Search results for: metal active gas welding

Authors: Tri Wisudawati, Radita Dwi Putera

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The role of human resources is the basic capital in determining the purpose of a business place. Without the role of human resources, activities in the company will not run smoothly. Every business place always has a risk of accidents. The magnitude of the risk that occurs depends on the type of industry, technology, and risk control efforts made. Work-related accidents are accidents that occur due to work or while carrying out work. Welding MSMEs have a fairly high risk to health, safety and the environment both from the side of workers who can cause accidents and from the side of the work environment, which has the potential to become a hazard and risk. Participatory ergonomic intervention can be a feasible and effective approach to reducing exposure to work-related risk factors in developing country industries. Complaints about occupational health and safety experienced by workers in the welding workshop industry should be able to be overcome by implementing an ergonomic intervention approach. The analysis process includes HIRARC analysis, participatory ergonomics analysis, and SEM-PLS analysis. Hierarch analysis is carried out by assessing the level of severity and likelihood, as well as risk control. At the participatory ergonomics analysis stage, it is obtained from the organizational culture and organizational stakeholders. At the SEM-PLS stage, an analysis is carried out to see whether there is a strong relationship between the research variables in order to produce occupational health and safety (K3) and worker productivity in the welding shop better and in accordance with welding safety standards. So that the output of this study is how participatory ergonomics interventions affect working conditions to improve occupational health and safety and the productivity of welding workers.

Keywords: ergonomic partisipatory, health and safety, welding workers, welding safety

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Authors: Ahbdelfattah M. Khourshid, T. Elabeidi

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Friction Stir Welding (FSW), a solid state joining technique, is widely being used for joining Al alloys for aerospace, marine automotive and many other applications of commercial importance. FSW were carried out using a vertical milling machine on Al 5083 alloy pipe. These pipe sections are relatively small in diameter, 5mm, and relatively thin walled, 2mm. In this study, 5083 aluminum alloy pipe were welded as similar alloy joints using (FSW) process in order to investigate mechanical and microstructural properties .rotation speed 1400 r.p.m and weld speed 10,40,70 mm/min. In order to investigate the effect of welding speeds on mechanical properties, metallographic and mechanical tests were carried out on the welded areas. Vickers hardness profile and tensile tests of the joints as a metallurgical investigation, Optic Microscopy and Scanning Electron Microscopy (SEM) were used for base and weld zones.

Keywords: friction stir welding (FSW), Al alloys, mechanical properties, microstructure

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Authors: Harish K. Arya, Kulwant Singh, R. K. Saxena

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The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on penetration and bead width. The penetration reduces with increase in plate thickness due to heat loss in thickness direction for same heat input, while bead width increases for thicker plate due to faster cooling.

Keywords: submerged arc welding, plate thickness, bead geometry, cooling rate

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Authors: Harish Kumar Arya, Kulwant Singh, R. K Saxena, Deepti Jaiswal

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The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on bead geometry and dilution. The penetration reduces with increase in plate thickness due to heat loss in thickness direction, while bead width and reinforcement increases for thicker plate due to faster cooling.

Keywords: submerged arc welding, plate thickness, bead geometry, cooling rate

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Authors: Edison A. Bonifaz

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In this work, a numerical procedure is proposed to design dense multi-material structures using the Directed Energy Deposition (DED) process. A thermo-mechanical finite element model to predict thermal cycles and residual stresses is presented. A numerical layer build-up procedure coupled with a moving heat flux was constructed to minimize strains and residual stresses that result in the multi-layer deposition of an AISI 316 austenitic steel on an AISI 304 austenitic steel substrate. To simulate the DED process, the automated interface of the ABAQUS AM module was used to define element activation and heat input event data as a function of time and position. Of this manner, the construction of ABAQUS user-defined subroutines was not necessary. Thermal cycles and thermally induced stresses created during the multi-layer deposition metal AM pool crystallization were predicted and validated. Results were analyzed in three independent metal layers of three different experiments. The one-way heat and material deposition toolpath used in the analysis was created with a MatLab path script. An optimal combination of feedstock and heat input printing parameters suitable for fabricating multi-material dense structures in the directed energy deposition metal AM process was established. At constant power, it can be concluded that the lower the heat input, the lower the peak temperatures and residual stresses. It means that from a design point of view, the one-way heat and material deposition processing toolpath with the higher welding speed should be selected.

