Composition Of Wire Research Articles

Analyzing the Influence of Titanium Content in 5087 Aluminum Filler Wires on Metal Inert Gas Welding Joints of AA5083 Alloy

As the demand for lightweight structures in the transportation industry continues to rise, AA5083 aluminum alloy has become increasingly prominent due to its superior corrosion resistance and weldability. To facilitate the production of high-quality, intricate AA5083 components, 5087 aluminum filler wire is commonly utilized in metal inert gas (MIG) welding processes for industrial applications. The optimization of filler wire composition is critical to enhancing the mechanical properties of AA5083 MIG-welded joints. This study investigates the effects of modifying 5087 aluminum filler wires with different titanium (Ti) contents on the microstructure and weldability of AA5083 alloy plates using MIG welding. The influence of Ti contents was systematically analyzed through comprehensive characterization techniques. The findings reveal that the constitutional supercooling induced by the Ti element and the formation of Al3Ti facilitate the heterogeneous nucleation of α(Al), thereby promoting grain refinement. When the Ti content of 5087 filler wire is 0.1 wt.%, the grain size of the weld center was 78.48 μm. This microstructural enhancement results in the improved ductility of the AA5083 MIG-welded joints, with a maximum elongation of 16.64% achieved at 0.1 wt.% Ti addition. The hardness of the joints was the lowest in the weld center zone. This study provides critical insights into the role of Ti content in MIG welding and contributes to the advancement of high-performance filler wire formulations.

Calculations of phase composition of austenitic high-nitrogen welding wire and study of a welded joint made from it

The processability of a material is directly related to the possibility of its production, operation and maintainability. One of the most important indicators of the processability of any metal is weldability. Austenitic steels with a high nitrogen content proved themselves as high-strength, corrosion- and cold-resistant materials, but the issue of their weldability is still not fully understood. The lack of welding filler materials on the market specifically designed for welding high-nitrogen steels is the primary obstacle to solving this problem. Thus, the goal of the work was to develop and obtain a laboratory sample of high-nitrogen welding wire. Based on calculations of nitrogen solubility and the phase composition of the weld metal, the chemical composition of Cr – Mn – Ni – Mo – V, N steel was selected for this wire. A defect-free ingot with 0.57 % N was obtained, and wire with a nitrogen content of 0.57 wt. % was produced using hot plastic deformation and drawing methods. Testing of this wire to obtain a welded joint of austenitic cast steel, close to it in chemical composition, with the welding process carried out according to the developed technological recommendations, made it possible to obtain a defect-free welded joint without loss of nitrogen in the weld metal. With a microhardness of the base metal of 252 HV50 , due to the alloying of the welding wire steel with nitrogen and vanadium, the metal of the weld and fusion line had a high microhardness (278 and 273 HV50 , respectively), significantly exceeding the microhardness of Cr – Ni cast austenite. The metal of the welded joint has high strength (0.9 of the base metal strength) and high impact toughness. The fracture of impact samples is characterized by a dimple structure characteristic of viscous materials. According to the obtained results, the new welding wire showed itself to be a promising material for welding austenitic high-nitrogen steels.

Solidification cracking susceptibility and carbide evolution behavior in ERNiMo-2 weld metal: Effect and mechanism of Si content

ERNiMo-2 wire is the matching welding filler metal for the GH3535 alloy, which is prone to occur solidification cracking during welding. Optimizing the composition of ERNiMo-2 wire is an effective way to reduce the welding solidification cracking susceptibility (WSCS) and improve the performance of GH3535 alloy welded joint. In this study, the WSCS of ERNiMo-2 wires with different Si content was evaluated by the trans-varestraint test, and the mechanism of Si affecting the weldability of ERNiMo-2 wire was revealed. The results showed that the solidification cracking temperature range (SCTR) of Si1-Si4 wires with Si content increasing is 102 °C, 123.2 °C, 119.1 °C and 116.3 °C, respectively. The existence of eutectic M2C and M6C in the form of liquid film at the end of solidification leads to partial wetting of the grain boundary, which reduces the binding force of the grain boundary and promotes crack initiation. Low solidification shrinkage, thermal shrinkage, solidification temperature range and a small amount of eutectic liquid in the mushy region make the Si1 wire have the best resistance to solidification cracking. The aforementioned factors increase with Si content, then resulting in the increase of WSCS of Si2. However, the amount and fluidity of eutectic liquid in weld metal increase when the Si content increases to Si3 and Si4, which leads to the occurrence of eutectic backfilling and decrease in WSCS of ERNiMo-2 wire.

