Gas Metal Research Articles

Enhancement of Additive Manufacturing Processes for Thin-Walled Part Production Using Gas Metal Arc Welding (GMAW) with Wavelet Transform

Additive manufacturing encompasses technologies that produce three-dimensional computer-aided design (CAD) models through a layer-by-layer production process. Compared to traditional manufacturing methods, additive manufacturing technologies offer significant advantages in producing intricate components with minimal energy consumption, reduced raw material waste, and shortened production timelines. AM methods based on shielded gas welding have recently piqued the interest of researchers due to their high efficiency and cost-effectiveness in manufacturing critical components. However, one of the most formidable challenges in additive manufacturing methods based on shielded gas welding lies in the irregularity of weld bead height at different points, compromising the precision of components produced using these techniques. In this current research, we aimed to achieve uniform weld heights along the welding path by considering the most influential parameters on weld bead geometry and conducting experimental tests. Input parameters of the process, including nozzle angle, welding speed, wire speed, and voltage, were considered. Simultaneously, image processing and wavelet transform were employed to assess the uniformity of weld bead height. These parameters were applied to produce intricate parts after identifying optimal parameters that yielded the smoothest weld lines. According to the results, the appropriate bead for manufacturing the part was extracted. The results show that the smoothest bead line is achieved in 27 V as the highest level of voltage, at a 90° nozzle position and the maximum wire feed rate. Parts manufactured using this method across different layers exhibited no distortions, and the repeatability of production substantiated the high reliability of this approach for component manufacturing.

Mechanical Properties and Microstructural Characteristics of Steel Pipes after Long-Time Hydrogen Exposure

There are three possibilities to transport hydrogen by high pressure pipeline (i) blending hydrogen into the existing natural gas pipeline system, (ii) after checking the integrity, using the natural gas transporting pipeline system to transport hydrogen, (iii) building a new pipeline system to transport pure hydrogen. In all three cases should be known the behaviour of the pipe material and its welded joints influenced under high pressure hydrogen. For this aim pipeline sections made of P355NH base material were investigated without and with hydrogen exposure, where the exposure time was 41 days. Gas metal arc welding and hybrid tungsten arc welding / gas metal arc welding were applied for preparation of the girth weld joints. Tensile, three point bending and hardness tests, furthermore microstructural investigations were performed both on base materials and girth welds of the pipeline sections. The testing results were analysed and compared with each other (base material vs. welded joints, without exposure vs. with exposure) and with limit values can be found in the literature. Conclusions were drawn on the behaviour of the investigated pipe material and its welded joints.

Coal mining activities driving the changes in bacterial community

The mechanism of the difference in bacterial community composition caused by environmental factors in the underground coal mine is unclear. In order to reveal the influence of coal mining activities on the characteristics of bacterial community structure in coal seam, 16S rRNA gene amplicon sequencing technology was used to determine the species abundance, biodiversity, and gene abundance of bacterial community in a coal mine in Shanxi Province, and the environmental factors such as metal elements, non-metal elements, pH value, and gas concentration of coal samples were determined. The results showed that environmental factors and bacterial communities had obvious regional characteristics. Mining activities greatly affected the α diversity of bacterial communities, mining working face > main airway > roadway roof > unexposed coal seam > tunneling roadway. The bacterial community composition of each sample point is also very different. The main airway, roadway roof, and unexposed coal seam are dominated by Actinobacteria while the mining working face and tunneling roadway are dominated by Proteobacteria. Among the gene abundances of metabolic pathways in each site, Citrate cycle had the greatest difference, followed by glycine, serine and threonine metabolism, and oxidative phosphorylation and methane metabolism had little difference. RDA analysis showed that the environmental factors affecting the bacterial community were mainly cadmium, oxygen, hydrogen, and gas content. CCA analysis divided the bacterial community into three categories. Degradation functional bacteria are located in mining working face, bacteria that tolerate poor environments are located in main airway and tunneling roadway, and human pathogens are mostly located in roadway roof and unexposed coal seam. The research results would provide support for realizing green and safe mining in coal mines.