Keywords: event series, thermal cycles, residual stresses, multi-pass welding, abaqus am modeler

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Authors: Juree Hong, Sanggeun Lee, Jungmok Seo, Taeyoon Lee

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We report a facile synthesis of metal nano particles (NPs) on graphene layer via galvanic displacement reaction between graphene-buffered copper (Cu) and metal ion-containing salts. Diverse metal NPs can be formed on graphene surface and their morphologies can be tailored by controlling the concentration of metal ion-containing salt and immersion time. The obtained metal NP-decorated single-layer graphene (SLG) has been used as hydrogen gas (H2) sensing material and exhibited highly sensitive response upon exposure to 2% of H2.

Keywords: metal nanoparticle, galvanic displacement reaction, graphene, hydrogen sensor

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Authors: Siri Marthe Arbo, Afaf Saai, Sture Sørli, Mette Nedreberg

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This work aims to establish a reliable approach for optimizing a Laser Metal Deposition (LMD) process for a critical maritime component, based on the material properties and structural performance required by the maritime industry. The component of interest is a water jet impeller, for which specific requirements for material properties are defined. The developed approach is based on the assessment of the effects of LMD process parameters on microstructure and material performance of standard AM 2205 duplex stainless steel powder. Duplex stainless steel offers attractive properties for maritime applications, combining high strength, enhanced ductility and excellent corrosion resistance due to the specific amounts of ferrite and austenite. These properties are strongly affected by the microstructural characteristics in addition to microstructural defects such as porosity and welding defects, all strongly influenced by the chosen LMD process parameters. In this study, the influence of deposition speed and heat input was evaluated. First, the influences of deposition speed and heat input on the microstructure characteristics, including ferrite/austenite fraction, amount of porosity and welding defects, were evaluated. Then, the achieved mechanical properties were evaluated by standard testing methods, measuring the hardness, tensile strength and elongation, bending force and impact energy. The measured properties were compared to the requirements of the water jet impeller. The results show that the required amounts of ferrite and austenite can be achieved directly by the LMD process without post-weld heat treatments. No intermetallic phases were observed in the material produced by the investigated process parameters. A high deposition speed was found to reduce the ductility due to the formation of welding defects. An increased heat input was associated with reduced strength due to the coarsening of the ferrite/austenite microstructure. The microstructure characterizations and measured mechanical performance demonstrate the great potential of the LMD process and generate a valuable database for the optimization of the LMD process for duplex stainless steels.

Keywords: duplex stainless steel, laser metal deposition, process optimization, microstructure, mechanical properties

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Authors: Yiqiang Ni, Xuanlong Chen, Enliang Li, Linting Zheng, Shizheng Yang

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Bipolar ICs are playing an important role in military applications, mainly used in logic gates, such as inverter and NAND gate. The defect of metal break located on the step is one of the main failure mechanisms of bipolar ICs, resulting in open-circuit or functional failure. In this situation, general failure localization methods like optical beam-induced resistance change (OBIRCH) and photon emission microscopy (PEM) might not be fully effective. However, active voltage contrast (AVC) can be used as a voltage probe, which may pinpoint the incorrect potential and thus locate the failure position. Two case studies will be present in this paper on how to implement AVC for failure localization, and the detailed failure mechanism will be discussed.

Keywords: bipolar IC, failure localization, metal break, open failure, voltage contrast

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Authors: Jay J. Vora, Vishvesh J. Badheka

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This work attempts to investigate the effect of oxide fluxes on 6mm thick Reduced Activation ferritic/martensitic steels (RAFM) during Activated TIG (A-TIG) welding. Six different fluxes Al₂O₃, Co₃O₄, CuO, HgO, MoO₃, and NiO were mixed with methanol for conversion into paste and bead-on-plate experiments were then carried out. This study, systematically investigates the influence of oxide-based flux powder and carrier solvent composition on the weld bead shape, geometric shape of weld bead and dominant depth enhancing mechanism in tungsten inert gas (TIG) welding of reduced activation ferritic/martensitic (RAFM) steel. It was inferred from the study that flux Co₃O₄ and MoO₃ imparted full and secure (more than 6mm) penetration with methanol owing to dual mechanism of reversed Marangoni and arc construction. The use of methanol imparted good spreadabilty and coverability and ultimately higher peak temperatures were observed with its use owing to stronger depth enhancing mechanisms than use of acetone with same oxide fluxes and welding conditions.

Keywords: A-TIG, flux, oxides, penetration, RAFM, temperature, welding

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Authors: Philip Baillie, Stuart W. Campbell, Alexander M. Galloway, Stephen R. Cater, Norman A. McPherson

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This study compared the mechanical and microstructural properties produced during friction stir welding(FSW) of S275 structural steel in air and underwater. Post weld tests assessed the tensile strength, micro-hardness, distortion, Charpy impact toughness and fatigue performance in each case. The study showed that there was no significant difference in the strength, hardness or fatigue life of the air and underwater specimens. However, Charpy impact toughness was shown to decrease for the underwater specimens and was attributed to a lower degree of recrystallization caused by the higher rate of heat loss experienced when welding underwater. Reduced angular and longitudinal distortion was observed in the underwater welded plate compared to the plate welded in air.