Microstructure evolution and mechanical properties of new Co-free maraging steel produced by wire arc additive manufacturing

In this work, P-MIG is used as additive process, a new low-cost Co-free maraging steel wire is used as raw material to additive manufacturing block component, and the microstructure and mechanical properties of the component is investigated. The microstructure of the component is composed of martensite and austenite, and the closer to the bottom, the more serious the elemental segregation and the more austenite content. From the top to the bottom the high-angle grain boundaries increase and the grain size decrease, the difference of the heat dissipation condition and the thermal cycle are the reasons for this phenomenon. The texture of austenite is mainly Cube texture, and the texture of martensite is Rotated Cube texture and Goss texture. The tensile strength of XD, YD, ZD three directions is 1172 ± 15 MPa, 1021 ± 7 MPa, 1139 ± 16 MPa, respectively, impact toughness is 64.7 ± 1.6 J/cm2, 51.1 ± 5.6 J/cm2, 51.4 ± 3.1 J/cm2, respectively, TRIP effect occurs in the process of tensile, the main mode of fracture in tensile and impact is toughness fracture. The microhardness decreases gradually from bottom to top, which is due to the short-lived aging strengthening by thermal cycle, the change of grain size and GND density. The results of the work reveal the successful application of the new low-cost Co-free maraging steel wire in WAAM and provide an important reference for the adjustment of additive process, subsequent heat treatment and the adjustment of wire composition.

Direct observation of magnetic domain walls in glass-coated submicronic amorphous wires

Results on the magnetic domain walls in rapidly solidified magnetostrictive and non-magnetostrictive amorphous submicronic wires are reported. Utilizing Lorentz transmission electron microscopy (LTEM) for the first time in this context, we have visualized and analyzed the domain walls in such ultra-thin amorphous wires. All the investigated samples display vortex magnetic domain walls, regardless of wire composition or diameter. In non-magnetostrictive wires, the domain walls maintain their structure and symmetry under varying magnetic field conditions. In contrast, magnetostrictive wires show an elongation of their domain walls upon magnetic field application, a response linked to the magnetoelastic coupling between magnetostriction and internal stresses induced during wire preparation. This study advances the understanding of magnetization reversal processes in amorphous submicronic wires. The insights gained are crucial for future developments in miniaturized magnetic devices.

Multi-scale analysis of corrosion-induced fracture failure mechanisms of high-strength steel wire

Currently, research on the mechanical properties of corroded steel wire is primarily conducted through corrosion testing, with a lack of in-depth theoretical investigations into the underlying mechanisms. Addressing this research gap, this study employs molecular dynamics (MD) and finite element theory to explore the corrosion process, micro- and macro-mechanical properties of corroded steel wire, and the fracture mechanisms after corrosion. The study achieves a coupling of micro- and macro-scale analyses. Firstly, a molecular dynamics model is established based on the chemical composition of high-strength steel wire, and a novel mixed potential function derived from quantum mechanics is employed to analyze the fracture mechanisms of corroded steel wire. Secondly, a simplified model of randomly corroded pits in steel wire is developed using Python in Abaqus, based on experimental measurements. Finally, the macroscopic fracture process and fracture strength of corroded steel wire are analyzed based on the results from molecular dynamics simulations. These results are then compared to experimental data to validate the accuracy of the theoretical analysis.

New Approach for Manufacturing Ti–6Al–4V+40%TiC Metal-Matrix Composites by 3D Printing Using Conic Electron Beam and Cored Wire. Pt. 1: Main Features of the Process, Microstructure Formation and Basic Characteristics of 3D Printed Material

In this paper, a new approach for additive manufacturing metal-matrix composites based on Ti–6Al–4V titanium alloy reinforced with titanium carbide particles, as well as layered structures consisted of such composite and Ti–6Al–4V alloy layers is considered. The approach is based on 3D printing with a conical electron beam using a special cored wire, whose composition corresponds to metal-matrix composite. The issues of production such a wire, the features of the 3D printing process, when using it, as well as the features of formation of the microstructure and phase composition of the printed composite material are described. The issues of titanium-carbide particles’ wetting with Ti–6Al–4V melt during process of 3D printing, as well as possible thermogravitational effects (floating or drowning) for solid TiC particles within the melt are considered in detail with additional experiments. The influence of individual components of the wire composition on the formation of the microstructure and its uniformity over the cross section of the printed layer is shown. The possibility of controlling the formation of homogeneous structural state and obtaining sufficiently high values of the hardness (of above 600 HV) of the metal-matrix composite layer printed on the Ti–6Al–4V baseplate is shown.