The influence of cooling time on the alloy distribution in weld metals

This research explores the impact of cooling time on the distribution of alloying elements within weld metals of high-strength steel, a critical factor in optimizing welding processes for advanced structural applications. Using gas metal arc welding (GMAW) and two different filler materials, this study systematically varies cooling times to analyze the resulting chemical compositions. Energy Dispersive X-ray (EDX) analysis was employed to examine the alloy content in the weld metal, base material, and heat-affected zone (HAZ). The results demonstrate that cooling time significantly influences the concentration of alloying elements, such as chromium, nickel, and manganese, within the weld metal, revealing complex diffusion behaviours that are dependent on the thermal cycles introduced during welding. Notably, an in-depth analysis of the HAZ shows a distinct diffusion pattern for silicon, indicating intricate microstructural changes. These findings highlight the importance of controlling cooling time to optimize the microstructural and chemical properties of welded joints in high-strength steels, with implications for improving weld performance and reliability.

Residual stress and deformation of welded T-joint between low carbon steel and stainless steel

The welded structures between carbon steel and stainless steel are widely used in many sectors such as pedestrian bridges, food industry, chemical industry, petroleum, and thermal power plants, … These composite structures take advantages of each material for different parts of structure. In the welded structures between carbon steel and stainless steel, the structure is made by T-joint that is the most common. The calculation of residual stress and welding strain of the T-joint between low-carbon and stainless steel materials is the basis to evaluate the working ability of this structure. In this study, the residual stress and welding deformation of the T-joint are determined by the imaginary force method. The double-sided weld of T-joint between low carbon steel and stainless steel is welded simultaneously by MIG welding process. The obtained results of residual stress and welding deformation in this case are compared with the case of single-sided weld so that we can find the difference between residual stress and welding deformation in two cases.

A Case Study on the Possibility of Extending the Service Life of the Demining Machine Belt

The operational practice of the design of the Bozena 5 demining machine has shown that its belts are the critical component that fundamentally affects the functionality of the entire machine. This article is a practical continuation and extension of the previous research results from the point of view of materials (research of the uniaxial fatigue life in bending and torsion), calculation (creation of the necessary mathematical, analytical and numerical models for the research) and construction (i.e., patented design of the belt tensioning of this machine). All these actions are aimed at a single objective—to achieve a condition that guarantees a sufficient service life without malfunctions, since repairing these machines in the field is often impossible. Therefore, this study examined the fatigue life of welded joints (uniaxial bending and torsion) of S960 QL and S500MC steels welded by MAG technology. Subsequently, the data were compared with previous results (electron and laser welds) and the influence of each type of weld on the fatigue life relative to the base material was discussed. It was found that conventional MAG technology had a more significant negative impact on the fatigue life of the base material than non-conventional technologies. This trend was particularly true for the bending stress. At the same time, the bending stress was identified by the FEM analysis as the dominant load on the belt. The maximum stress in the belt link under the considered boundary conditions was approximately 240 MPa (in bending). This stress corresponded to the continuous fatigue life (more than 107 cycles) for both base materials tested (S960QL, S500MC). In the whole studied spectrum of controlled deformation amplitudes (Manson–Coffin), the life of MAG welds was lower in comparison with the base material and with welds made by unconventional technologies. All the activities carried out so far (research on microstructure, hardness, strength, residual stresses, tribological properties and fatigue life) have shown that the original belt design (S500MC) using MAG technology has significant deficiencies in the state of optimal life. It is expected that the proposed material change (use of S960QL instead of S500MC) and work with advanced technologies will bring this state significantly closer.

Robotic MAG welding defects and quality assessment with a defect threshold decision model-driven method

The use of machine vision and deep learning methods for online monitoring and evaluation of welding quality during the welding process and timely detection and correction of welding defects is essential for intelligent welding manufacturing. In this paper, with the goal of online monitoring of the welding quality of the robotic arc welding for the excavator boom, we established a multi-source sensing system for robotic arc welding processes. We have developed various feature extraction algorithms for extracting information about welding pools, arc sounds, currents, voltages, and other features. We proposed to extract welding pool image features using Res2-MobileNetV3 to obtain a 12-dimensional welding pool feature, which enabled good inter-class discrimination among different welding defects. We designed a welding defect threshold decision (DD) strategy model using the responsive machine learning and lightweight network Res2-MobileNetV3 method, achieving a welding defect recognition accuracy of 96.59%. Finally, we tested the accuracy and reliability of the welding defect recognition model on an actual welding scene for the robotic welding of the excavator boom. It provided valuable scientific methods and technological approaches for intelligent welding in complex scenes.