Keywords: Charpy impact toughness, distortion, fatigue, friction stir welding(FSW), micro-hardness, underwater

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Authors: Stuart W. Campbell, Alexander M. Galloway, Norman A. McPherson, Duncan Camilleri, Daniel Micallef

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Gas tungsten arc welding requires a gas shield to be present in order to protect the arc area from contamination by atmospheric gases. As a result of each gas having its own unique thermophysical properties, the shielding gas selected can have a major influence on the arc stability, welding speed, weld appearance and geometry, mechanical properties and fume generation. Alternating shielding gases is a relatively new method of discreetly supplying two different shielding gases to the welding region in order to take advantage of the beneficial properties of each gas, as well as the inherent pulsing effects generated. As part of an ongoing process to fully evaluate the effects of this novel supply method, a computational fluid dynamics model has been generated to include the gas dependent thermodynamic and transport properties in order to evaluate the effects that an alternating gas supply has on the arc plasma. Experimental trials have also been conducted to validate the model arc profile predictions.

Keywords: Alternating shielding gases, ANSYS CFX, Gas tungsten arc welding(GTAW), magnetohydrodynamics(MHD)

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Authors: Amruta Rout, Golak Bihari Mahanta, Gunji Bala Murali, Bibhuti Bhusan Biswal, B. B. V. L. Deepak

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The use of industrial robots for performing welding operation is one of the chief sign of contemporary welding in these days. The weld joint parameter and weld process parameter modeling is one of the most crucial aspects of robotic welding. As weld process parameters affect the weld joint parameters differently, a multi-objective optimization technique has to be utilized to obtain optimal setting of weld process parameter. In this paper, a hybrid optimization technique, i.e., Principal Component Analysis (PCA) combined with fuzzy logic has been proposed to get optimal setting of weld process parameters like wire feed rate, welding current. Gas flow rate, welding speed and nozzle tip to plate distance. The weld joint parameters considered for optimization are the depth of penetration, yield strength, and ultimate strength. PCA is a very efficient multi-objective technique for converting the correlated and dependent parameters into uncorrelated and independent variables like the weld joint parameters. Also in this approach, no need for checking the correlation among responses as no individual weight has been assigned to responses. Fuzzy Inference Engine can efficiently consider these aspects into an internal hierarchy of it thereby overcoming various limitations of existing optimization approaches. At last Taguchi method is used to get the optimal setting of weld process parameters. Therefore, it has been concluded the hybrid technique has its own advantages which can be used for quality improvement in industrial applications.

Keywords: robotic arc welding, weld process parameters, weld joint parameters, principal component analysis, fuzzy logic, Taguchi method

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Authors: R. A. Ribeiro, P. D. Angelo Assunção, E. M. Braga

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The microhardness in weld beads is a function of the microstructure obtained in the welding process, and this by its time is dependent of the input variables established at the outset of the process. In this study the influence of angle between the plate and the cold wire, the position in which the cold wire is introduced and the rate in which this introduction is made are assessed as input parameters in CW-GMAW process. This paper looks to show that ordinary changes in the frame of CW-GMAW can improve microhardness, which is expected to vary as the input parameters change. To properly correlate the changes in the input parameters to consequent changes in microhardness of the weld bead, a full factorial design was employed. In fact, changes in the operational parameters improved the overall microhardness of the weld bead, which in turns can be an indication of improvement in the resistance to abrasive wear, constituting a cheap way to augment the abrasion wear resistance of welds used for cladding.

Keywords: abrasion, CW-GMAW, full factorial design, microhardness

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Authors: H.-G. Herrmann, M. Schwarz, J. Summa, F. Grossmann

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In this work, different non-destructive testing methods for the characterization of defects and interfaces are presented. It is shown that, by means of active thermography, defects in the interface and in the carbon fiber reinforced polymer (CFRP) itself can be detected and determined. The bonding of metal and thermoplastic can be characterized very well by ultrasonic testing with electromagnetic acoustic transducers (EMAT). Mechanical testing is combined with passive thermography to correlate mechanical values with the defect-size. There is also a comparison between active and passive thermography. Mechanical testing shows the influence of different defects. Furthermore, a correlation of defect-size and loading to rupture was performed.