Effect of silver and heat treatment on properties of 03Kh17N10M2 austenitic steel wire

The article examines the influence of various heat treatments, their temperature, as well as silver alloying on mechanical properties, phase composition and structure of steel wire from chromium-nickel-molybdenum austenitic stainless steel 03Kh17N10M2. Choice of the amount of silver alloying was based on previous studies of the antibacterial effect of modifying medical steels with silver. Since the antibacterial effect was confirmed on several bacterial strains, for the most efficient operation of alloys, it is necessary to determine the best temperature mode for working with them. Steel for the study was smelted and then transformed into wire through rolling, forging and drawing operations. On the obtained wire samples of different diameters with a silver content (0; 0.2 and 0.5 wt. %) mechanical tests were carried out to determine the elongation, yield strength and tensile strength. Various modes and temperatures of heat treatment were tested on wire of different diameters to study their effect on mechanical properties and structure. Microstructure of the wire samples subjected to heat treatment and obtained after drawing was investigated. A phase analysis was also carried out to determine the effect of silver in various quantities on austenitic steel. According to the results of the phase composition analysis, it was concluded that silver reduces the amount of gamma phase in steel, and this effect increases in proportion to the increase in silver amount. This change correlates with a slight drop in the metal ductility. At the same time, there are no significant changes in the strength characteristics and microstructure from the presence of silver.

Hierarchical Self-Assembly of Carbon Dots into High-Aspect-Ratio Nanowires.

We report a spontaneous and hierarchical self-assembly mechanism of carbon dots prepared from citric acid and urea into nanowire structures with large aspect ratios (>50). Scattering-type scanning near-field optical microscopy (s-SNOM) with broadly tunable mid-IR excitation was used to interrogate details of the self-assembly process by generating nanoscopic chemical maps of local wire morphology and composition. s-SNOM images capture the evolution of wire formation and the complex interplay between different chemical constituents directing assembly over the nano- to microscopic length scales. We propose that residual citrate promotes tautomerization of melamine surface functionalities to produce supramolecular shape synthons comprised of melamine-cyanurate adducts capable of forming long-range and highly directional hydrogen-bonding networks. This intrinsic, heterogeneity-driven self-assembly mechanism reflects synergistic combinations of high chemical specificity and long-range cooperativity that may be harnessed to reproducibly fabricate functional structures on arbitrary surfaces.

Effect of filling materials on microstructure and properties of CMT-laser beam oscillation hybrid welding behavior of dissimilar Al–Mg–Si alloys

Laser oscillation-assisted cold metal transfer hybrid welding was conducted on 2.0 mm-thick 6082 and a new 6xxx aluminum alloys. The influence of wire composition on microstructure and mechanical properties of the 6082 and new 6xxx alloy joints is studied. Our results show that, due to the difference in surface tension, the cross section of a joint filled with ER4047 wire typically presents a wider U-shape profile, while the ER5183 filled joint shows a relatively narrower V-shape profile. The average grain size of the ER5183 joint is smaller than that of the ER4047 joint. The ER4047 joint exhibits better fluidity, resulting in a higher proportion of high-angle boundaries compared to the ER5183 joint, which we attribute to the higher Si content. Equiaxed grains are also observed near the fusion boundary on the new 6xxx side, while no equiaxed grain formation is observed on the 6082 side. EDS data demonstrates severe elemental segregation in the center of weld and the partially melted zone, suggesting that multiple secondary phases form unevenly within inter-dendritic regions and grain boundaries of α-Al during the welding process. The microhardness of the weld zone and the heat-affected zone on both sides in the ER5183 joint is higher than that of the ER4047 joint. The corrosion test evidences that the ER5183 joint has a slightly better corrosion resistance than the ER4047 joint. Our findings provide a new understanding on joining of dissimilar Al–Mg–Si alloys and guide the selection of appropriate filling materials and welding processes.