Effect of water quenching into strength, hardness and microstructure of the welded AA 6061 plates

Purpose The purpose of this study is to find the effect of heat treatment on the mechanical proeprties of aluminum. Aluminum exhibits a good response to heat treatment, especially quenching, according to the mechanical property improvement. The presence and orientation of secondary phases (Al-Fe-Mn-Si) are greatly affected by the quenching process. Design/methodology/approach The present work deals with the effect of water quenching on the mechanical properties of welded AA 6061 plates which were joined by using metal inert gas (MIG) welding, tungsten inert gas welding and friction stir welding (FSW). Three tests like tensile, bending and hardness were considered. The microstructural variation was analyzed by optical microscopy and elemental mapping through field emission scanning electron microscope. Findings A significant enhancement in the tensile strength and hardness was achieved on postquenched specimens. This improvement in mechanical properties is caused by the distribution of fine alloying elements throughout the metal solution rather than precipitation at the grain boundaries. In comparison to the “untreated specimens,” an improvement of 76.7%, 25.32% and 56.81% in the tensile strength of quenched TIGW, MIGW and FSW specimens, respectively, was observed. Originality/value The quenching process has increased the strength of the MIG welded joint over the base metal. The MIG welded joint has a larger flexural modulus than the other two welded plates, according to the results of the bending test. Furthermore, a uniform distribution of hardness was observed in postquenched welded specimens. It was found that welded zone was harder than heat-affected zone. Out of all the specimens, the base metal zone has the lowest hardness.

Comparing the interstellar and circumgalactic origin of gas in the tails of jellyfish galaxies

Simulations and observations have found long tails in `jellyfish galaxies', which are commonly thought to originate from ram-pressure stripped gas of the interstellar medium (ISM) in the immediate galactic wake. At larger distances from the galaxy, the long tails have been claimed to form in situ, owing to thermal instability and fast radiative cooling of mixed ISM and intracluster medium (ICM). In this paper, we use magnetohydrodynamical wind tunnel simulations of a galaxy with the arepo code to study the origin of gas in the tails of jellyfish galaxies. To this end, we modelled the galaxy orbit in a cluster by accounting for a time-varying galaxy velocity, ICM density, and the turbulent magnetic field. By tracking gas flows between the ISM, the circumgalactic medium (CGM), and the ICM, we find -- contrary to popular opinion -- that the majority of the gas in the tail originates in the CGM. Prior to the central passage of the jellyfish galaxy in the cluster, the CGM is directly transported to the clumpy jellyfish tail that has been shattered into small cloudlets. After the central cluster passage, gas in the tail originates both from the initial ISM and the CGM, but that from the latter is accreted onto the galactic ISM before being ram-pressure stripped to form filamentary tentacles in the tail. Our simulation shows a declining gas metallicity in the tail as a function of downstream distance from the galaxy. We conclude that the CGM plays an important role in shaping the tails of jellyfish galaxies.

Revealing the embrittlement phenomena after post-weld heat treatment of high-strength weld metal using high-resolution microscopy

High strength combined with sufficient toughness is a fundamental prerequisite for steel in the field of lightweight construction. Joining high-strength steels by means of welding requires the use of highly advanced filler metals and a stress-relief post-weld heat treatment (PWHT) for optimum performance of the joint. However, such a heat treatment can lead to embrittlement in the weld metal. In this context, the present work deals with the influence of different PWHT holding temperatures on the microstructure and mechanical properties of a high-strength multipass all-weld metal to reveal the embrittlement phenomena. The all-weld metal was fabricated via gas metal arc welding using a metal cored wire with a minimum yield strength of 690 MPa. Charpy V-notch impact testing and tensile testing were carried out to characterize the strength and toughness of the all-weld metal in the as-welded condition and after a 2 h stress-relief PWHT at 520 °C, 580 °C, and 620 °C. The microstructure was characterized utilizing high-resolution techniques such as atom probe tomography and high-energy X-ray diffraction. The strength and toughness of the all-weld metal both decrease after PWHT with different holding temperatures. The cause for the observed embrittlement was found to be the formation of Mn-rich cementite precipitates. These carbides increase in size and phase fraction with increasing holding temperature and lead to a brittle transcrystalline cleavage fracture. Consequently, it was concluded that a gas metal arc welded joint with the investigated filler metal should not be exposed to stress-relief PWHT at temperatures higher than 580 °C.