 

Keywords: defect evaluation, EMAT, mechanical testing, thermography

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Authors: Napat Hataivichian

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The effect of transition metal doping on Pt/Al2O3 catalyst used in propane dehydrogenation reaction at 500˚C was studied. The preparation methods investigated were sequential impregnation (Pt followed by the 2nd metal or the 2nd metal followed by Pt) and co-impregnation. The metal contents of these catalysts were fixed as the weight ratio of Pt per the 2nd metal of around 0.075. These catalysts were characterized by N2-physisorption, TPR, CO-chemisorption and NH3-TPD. It was found that the impregnated 2nd metal had an effect upon reducibility of Pt due to its interaction with transition metal-containing structure. This was in agreement with the CO-chemisorption result that the presence of Pt metal, which is a result from Pt species reduction, was decreased. The total acidity of bimetallic catalysts is decreased but the strong acidity is slightly increased. It was found that the stability of bimetallic catalysts prepared by co-impregnation and sequential impregnation where the 2nd metal was impregnated before Pt were better than that of monometallic catalyst (undoped Pt one) due to the forming of Pt sites located on the transition metal-oxide modified surface. Among all preparation methods, the sequential impregnation method- having Pt impregnated before the 2nd metal gave the worst stability because this catalyst lacked the modified Pt sites and some fraction of Pt sites was covered by the 2nd metal.

Keywords: alumina, dehydrogenation, platinum, transition metal

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Authors: Jaibir Sharma, Lee JaeWung, Merugu Srinivas, Navab Singh

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This paper presents thermal annealing dewetting technique for the preparation of porous metal membrane for thin film encapsulation application. Thermal annealing dewetting experimental results reveal that pore size in porous metal membrane depend upon i.e. 1. The substrate on which metal is deposited for formation of porous metal cap membrane, 2. Melting point of metal used for porous metal cap layer membrane formation, 3. Thickness of metal used for cap layer, 4. Temperature used for porous metal membrane formation. Silver (Ag) was used as a metal for preparation of porous metal membrane by annealing the film at different temperature. Pores in porous silver film were analyzed using Scanning Electron Microscope (SEM). In order to check the usefulness of porous metal film for thin film encapsulation application, the porous silver film prepared on amorphous silicon (a-Si) was release using XeF2. Finally, guide line and structures are suggested to use this porous membrane for thin film encapsulation (TFE) application.

Keywords: dewetting, themal annealing, metal, melting point, porous

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Authors: Mohammed A. Tashkandi, Jawdat A. Al-Jarrah, Masoud Ibrahim

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This paper investigates the shear strength of the joints produced by friction stir spot welding process (FSSW). FSSW parameters such as tool rotational speed, plunge depth, shoulder diameter of the welding tool and dwell time play the major role in determining the shear strength of the joints. The effect of these four parameters on FSSW process as well as the shear strength of the welded joints was studied via five levels of each parameter. Taguchi method was used to minimize the number of experiments required to determine the fracture load of the friction stir spot-welded joints by incorporating independently controllable FSSW parameters. Taguchi analysis was applied to optimize the FSSW parameters to attain the maximum shear strength of the spot weld for this type of aluminum alloy.

Keywords: Friction Stir Spot Welding, Al6061 alloy, Shear Strength, FSSW process parameters

Procedia PDF Downloads 432

Authors: Egoitz Aldanondo, Ekaitz Arruti, Amaia Iturrioz, Ivan Huarte, Fidel Zubiri

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Manufacturing aeronautic structures joining extruded profiles or stringers to sheets or skins of aluminium is a typical manufacturing procedure in aeronautic structures. Although riveting is the conventional manufacturing technology to produce such joints, the Friction Stir Welding (FSW) and Laser Beam Welding (LBW) technologies have also demonstrated their potential for this kind of applications. Therefore, FSW and LBW technologies have the potential to continue their development as manufacturing processes for aeronautic structures showing benefits such as time-saving, light-weighting and overall cost reduction. In addition to that, new aluminium-lithium based alloy developments represent great opportunities for advanced aeronautic structure manufacturing with potential benefits such as lightweight construction or improved corrosion resistance. This work presents the main approaches by FSW and LBW to develop those technologies to produce stiffened panel structures such as fuselage by stringer-skin joints and using innovative aluminium-lithium alloys. Initial welding tests were performed in AA2198-T3S aluminium alloys for LBW technology and with AA2198-T851 for FSW. Later tests for both FSW and LBW have been carried out using AA2099-T83 alloy extrusions as stringers and AA2060-T8E30 as skin materials. The weld quality and properties have been examined by metallographic analysis and mechanical testing, including shear tensile tests and pull-out tests. The analysis of the results have shown the relationships between processing conditions, micro-macrostructural properties and the mechanical strength of the welded joints. The effects produced in the different alloys investigated have been observed and particular weld formation mechanics have been studied for each material and welding technology. Therefore, relationships between welding conditions and the obtained weld properties for each material combination and welding technology will be discussed in this presentation.