Experimental investigation of the influence of wire offset and composition on complex profile WEDM of Ti6Al4V using trim-pass strategy

Experimental investigation of the influence of wire offset and composition on complex profile WEDM of Ti6Al4V using trim-pass strategy

Individual Effects of Alkali Element and Wire Structure on Metal Transfer Process in Argon Metal-Cored Arc Welding.

This study aimed to clarify the effect of wire structure and alkaline elements in wire composition on metal transfer behavior in metal-cored arc welding (MCAW). A comparison of metal transfer in pure argon gas was carried out using a solid wire (wire 1), a metal-cored wire without an alkaline element (wire 2), and another metal-cored wire with 0.084 mass% of sodium (wire 3). The experiments were conducted under 280 and 320 A welding currents, observed by high-speed imaging techniques equipped with laser assistance and bandpass filters. At 280 A, wire 1 showed a streaming transfer mode, while the others showed a projected one. When the current was 320 A, the metal transfer of wire 2 changed to streaming, while wire 3 remained projected. As sodium has a lower ionization energy than iron, the mixing of sodium vapor into the iron plasma increases its electrical conductivity, raising the proportion of current flowing through metal vapor plasma. As a result, the current flows to the upper region of the molten metal on the wire tip, with the resulting electromagnetic force causing droplet detachment. Consequently, the metal transfer mode in wire 3 remained projected. Furthermore, weld bead formation is the best for wire 3.

Effects of the filler wire composition on the structures and mechanical performance of 2195 Al Li alloy TIG joints

The mechanical properties of AlLi alloy joints are closely related to the composition of the welding consumables. The present study aims to improve the mechanical properties of 2195 AlLi alloy joints by adjusting the filler wire composition. The 2195 AlLi alloy filler wire (same composition welding, SCW) and a self-designed filler wire (dissimilar composition welding, DCW) are used for the TIG welding of 2195 AlLi alloy sheets in this study. The results reveal that increasing Cu concentration in the filler wire leads to more eutectic formation in the DCW weld, and the possible solidification crack can be healed in time by the liquid metal in the final solidification stage; significant grain refining in the DCW weld is caused by adding Ti and Zr into the filler wire, the refined grains enable the joint to tolerate more plastic deformation and reduce the continuity of the eutectics along the grain boundaries. The positive effects of filler wire composition adjustment on the joint mechanical properties are verified by the mechanical tests. The plastic deformation is concentrated in the weld, and the weld elongation of the DCW joint is much higher than the SCW joint. In addition, the solidification crack can be observed in the SCW joint but not in the DCW joint. These findings can guide the design of subsequent filler wires matched to 2195 AlLi alloy.

K-shell radiation and bright spot characteristics of high-energy-density Fe-Cr-Ni plasmas influenced by X-pinch load geometry

K-shell radiation is diagnostically advantageous for the study of high-energy-density plasmas. The current work investigates the influence of load geometry on K-shell x-rays in Z-pinch plasmas produced on the 1-MA Zebra generator. Stainless steel (Fe: 69%, Cr: 20%, Ni: 9%) X-pinch wire loads are fielded with an interwire angle of 31° (small-angle) or 62.5° (large-angle), respectively and studied using various x-ray diode, imaging, and spectroscopic diagnostics. The large-angle geometry produced large, individual x-ray-emitting bright spots (> 3 keV) at the wire cross-point averaging areas ≥ 1 mm2, with noteworthy soft x-ray (> 0.75 keV) bursts and radiation yields ≤ 14.6 kJ. The small-angle geometry produced multiple x-ray-emitting bright spots extending the pinch axis with smaller average sizes (≤ 0.5 mm2), consistent with stronger current, increased radiation yield (≥ 15.5 kJ), and notable hard x-ray (> 9 keV) bursts, which peak with largest cumulative bright spot size. Spectroscopic analysis is performed with non-LTE collisional-radiative modeling, indicating a cold, nonthermal plasma region radiating from neutral to Ne-like ions, a hot, thermal region radiating from Fe and Cr He- and Li-like ions, and an intermediate region radiating Kα satellites from Li-like to O-like ions. Modeling of the nonthermal and satellite features imply a fractional hot electron abundance ∼0.1% and ∼0.5% for large- and small-angle geometries, respectively. Relative intensity analysis is performed on Heα and Kα lines, revealing intensity ratios that deviate from the original wire composition. Optical depth estimates allude to optically thick, thermal K-shell plasmas with densities consistent with non-LTE modeling.

