME) by Rockwell, macro-, and micro-Vickers hardness tests. The results indicate distinct hardness peaks in two steels and an inflection in the other around the TME temperature. A new analytical approach for examining the slope of hardness-tempering temperature plots appears to reveal the TME phenomenon more sensitively. Dilatometric examinations substantiate that the temperature of hardness peak/inflection occurs beyond the second stage of tempering.     

Prediction of burning rate of coal in fluidized-bed combustion

A theory has been proposed to evaluate the burning rate of a single carbon particle in a continuously operated coal-fired fluidized bed. Experimental verification was carried out in a laboratory scale 200 mm × 200 mm combustor. The burning rate increases with the increase of the fluidization velocity and the size of the bed material. The predicted data on burning rate agree fairly well with the experimental values. The gas concentration in the bed and freeboard has also been measured and it is seen that the consumption of oxygen mostly takes place in the bed.     

In situ repair welding of steam turbine shroud for replacing a cracked blade

A root-cracked blade in a high-pressure steam turbine of a nuclear power plant had to be replaced with a new blade by cutting the shroud to remove the cracked blade. This necessitated in situ welding of a new shroud piece with the existing shroud after the blade replacement. The in situ welding of the shroud, a 12% Cr martensitic stainless steel with tempered martensite microstructure, was carried out using gastungsten arc welding and 316L austenitic stainless steel filler metal followed by localized postweld heat treatment at 873 K for 1 h using a specially designed electrical resistance-heating furnace. Mock-up trials were carried out to ensure that sound welds could be made under the constraints present during the in situ repair welding operation. In situ metallography of the repair weld after postweld heat treatment confirmed the adequate tempering of the martensitic structure in the heat-affected zone. Metallurgical investigations carried out in the laboratory on a shroud test-piece that had been welded using the same procedure as employed in the field confirmed the success of the in situ repair operation. The alternate option available was replacing the cracked blade and the shroud piece to which it is riveted with a new one, reducing the height of all the blades attached to the shroud by machining, riveting the blades with reduced height to the new shroud, and, finally, dynamic balancing of the entire turbine after completion of the repair. This option is both time-consuming and expensive. Hence, the successful completion of this repair welding resulted in enormous savings both in terms of reducing the downtime of the plant and the cost of the repair. The turbine has been put back into service and has been operating satisfactorily since December 2000.     

A local asynchronous distributed privacy preserving feature selection algorithm for large peer-to-peer networks

In this paper we develop a local distributed privacy preserving algorithm for feature selection in a large peer-to-peer environment. Feature selection is often used in machine learning for data compaction and efficient learning by eliminating the curse of dimensionality. There exist many solutions for feature selection when the data are located at a central location. However, it becomes extremely challenging to perform the same when the data are distributed across a large number of peers or machines. Centralizing the entire dataset or portions of it can be very costly and impractical because of the large number of data sources, the asynchronous nature of the peer-to-peer networks, dynamic nature of the data/network, and privacy concerns. The solution proposed in this paper allows us to perform feature selection in an asynchronous fashion with a low communication overhead where each peer can specify its own privacy constraints. The algorithm works based on local interactions among participating nodes. We present results on real-world dataset in order to test the performance of the proposed algorithm.     

Analysis of Elevated Temperature Flow Behavior of 316LN Stainless Steel Under Compressive Loading

To understand the flow behavior of a newly developed austenitic stainless steel 316LN with 0.14 wt% nitrogen, isothermal compression tests have been carried out in the hot working domain. From the analysis of flow behavior, it is observed that the nitrogen enhanced steel, in its hot working domain exhibits strain and strain rate hardening with thermal softening. The flow behavior analysis also demonstrates the coupled effect of strain–temperature and strain rate temperature on the flow stress. To depict the flow behavior of the material, strain compensated Arrhenius (SCA) equation and Model D8A have been used. The SCA predicts the flow curves with an average absolute error of 9.27% and a correlation coefficient of 0.977, whereas the prediction by Model D8A gives the average absolute relative error as 10.86% with a correlation coefficient of 0.966. For high temperature and intermediate strain rate, both Model D8A and SCA equation depict the flow behavior of 316L (0.14)N SS with good correlation and generalization. However, at low temperature and high strain rate domain, both the models are unable to depict the behavior; this is attributed to the fact that the material shows two slope behaviors where the constants have been calculated assuming a linear relationship between stress and strain rate.     

Influence of microstructural inhomogeneities on the fracture toughness of modified 9Cr–1Mo steel at 298–823 K

Quasistatic fracture behaviour of two heats of modified 9Cr–1Mo steel for steam generator applications have been assessed at 298, 653 and 823 K. J–R curves were established and the elastic–plastic fracture toughness values at 0.2 mm crack extension (J_0.2) were determined. The fracture mechanisms were entirely different for the two steels at 298 K, with brittle fracture controlled by cleavage crack initiation in one and ductile fracture in the other by void nucleation and growth. At 653 and 823 K, fracture in both materials was by ductile crack growth. The difference in behaviour between the two steels at 298 K was attributed to the differences in microstructure, distribution and density of inclusions as well as phosphorous contents.