Keywords: AA2060-T8E30, AA2099-T83, AA2198-T3S, AA2198-T851, friction stir welding, laser beam welding

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Authors: Yuri A. Kalvachev, Totka D. Todorova

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Zeolite mordenite has been investigated as a transition metal support for the preparation of efficient catalysts in the oxidation of volatile organic compounds (VOCs). The highly crystalline mordenite samples were treated with hydrofluoric acid and ammonium fluoride to get hierarchical material with secondary porosity. The obtained supports by this method have a high active surface area, good diffusion properties and prevent the extraction of metal components during catalytic reactions. The active metal phases platinum and copper were loaded by impregnation on both mordenite materials (parent and acid treated counterparts). Monometalic Pt and Cu, and bimetallic Pt/Cu catalysts were obtained. The metal phases were fine dispersed as nanoparticles on the functional porous materials. The catalysts synthesized in this way were investigated in the reaction of complete oxidation of propane and benzene. Platinum, copper and platinum/copper were loaded and there catalytic activity was investigated and compared. All samples are characterized by X-ray diffraction analysis, nitrogen adsorption, scanning electron microscopy (SEM), X-ray photoelectron measurements (XPS) and temperature programed reduction (TPR). The catalytic activity of the samples obtained is investigated in the reaction of complete oxidation of propane and benzene by using of Gas Chromatography (GC). The oxidation of three organic molecules was investigated—methane, propane and benzene. The activity of metal loaded mordenite catalysts for methane oxidation is almost the same for parent and treated mordenite as a support. For bigger molecules as propane and benzene, the activity of catalysts based on treated mordenite is higher than those based on parent zeolite.

Keywords: metal loaded catalysts, mordenite, VOCs oxidation, zeolites

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Authors: Thirupathi Thippani, Kothandaraman Ramanujam

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Current research on energy storage has been paid to metal-air batteries, because of attractive alternate energy source for the future. Metal – air batteries have the probability to significantly increase the power density, decrease the cost of energy storage and also used for a long time due to its high energy density, low-level pollution, light weight. The performance of these batteries mostly restricted by the slow kinetics of the oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) on cathode during battery discharge and charge. The ORR and OER are conventionally carried out with precious metals (such as Pt) and metal oxides (such as RuO₂ and IrO₂) as catalysts separately. However, these metal-based catalysts are regularly undergoing some difficulties, including high cost, low selectivity, poor stability and unfavorable to environmental effects. So, in order to develop the active, stable, corrosion resistance and inexpensive bi-functional catalyst material is mandatory for the commercialization of zinc-air rechargeable battery technology. We have attempted and synthesized non-precious metal (NPM) catalysts comprising cobalt and N-doped multiwalled carbon nanotubes (N-MWCNTs-Co) were synthesized by the solid-state pyrolysis (SSP) of melamine with Co₃O₄. N-MWCNTs-Co acts as an excellent electrocatalyst for both the oxygen reduction reaction (ORR) and the oxygen evolution reaction (OER), and hence can be used in secondary metal-air batteries and in unitized regenerative fuel cells. It is important to study the OER and ORR at high concentrations of KOH as most of the metal-air batteries employ KOH concentrations > 4M. In the first 16 cycles of the zinc-air battery while using N-MWCNTs-Co, 20 wt.% Pt/C or 20 wt.% IrO₂/C as air electrodes. In the ORR regime (the discharge profile of the zinc-air battery), the cell voltage exhibited by N-MWCNTs-Co was 44 and 83 mV higher (based on 5th cycle) in comparison to of 20 wt.% Pt/C and 20 wt.% IrO₂/C respectively. To demonstrate this promise, a zinc-air battery was assembled and tested at a current density of 0.5 Ag⁻¹ for charge-discharge 100 cycles.