Effect of wire composition on microstructure and penetration crack of laser-cold metal transfer hybrid welded Cu and stainless steel joints

In this paper, Cu-based and Ni-based filler metals were used to obtain laser-CMT hybrid welded copper/stainless steel (Cu/SS) joints. The effect of wire compositions on the microstructure and mechanical properties of T2 Cu/304 SS dissimilar metal joint was studied. The results showed that Fe–Cu liquid phase separation occurred in the fusion zone of the Cu-based weld, and Cu penetration cracks appeared in the heat-affected zone (HAZ) on the steel side. The Cu penetration cracks formation is derived from supersaturated Cu atoms penetrating, gathering and merging at the steel side fusion line along the austenite grain boundaries. The penetration cracks can be eliminated effectively by the Ni-based filler metal, because the diffusion of Cu into the fusion zone and the HAZ on the steel side is limited significantly by the increase of Ni content. The Ni-based weld consisted of dendrite grains in the fusion zone, and Fe-rich blocks and Ni-rich islands nearby the HAZ of Cu-side.

Effect of Filler Wire Composition on Hot-Dip Galvanizing Performance of S355JR Structural Steel Joints

Effect of Filler Wire Composition on Hot-Dip Galvanizing Performance of S355JR Structural Steel Joints

Study of effect of chemical composition on microhardness parameters of deposited metal by Fe—C—Si—Mn— Cr—W—V alloy

Studies of the deposited layer obtained using flux-cored wires of the Fe—C—Si—Mn—Cr—W—V system by introducing titanium and carbon-fluorine-containing material into their composition — gas cleaning dust of aluminum production, wt.%: 21...46 Al2O3; 18...27 F; 8...15 Na2O; 0.4...6 K2O; 0.7...2.3 CaO; 0.5...2.5 SiO2; 2.1...3.3 Fe2O3; 12.5...30.2 CTotal; 0.07...0.9 MnO; 0.06...0.9 MgO; 0.09...0.19 S; 0.10...0.18 P. The deposited layer was obtained using submerged arc surfacing by the ASAW-1250 welding tractor using a fabricated flux-cored wire made from slag produced by silicomanganese with a chemical composition, mass. %: 0.50 FeO; 15.16 MnO; 29.13 CaO; 42.40 SiO2; 6.80 Al2O3;1.39 MgO; 0.18 Na2O; 0.59 K2O; 0.28 S; 0.022 P; 0.004 ZnO; 0.024 C; 0.32 F; 0.17 TiO2; 0.033 Cr2O3. The studies carried out made it possible to establish the relationship between the chemical composition of the deposited flux-cored wire and the structure and properties of the deposited metal. It has been established that the introduction of titanium increases the values of hardness and microhardness. The use of a carbon-fluorine-containing additive leads to microstructural changes expressed in obtaining the structure — ferrite, perlite and bainite, in contras t to the structure — martensite, δ-ferrite and residual austenite, as well as to an increase in the size of martensite needles in the structure of the deposited layer. Microstructural changes are due to the introduction of a carbon fluorine-containing additive into the composition of flux-cored wire and are accompanied by a change in microhardness and hardness. With an increase in the content of the carbon-fluorine-containing additive in the composition of flux-cored wire, an increase in the microhardness and hardness of the deposited metal is observed.

Effect of wire composition on microstructure and properties of wire and arc additive manufactured ZAlCu5MnCdVA aluminum alloy

PurposeWire and arc additive manufacturing (WAAM) technology-based cold metal transfer (CMT) to produce large aluminum alloy parts has become more and more popular. In WAAM, wire is the only raw material. The purpose of this paper is to study the effect of wire composition on the microstructure and properties of the ZAlCu5MnCdVA alloy deposited by WAAM.Design/methodology/approachTwo thin-walled ZAlCu5MnCdVA alloys with different wire compositions were prepared by WAAM. The copper contents were 4.7% (Al-4.7Cu) and 5.0% (Al-5.0Cu), respectively. The microstructure, element distribution and evolution of precipitated phases of the two samples were characterized and analyzed by optical microscopy, scanning electron microscopy and transmission electron microscopy. Hardness and tensile properties of samples were tested, and strengthening mechanism was analyzed in detail.FindingsThe results show that grain sizes of Al-4.7Cu and Al-5.0Cu are less than 40 μm. The average mass fraction of Cu in Al matrix and the number of nanometer scale θ'' and θ' phases are the main factors affecting the tensile properties of Al-Cu alloy. Tensile properties of two materials show different characteristics at room temperature and high temperature. Al-5.0Cu is better at room temperature and Al-4.7Cu is better at high temperature. The yield strength (YS), ultimate tensile strength (UTS) and elongation in the x direction of Al-5.0Cu at room temperature are 451 ± 10.2 MPa, 486 ± 10.2 MPa and 9 ± 0.5%, respectively. The YS, UTS and elongation in the x direction of Al-4.7Cu at high temperature are 290 ± 4.5 MPa, 356 ± 7.0 MPa and 13% ± 0.2%, respectively.Originality/valueExperiments show that the increase of Cu element can improve the properties at room temperature of the ZAlCu5MnCdVA alloy by WAAM, but its properties at high temperature decrease.

Experimental and numerical investigation of laser beam-welded Al–Cu–Li joints using micro-mechanical characteristics

The local tensile mechanical properties of laser beam-welded joints of AA2198 alloy with Al–Si filler wire were experimentally investigated. For this purpose, micro-flat tensile specimens were extracted from the fusion zone and the heat-affected zone. The chemical composition of the filler wire affects the local mechanical properties in the fusion zone, showing an approximately 26% decrease in yield strength from the radiation exposure side to the weld root side. The effect of post–weld heat treatment on the tensile mechanical behavior was additionally investigated for different heat treatment artificial ageing conditions. The maximum yield strength increase was noticed for 48 h of artificial ageing for the weld root side of the fusion zone. Several approximations were proposed to correlate the hardness measurements with the local tensile mechanical properties of the welded joint that allow for a fast assessment of the global tensile mechanical behaviour of the welded joint. To evaluate the effect of (i) artificial ageing and (ii) geometrical imperfections of the weld on the mechanical behavior of the welded joint, finite element analyses were performed, using the local mechanical properties as input to the model. It is shown that the local mechanical properties of the fusion zone play a pivotal role on the strain localization and fracture of the welded joint.

Elemental and phase composition of electric arc coating formed with a flux-cored wire of Fe – C – Si – Mn – Сr – Ni – Mo system

The authors have studied the elemental and phase compositions of electric arc coating with a flux-cored wire of Fe – C – Si – Mn – Cr – Ni – Mo system. Formation of electric arc coating was carried out using ASAW-1250 welding tractor with fabricated flux-cored wire on plates made of 09G2S steel. Aluminum production gas cleaning dust has been introduced into the composition of flux cored wire (instead of amorphous carbon). Chemical composition of the deposited metal was determined by X-ray fluorescence method on XRF-1800 spectrometer and by the atomic emission method on DFS-71 spectrometer. Microstructure of the electric arc coatings was studied using OLYMPUSGX-51 optical microscope. Analysis of phase and elemental compositions was performed by scanning electron microscopy using LEO EVO 50 instrument. Segregation of tungsten and molybdenum was revealed in electric arc coating. Concentration of tungsten changes more than 3 times, and molybdenum – more than 2 times. Fractures of the samples are formed as a result of ductile fracture of the material. There are surface layers on the samples fractures, thickness of which is determined by chemical and elemental composition of the electric arc coating. The layer under consideration is characterized by a relatively small diameter of fracture pits compared to the samples volume. Their diameter ranges from tenths to tens of micrometers. The largest pits are formed on particles of the second phase with micron sizes (2 – 3 µm). Contamination of metal of electric arc coatings with non­metallic inclusions was studied. It was established that chemical composition of flux-cored wire of the studied system does not significantly affect the level of contamination with non-metallic inclusions in electric arc coatings. Parameter a of crystal lattice and values of areas of coherent scattering of Fe and CrC phases formed as a result of hardfacing were determined by X-ray phase analysis.