Effects of Oxide Powders as Activating Flux on AMIG 304L Welds

Activating metal inert gas (AMIG) welding was designed to address difficulties with MIG welding, such as the limitation on workpiece thickness that may be welded in a single pass. This investigation was carried out on 304L stainless steel using ER 308L as a filler metal. Five oxides (SiO2, TiO2, Fe2O3, Mn2O3, and Cr2O3) have been investigated without edge preparation. The welded joints were evaluated for weld morphology, microstructure, mechanical properties, and corrosion, and the findings were compared. The depth of the AMIG weld was determined to be greater than that of the MIG weld. The microstructure is composed of austenitic and retained delta ferrite with 3.3% for MIG and up to 8% for AMIG weld carried out with Cr2O3 oxide flux, the tensile strength is up to 604 MPa when using Cr2O3 oxide against MIG weld (532 MPa), and the resistance to sudden load in AMIG welds (189 J/cm2) is higher than that of MIG weld (149 J/cm2). The corrosion resistance of the weld made with Fe2O3 oxide flux is greater than that of the other AMIG and MIG welds, as well as the parent metal. The AMIG welding technique variant enhances productivity and decreases the cost and energy consumption of the welding material compared to the traditional MIG process. This allows for joining the same thickness without affecting mechanical properties and corrosion resistance, meeting the industry’s requirements.

Influence of the Pulse Mode of Manual Metal Arc Welding on Weldment Distortions.

As a result of the thermo-mechanical impact during welding, distortions are generated in welded structures. These distortions significantly influence the geometric and dimensional accuracy of welded structures, in many cases lowering their working characteristics and reliability. An optimal design for welded structures is a prerequisite for increased reliability and reduction in manufacturing cost, and such an optimal design can be achieved knowing the distortions in weldments. Despite the fact that pulsed metal inert gas welding and metal active gas welding have been broadly applied in the last few decades, nowadays, few manufacturers, for instance, Fronius, EWM, Redco, and Perfect Power Welders, offer such an option for manual arc welding. This work aims to determine the influence of the parameters of pulsed welding modes on distortions that are generated during manual arc welding. Two different inverter welding power sources were used, and the welding distortions were measured by 3D scanning. The results showed that the pulsed mode during manual arc welding led to a reduction in distortions compared to the conventional welding mode. The crucial part of the manual welding system proved to be the qualification and performance of the welder.

Innovative D-process MIG welding for enhanced performance of thick sections of MDN 250 in aerospace applications

Maraging steel, known for its exceptional strength, toughness and ductility, is widely used in aerospace and hypersonic missile manufacturing. The present study investigates the feasibility of joining 12 mm thick sections of maraging steel using advanced D-Process MIG welding technology. The D-Process integrates different welding modes such as MIG, Single Pulse-MIG and Double Pulse-MIG to optimize welding parameters, minimizing heat input. Additionally, the research investigates the influence of various post-weld heat treatments (PWHTs) on the performance of welded joints. The PWHTs included in the study are Ageing Treatment (AT), Solution Treatment + Ageing Treatment (SAT) and Homogenizing Treatment + Solution Treatment + Ageing Treatment (HSAT). Metallographic and mechanical tests were conducted on as-welded (AW) and PWHT conditions. Results showed the HSAT condition yielded superior properties with an average UTS of 1771 MPa, YS of 1734 MPa, and an average fracture toughness (FT) of 88 MPa√m. This underscores the efficacy of D-Process welding in meeting stringent requirements for maraging steel in aerospace and high-performance applications.

Microstructure and mechanical properties of Inconel 686 fabricated by gas metal arc welding-based wire arc directed energy deposition: impact of cryogenic treatments

Microstructure and mechanical properties of Inconel 686 fabricated by gas metal arc welding-based wire arc directed energy deposition: impact of cryogenic treatments

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.

Effect of Microgravity on the Metal Droplet Transfer and Bead Characteristics in the Directed Energy Deposition-Arc Process

Abstract Directed energy deposition-arc (DED-arc) is a viable method of metal 3D printing for manufacturing in-space under microgravity conditions. This study investigates the effect of reduced gravity on the droplet transfer in a gas metal arc welding (GMAW)-based DED-arc process. Single bead deposited using GMAW welding process under microgravity and standard terrestrial gravity (1 g) are compared. Microgravity was simulated in a drop tower where the experimental capsule was subjected to 2.5 s of free-fall. The experimental setup for GMAW welding process, including high-speed cameras and sensors, was present within the experimental capsule. Droplet frequency and diameter were measured and compared between microgravity and 1 g using the images obtained. Further, the impact of reduced gravity on weld bead geometry and the distribution of gas porosity was investigated. Microhardness analysis was also conducted on both 1 g and reduced gravity samples to assess variations in material hardness. A statistically significant difference in droplet diameter and frequency was found. This difference is attributed to the reduction in gravitational force. Upon analyzing the weld bead geometry, noticeable variations are detected in the contact angles and the reinforcement of beads formed under different gravity conditions. These differences are attributed to alterations in convection within the molten weld pool. The blowhole analysis revealed a noticeable trend, wherein reduced gravity facilitated the coalescence of gas porosity, resulting in larger diameters due to alterations in weld pool convection. There were no statistically significant changes observed in both microhardness and surface finish.