Keywords: oxygen reduction reaction (ORR), oxygen evolution reaction(OER), non-platinum, zinc air battery

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Authors: Gayathri Devi V, Aravamudan Kannan, Amit Sircar

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In the inner fuel cycle system of a nuclear fusion reactor, the Hydrogen Isotopes Removal System (HIRS) plays a pivoted role. It enables the effective extraction of the hydrogen isotopes from the breeder purge gas which helps to maintain the tritium breeding ratio and sustain the fusion reaction. One of the components of HIRS, Cryogenic Molecular Sieve Bed (CMSB) columns with zeolites adsorbents are considered for the physisorption of hydrogen isotopes at 1 bar and 77 K. Even though zeolites have good thermal stability and reduced activation properties making them ideal for use in nuclear reactor applications, their modest capacity for hydrogen isotopes adsorption is a cause of concern. In order to enhance the adsorbent capacity in an informed manner, it is helpful to understand the adsorption phenomena at the quantum electronic structure level. Physicochemical modifications of the adsorbent material enhances the adsorption capacity through the incorporation of active sites. This may be accomplished through the incorporation of suitable metal ions in the zeolite framework. In this work, molecular hydrogen isotopes adsorption on the active sites of functionalized zeolites are investigated in detail using Density Functional Theory (DFT) study. This involves the utilization of hybrid Generalized Gradient Approximation (GGA) with dispersion correction to account for the exchange and correlation functional of DFT. The electronic energies, adsorption enthalpy, adsorption free energy, Highest Occupied Molecular Orbital (HOMO), Lowest Unoccupied Molecular Orbital (LUMO) energies are computed on the stable 8T zeolite clusters as well as the periodic structure functionalized with different active sites. The characteristics of the dihydrogen bond with the active metal sites and the isotopic effects are also studied in detail. Validation studies with DFT will also be presented for adsorption of hydrogen on metal ion functionalized zeolites. The ab-inito screening analysis gave insights regarding the mechanism of hydrogen interaction with the zeolites under study and also the effect of the metal ion on adsorption. This detailed study provides guidelines for selection of the appropriate metal ions that may be incorporated in the zeolites framework for effective adsorption of hydrogen isotopes in the HIRS.

Keywords: adsorption enthalpy, functionalized zeolites, hydrogen isotopes, nuclear fusion, physisorption

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Authors: M. R. Daneshgar, S. E. Habibi, E. Daneshgar, A. Daneshgar

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In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.

Keywords: stiffened cylindrical shell, fillet welds, residual stress, angular distortion, finite element method

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Authors: Aboozar Aghaei

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In the present work, the dissimilar Monel400 and SS316 were joined by friction stir welding (FSW). The applied rotating speed was 400 rpm, whereas the traverse speed varied between 50 and 150 mm/min. At a constant rotating speed, the sound welds were obtained at the welding speeds of 50 and 100 mm/min. However, a groove-like defect was formed when the welding speed exceeded 100 mm/min. The mechanical properties of the joints were evaluated using tensile and fatigue tests. The fatigue strength of dissimilar FSWed specimen was higher than that of both Monel400 and SS316. To study the failure behavior of FSWed specimens, the fracture surfaces were analyzed using scanning electron microscope (SEM). The failure analysis indicates that different mechanisms may contribute to the fracture of welds. This was attributed to the dissimilar characteristics of dissimilar materials exhibiting different failure behaviors.

Keywords: mechanical properties, stainless steel, frictions, monel

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Authors: Matthew E. Potter, Daniel J. Stewart, Lindsay M. Armstrong, Pier J. A. Sazio, Robert R. Raja

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Rising CO₂ levels in the atmosphere means that CO₂ is a highly desirable feedstock. This requires specific catalysts to be designed to activate this inert molecule, combining a catalytic site tailored for CO₂ transformations with a support that can readily adsorb CO₂. Metal organic frameworks (MOFs) are regularly used as CO₂ sorbents. The organic nature of the linker molecules, connecting the metal nodes, offers many post-synthesis modifications to introduce catalytic active sites into the frameworks. However, the metal nodes may be coordinatively unsaturated, allowing them to bind to organic moieties. Imidazoles have shown promise catalyzing the formation of cyclic carbonates from epoxides with CO₂. Typically, this synthesis route employs toxic reagents such as phosgene, liberating HCl. Therefore an alternative route with CO₂ is highly appealing. In this work we design active sites for CO₂ activation, by tethering substituted-imidazole organocatalytic species to the available Cr3+ metal nodes of a Cr-MIL-101 MOF, for the first time, to create a tailored species for carbon capture utilization applications. Our tailored design strategy combining a CO₂ sorbent, Cr-MIL-101, with an anchored imidazole results in a highly active and selective multifunctional catalyst, achieving turnover frequencies of over 750 hr-1. These findings demonstrate the synergy between the MOF framework and imidazoles for CO₂ utilization applications. Further, the effect of substrate variation has been explored yielding mechanistic insights into this process. Through characterization, we show that the structural and compositional integrity of the Cr-MIL-101 has been preserved on functionalizing the imidazoles. Further, we show the binding of the imidazoles to the Cr3+ metal nodes. This can be seen through our EPR study, where the distortion of the Cr3+ on binding to the imidazole shows the CO₂ binding site is close to the active imidazole. This has a synergistic effect, improving catalytic performance. We believe the combination of MOF support and organocatalyst allows many possibilities to generate new multifunctional catalysts for CO₂ utilisation. In conclusion, we have validated our design procedure, combining a known CO₂ sorbent, with an active imidazole species to create a unique tailored multifunctional catalyst for CO₂ utilization. This species achieves high activity and selectivity for the formation of cyclic carbonates and offers a sustainable alternative to traditional synthesis methods. This work represents a unique design strategy for CO₂ utilization while offering exciting possibilities for further work in characterization, computational modelling, and post-synthesis modification.

Keywords: carbonate, catalysis, MOF, utilisation

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Authors: Michal Urzynicok, Krzysztof Kwiecinski

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The development of materials used in the power generation industry for the production of boilers and their parts is characterized by high steam parameters, which present new challenges. Implementation of new combinations of alloying elements that lead to the best possible mechanical properties, including creep resistance, greatly affects new steels' weldability. All new grades have to undergo many different examinations, in regards to bending and welding, in order to enable the development of fabrication technologies, ensuring failure-free production and assembly of boiler components. 12% Cr martensitic steels like THOR™ 115 or VM-12 SHC are characterized by high oxidation resistance in high-temperature environments. At the moment, VM-12 SHC can be found in many boilers where both headers and superheater coils were produced. As this material is very difficult to obtain, a search for a proper replacement has begun. A new creep strength-enhanced ferritic steel for service in supercritical and ultra-supercritical boiler applications was developed by Tenaris in Italy and it is designated as Thor™115 (Tenaris High Oxidation Resistance). As high demand in power plants occurred to replace some parts of existing installations fabricated from VM12-SHC with other alternatives, a new development of welding procedures has begun to prepare fabricators for the challenges of joining old components with new THOR™ 115 material. This paper covers the first research of welding of dissimilar joints made out of VM12-SHC and THOR™ 115.

Keywords: thor, vm12, dissimilar welding, weldability

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Authors: Sobia Mushtaq, Firdaus E. Bareen, Asma Tayyeb

Abstract:

This study conducted to investigate the metal biosorption potential of indigenous Trichoderma species (T. harzianum KS05T01, T. longibrachiatum KS09T03, Trichoderma sp KS17T09., T. viridi KS17T011, T. atrobruneo KS21T014, and T. citrinoviride) that have been isolated from contaminated soil of Kasur Tannery Waste Management Agency. The effect of different biosorption parameters as initial metal ion concentration, pH, contact time , and temperature of incubation was investigated on the biosorption potential of these species. The metal removal efficiency and (E%) and metal uptake capacity (mg/g) increased along with the increase of initial metal concentration in media. The Trichoderma species can tolerate and survive under heavy metal stress up to 800mg/L. Among the two isotherm models were applied on the biosorption data, Langmuir isotherm model and Freundlich isotherm model, maximum correlation coefficients values (R 2 ) of 1was found for Langmuir model, which showed the better fitted model for the Trichoderma biosorption. The metal biosorption was increased with the increase of temperature and pH of the media. The maximum biosorption was observed between 25-30 o C and at pH 6.-7.5, while the biosorption rate was increased from 3-6 days of incubation, and then the rate of biosorption was slowed down. The biosorption data was better fitted for Pseudo kinetic first order during the initial days of biosorption. Thermodynamic parameters as standard Gibbs free energy (G), standard enthalpy change (H), and standard entropy (S) were calculated. The results confirmed the heavy metal biosorption by Trichoderma species was endothermic and spontaneous reaction in nature. The FTIR spectral analysis and SEM-EDX analysis of the treated and controlled mycelium revealed the changes in the active functional sites and morphological variations of the outer surface. The data analysis envisaged that high metal tolerance exhibited by Trichoderma species indicates its potential as efficacious and successful mediator for bioremediation of the heavy metal polluted environments.

Keywords: heavy metal, fungal biomass, biosorption, kinetics

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Authors: F. Villaret, I. Jacot, Y. Shen, Z. Kong, T. XU, Y. Wang, D. Lu

Abstract:

Wire Arc Additive Manufacturing (WAAM) allows the rapid production of large, homogeneous parts with complex geometry. However, in the nuclear field, parts can reach dimensions of ten to a hundred tons. In this case, the usual WAAM TIG or CMT processes do not have sufficient deposition rates to consider the manufacture of parts of such dimensions within a reasonable time. The submerged arc welding process (SAW, Submerged Arc Welding) allows much higher deposition rates. Although there are very few references to this process for additive manufacturing in the literature, it has been used for a long time for the welding and coating of nuclear power plant vessels, so this process is well-known and mastered as a welding process. This study proposes to evaluate the SAW process as an additive manufacturing technique by taking as an example a low-alloy steel of type 16MND5. In the first step, a parametric study allowed the evaluation of the effect of the different parameters and the deposition rate on the geometry of the beads and their microstructure. Larger parts were also fabricated and characterized by metallography and mechanical tests (tensile, impact, toughness). The effect of different heat treatments on the microstructure is also studied.

Keywords: WAAM, low alloy steel, submerged arc, caracterization

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Authors: Ian Jones, Jonathan Griffiths

Abstract:

Laser welding offers the potential for making very precise joints in plastics products, both in terms of the joint location and the amount of heating applied. These methods have allowed the production of complex products such as microfluidic devices where channels and structure resolution below 100 µm is regularly used. However, to date, the dimension of welds made using lasers has been limited by the focus spot size that is achievable from the laser source. Theoretically, the minimum spot size possible from a laser is comparable to the wavelength of the radiation emitted. Practically, with reasonable focal length optics the spot size achievable is a few factors larger than this, and the melt zone in a plastics weld is larger again than this. The narrowest welds feasible to date have therefore been 10-20 µm wide using a near-infrared laser source. The aim of this work was to prepare laser absorber tracks and channels less than 10 µm wide in PMMA thermoplastic using EB lithography followed by sealing of channels using laser welding to carry out welds with widths of the order of 1 µm, below the resolution limit of the near-infrared laser used. Welded joints with a width of 1 µm have been achieved as well as channels with a width of 5 µm. The procedure was based on the principle of transmission laser welding using a thin coating of infrared absorbent material at the joint interface. The coating was patterned using electron-beam lithography to obtain the required resolution in a reproducible manner and that resolution was retained after the transmission laser welding process. The joint strength was ratified using larger scale samples. The results demonstrate that plastics products could be made with a high density of structure with resolution below 1 um, and that welding can be applied without excessively heating regions beyond the weld lines. This may be applied to smaller scale sensor and analysis chips, micro-bio and chemical reactors and to microelectronic packaging.

Keywords: microchannels, polymer, EB lithography, laser welding

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Authors: B. SahaRoy, T. Medhi, S. C. Saha

Abstract:

To understand the friction stir welding process, it is very important to know the nature of the material flow in and around the tool. The process is a combination of both thermal as well as mechanical work i.e it is a coupled thermo-mechanical process. Numerical simulations are very much essential in order to obtain a complete knowledge of the process as well as the physics underlying it. In the present work a model based approach is adopted in order to study material flow. A thermo-mechanical based CFD model is developed using a Finite Element package, Comsol Multiphysics. The fluid flow analysis is done. The model simultaneously predicts shear strain fields, shear strain rates and shear stress over the entire workpiece for the given conditions. The flow fields generated by the streamline plot give an idea of the material flow. The variation of dynamic viscosity, velocity field and shear strain fields with various welding parameters is studied. Finally the result obtained from the above mentioned conditions is discussed elaborately and concluded.

Keywords: AA6061-T6, CFD modelling, friction stir welding, material flow

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Authors: A. B. Chehreh, M. Grätzel, M. Klein, J. P. Bergmann, F. Walther

Abstract:

Friction stir welding (FSW) is an advantageous method in the thermal joining processes, featuring the welding of various dissimilar and similar material combinations, joining temperatures below the melting point which prevents irregularities such as pores and hot cracks as well as high strengths mechanical joints near the base material. The FSW process consists of a rotating tool which is made of a shoulder and a probe. The welding process is based on a rotating tool which plunges in the workpiece under axial pressure. As a result, the material is plasticized by frictional heat which leads to a decrease in the flow stress. During the welding procedure, the material is continuously displaced by the tool, creating a firmly bonded weld seam behind the tool. However, the mechanical properties of the weld seam are affected by the design and geometry of the tool. These include in particular microstructural and surface properties which can favor crack initiation. Following investigation compares the dynamic properties of FSW weld seams with conventional and stationary shoulder geometry based on load increase test (LIT). Compared to classical Woehler tests, it is possible to determine the fatigue strength of the specimens after a short amount of time. The investigations were carried out on a robotized welding setup on 2 mm thick EN AW 5754 aluminum alloy sheets. It was shown that an increased tensile and fatigue strength can be achieved by using the stationary shoulder concept. Furthermore, it could be demonstrated that the LIT is a valid method to describe the fatigue behavior of FSW weld seams.

Keywords: aluminum alloy, fatigue performance, fracture, friction stir welding

Procedia PDF Downloads 153