Nrf-2/HO-1 activation protects against oxidative stress and inflammation induced by metal welding fume UFPs in 16HBE cells

As one of the main occupational hazards, welding fumes can cause oxidative damage and induce series of diseases, such as COPD or asthma. To clarify the effects of the metal fume ultrafine particulates (MF-UFPs) of welding fumes on oxidative damage, UFPs were collected by melt inert gas (MIG) and manual metal arc (MMA) welding, and the composition was confirmed. Human bronchial epithelial 16HBE cells were treated with 0–1000 µg/cm2 MF-UFPs to analyse the cytotoxicity, oxidative stress and cytokines. The protein and mRNA expression of Keap1-Nrf-2/antioxidant response elements (AREs) signalling pathway components were also analysed. After 4 h of treatment, the cell viability decreased 25% after 33.85 and 32.81 µg/cm2 MIG/MMA-UFPs treated. The intracellular ATP concentrations were also decreased significantly, while LDH leakage was increased. The decreased mitochondrial membrane potential and increased ROS suggested the occurrence of oxidative damage, and the results of proteome profiling arrays also showed a significant increase in IL-6 and IL-8. The expression of AREs which related to antioxidant and anti-inflammatory were also increased. These results indicate that the MF-UFPs can cause oxidative stress in 16HBE cells and activate the Nrf-2/ARE signalling pathway to against oxidative damage.

Fabrication and characterization of a new high-strength alloy via WAAM using GMAW+cold wire feeding

The demand for high-strength steels has continued to increase in various fields of industry due to the advancement in technology. The wire arc additive manufacturing (WAAM) enables the fabrication of high-strength structures from different materials by controlling the raw wire in layers. This study focuses on the fabrication of high-strength steel by WAAM using the gas metal arc welding + cold wire feeding (GMAW + CWF) technique. A new alloy was formed by simultaneously adding 316LSi stainless steel from the CWF to the low alloyed ER70S-6 steel from the GMAW torch. In this way, three different new alloyed structures were produced with varied 316LSi ratios ranging from 10 %, 20 % and 25 % respectively. Besides, their metallurgical and mechanical properties were compared with each other and with single material WAAMed structures. In the macrostructure examinations, no defects due to the mixture of both materials were found and both materials melted properly to create the new alloy. Due to the alloying elements transferred from 316LSi, the microstructure of the new material parts were completely changed compared to the single material WAAMed components and bainite and martensite phases were found in the new alloys. The hardness increased significantly compared to the single-material WAAMed structures and increased up to 139 % and 84 % compared to the single-material WAAMed ER70S-6 and 316LSi, respectively. The tensile strength showed a great improvement and reached almost 1200 MPa, increased by 142 % compared to the single-material WAAMed structure. The fabricated new alloys have the potential to be a candidate material for industries that use high-strength steel.

Sn-doped n-type GaN freestanding layer: Thermodynamic study and fabrication by halide vapor phase epitaxy

Results of a thermodynamic study of Sn doping and fabrication of a Sn-doped GaN freestanding layer with high structural quality by halide vapor phase epitaxy (HVPE) are described in this paper. Thermodynamic analysis revealed that SnCl2 and/or SnCl act as Sn precursors through the reaction between Sn metal and HCl gas. The equilibrium partial pressures of SnCl2 and SnCl increase with the input HCl partial pressure. To generate Sn precursors effectively, it is desirable that the reaction between Sn metal and HCl gas occurs in the inert gas ambient. On the basis of results of the thermodynamic study, the Sn-doped GaN freestanding layer with a Sn concentration of 5.7 × 1019 cm−3 is fabricated by removing the GaN seed substrate after HVPE growth. The Sn-doped GaN freestanding layer has high crystal quality, and the lattice constants along the c- and a-axes of the Sn-doped GaN freestanding layer are larger than those of the GaN seed substrate because of the high electron density and the size effect of Sn atoms.

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy