Gas Metal Research Articles

Microstructure and Mechanical Properties of Gas Metal Arc-welded Fe–Mn–Si Seismic Damping Alloy

Microstructure and Mechanical Properties of Gas Metal Arc-welded Fe–Mn–Si Seismic Damping Alloy

Microfabricated vapor cells with chemical polishing and two-step low-temperature anodic bonding for single-beam magnetometer

With the miniaturization of quantum sensors, the fabrication of alkali metal vapor cells based on micro-electromechanical systems (MEMS) has become increasingly important. However, the fabrication of MEMS vapor cells remains a challenge. In this study, a microfabricated millimeter-level vapor cell was fabricated and tested. The silicon cavity was fabricated by dry etching and chemical polishing. After injection of alkali metal and buffer gas, a two-step low-temperature anodic bonding was employed. The first step was non-isothermal to keep the alkali metal in the low-temperature pole plate and the second step was isothermal to improve the bonding strength, enhancing the hermeticity. Then, the vapor cell was tested for sidewall roughness, bonding strength, and leakage rate. Subsequently, Rb D1 line absorption spectroscopy, stability, and the single-beam magnetometer signal were tested. The results show the fabricated vapor cell had high stability, providing a basis for the miniaturization of quantum devices.

Multi-objective Optimization of Short-Circuit Gas Metal Arc Welding for Overhang Structures by Grey Relational Analysis Integrated Taguchi Method

Multi-objective Optimization of Short-Circuit Gas Metal Arc Welding for Overhang Structures by Grey Relational Analysis Integrated Taguchi Method

Effect of Different Welding Modes on Morphology and Property of SS316L Stainless Steel Deposition by Robotic Metal-Inert Gas Welding.

The widespread adoption of arc additive manufacturing techniques across various industries has advanced the field of SS316L stainless steel manufacturing. It is crucial to acknowledge that different welding modes exert distinct influences on the forming and mechanical performance. This study analyzed the thermal input associated with four specific welding modes in LORCH MIG welding, clarifying the transition dynamics of molten droplets through waveform analysis and examining the resultant effects on microstructure and performance characteristics. The Pulse, Speed-Pulse-XT, and Twin-Pulse modes were found to induce spatter during the manufacturing process, consequently reducing molding efficiency in comparison to the SA-XT mode. Notably, the Twin-Pulse mode, characterized by double-pulse agitation, generated fish scale patterns along the lateral surfaces of the fabricated parts, promoting anisotropic grain growth. This microstructural refinement, compared to single-pulse samples with equivalent thermal input, resulted in enhanced mechanical properties. Nevertheless, the horizontal tensile strength of the three pulse modes was lower than the industrial standard for SA-XT mode and forging. In contrast, the SA-XT mode with an average hardness of 168.1 ± 6.9 HV and a tensile strength of 443.58 ± 5.7 MPa. Therefore, while three pulse modes offer certain microstructural advantages, the SA-XT mode demonstrates superior overall performance.

Non-Oxidative Coupling of Methane via Plasma-Catalysis Over M/γ-Al2O3 Catalysts (M = Ni, Fe, Rh, Pt and Pd): Impact of Active Metal and Noble Gas Co-Feeding

Plasma-catalysis has attracted significant interest in recent years as an alternative for the direct upgrading of methane into higher-value products. Plasma-catalysis systems can enable the electrification of chemical processes; however, they are highly complex with many previous studies even reporting negative impacts on methane conversion. The present work focuses on the non-oxidative plasma-catalysis of pure methane in a Dielectric Barrier Discharge (DBD) reactor at atmospheric pressure and with no external heating. A range of transition and noble metals (Ni, Fe, Rh, Pt, Pd) supported on γ-Al2O3 are studied, complemented by plasma-only and support-only experiments. All reactor packings are investigated either with pure methane or co-feeding of helium or argon to assess the role of noble gases in enhancing methane activation via energy transfer mechanisms. Electrical diagnostics and charge characteristics from Lissajous plots, and electron temperature and collision rates calculations via BOLSIG+ are used to support the findings with the aim of elucidating the impact of both active metal and noble gas on the reaction pathways and activity. The optimal combination of Pd catalyst and Ar co-feeding achieves a substantial improvement over non-catalytic pure methane results, with C2+ yield rising from 30% to almost 45% at a concurrent reduction of energy cost from 2.4 to 1.7 \\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\:\ ext{M}\ ext{J}\\:{\ ext{m}\ ext{o}\ ext{l}}_{\ ext{C}{\ ext{H}}_{4}}^{-1}$$\\end{document} and from 9 to 4.7 \\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\:\ ext{M}\ ext{J}\\:\ ext{m}\ ext{o}{\ ext{l}}_{{\ ext{C}}_{2+}}^{-1}$$\\end{document}. Pd, along with Pt, further displayed the lowest coke deposition rates among all packings with overall stable product composition during testing.

Dilute Electrolytes with Fluorine‐Free Ether Solvents for 4.5 V Lithium Metal Batteries

AbstractThe limited oxidation stability of ether solvents has posed significant challenges for their applications in high‐voltage lithium metal batteries (LMBs). To tackle this issue, the prevailing strategy either adopts a high concentration of fluorinated salts or relies on highly fluorinated solvents, which will significantly increase the manufacturing cost and create severe environmental hazards. Herein, an alternative and sustainable salt engineering approach is proposed to enable the utilization of dilute electrolytes consisting of fluorine (F)‐free ethers in high‐voltage LMBs. The proposed 0.8 M electrolyte supports stable lithium plating‐stripping with a high Coulombic efficiency of 99.47 % and effectively mitigates the metal dissolution, phase transition, and gas release issues of the LiNi0.8Co0.1Mn0.1O2 (NCM811) cathode upon charging to high voltages. Consequently, the 4.5 V high‐loading Li||NCM 811 cell shows a capacity retention of 75.2 % after 300 cycles. Multimodal experimental characterizations coupled with theoretical investigations demonstrate that the boron‐containing salt plays a pivotal role in forming the passivation layers on both anode and cathode. The present simple and cost‐effective electrolyte design strategy offers a promising and alternative avenue for using commercially mature, environmentally benign, and low‐cost F‐free ethers in high‐voltage LMBs.

Optimization of gas metal arc welding parameters for dissimilar steel welds: A case study on duplex stainless steel 2205 and stainless steel 316L

The significance of welded connections in steel structures necessitates precise structural designs and processing adaptations to ensure robust mechanical strength and durability. Gas metal arc welding (GMAW) employing controlled curves presents advantages over conventional methods, offering enhanced weld bead properties, improved aesthetics, and reduced thermal inputs. This research investigates the impact of GMAW parameters using controlled curves on the microstructure and geometry of welds between dissimilar structural steels—duplex stainless steel 2205 and stainless steel 316L grade 50—commonly employed in construction. The aim is to optimize the GMAW welding process with controlled curves and surface tension transfer between these dissimilar steels. Through a 23-factorial experimental design encompassing feed speed (Va), arc focus (FC), and peak-to-base amplitude (APB), the study examines welding energy, geometry, deposition efficiency, microstructure, microhardness, tensile strength, and corrosion properties. Optimal welding energy fosters refined microstructures and uniform hardness, aiding in predicting weld throat area. Higher energy levels expand the heat-affected zone and coarse grains, while lower energies escalate variability. Predictive models facilitate fine-tuning welding energy and throat area for desirable properties and penetration while minimizing disruptions. This process optimization can be achieved by employing derived equations that limit welding energy and curve parameters, striking a desired balance between cost, structural integrity, and reliability.

Novel synthesis of 1-D silicon nanowires grown on pyramidal black silicon substrates and intense visible emission

This work shows a new way to grow 1-D Silicon Nanowires (SiNWs) over pyramidal black silicon used as substrates. These nanostructures are grown by the plasma-assisted vapor–liquid-solid (VLS) as a bottom-up process, using tin thin films as a catalytic metal and dichlorosilane gas as a silicon precursor. SiNWs were obtained with diameters from 300-600 nm and 4–6 µm lengths on the black silicon surface. Due to the pyramid-shaped and porous nature of the black silicon surface, SiNWs form a complex mesh nanostructure. This network has a large surface area and exhibits intense and effective photoluminescence with a peak in the green spectrum, which is attributed to the quantum confinement effect that occurred in small nc-Si embedded inside SiNWs. These structural configurations hold significant promise for applications in optical biosensors, solar cells, and other prospective fields.

Dilute Electrolytes with Fluorine-Free Ether Solvents for 4.5 V Lithium Metal Batteries.

The limited oxidation stability of ether solvents has posed significant challenges for their applications in high-voltage lithium metal batteries (LMBs). To tackle this issue, the prevailing strategy either adopts a high concentration of fluorinated salts or relies on highly fluorinated solvents, which will significantly increase the manufacturing cost and create severe environmental hazards. Herein, an alternative and sustainable salt engineering approach is proposed to enable the utilization of dilute electrolytes consisting of fluorine (F)-free ethers in high-voltage LMBs. The proposed 0.8 M electrolyte supports stable lithium plating-stripping with a high Coulombic efficiency of 99.47 % and effectively mitigates the metal dissolution, phase transition, and gas release issues of the LiNi0.8Co0.1Mn0.1O2 (NCM811) cathode upon charging to high voltages. Consequently, the 4.5 V high-loading Li||NCM 811 cell shows a capacity retention of 75.2 % after 300 cycles. Multimodal experimental characterizations coupled with theoretical investigations demonstrate that the boron-containing salt plays a pivotal role in forming the passivation layers on both anode and cathode. The present simple and cost-effective electrolyte design strategy offers a promising and alternative avenue for using commercially mature, environmentally benign, and low-cost F-free ethers in high-voltage LMBs.

Local Volume Dwarf Cas 1: Gas Metallicity, Extinction, and Distance

Local Volume Dwarf Cas 1: Gas Metallicity, Extinction, and Distance

Innovative Metal Powder Production Using CFD with Convergent-Divergent Nozzles in Wire Arc Atomization

This study aims to enhance the production of metal powders using a novel approach that integrates computational fluid dynamics (CFD) with convergent-divergent (C-D) nozzles in wire arc spraying atomization (WASA). The primary objective is to investigate the influence of nozzle design on particle size distribution and production efficiency. Utilizing the ANSYS CFD Fluent program, simulations were conducted to analyze the effects of various parameters, including throat diameter and divergent angles, on gas dynamics and metal droplet behavior. The findings reveal that C-D nozzles facilitate the acceleration of gas flow to supersonic speeds, significantly improving the shear force acting on the molten metal, thereby promoting the fragmentation of droplets into smaller particles. Notably, the optimized nozzle configuration achieved a median particle size (D50) of 44.42 µm, suitable for additive manufacturing applications. The novelty of this work lies in its comprehensive simulation framework that allows for rapid virtual testing, potentially leading to significant improvements in the efficiency and quality of metal powder production processes. This research addresses critical gaps in the existing literature and provides a robust foundation for future studies in the field of metal powder manufacturing. Doi: 10.28991/HIJ-2024-05-03-02 Full Text: PDF

Ultrasonic evaluation of wire arc additively manufactured parts with heterogeneous microstructure

Abstract In Wire Arc Additive Manufacturing (WAAM) components manufactured by gas metal arc welding strategy, periodically alternating patterns of fine- and coarse-grained microstructures develop along the building direction, depending on the temperature evolution. Ultrasonic non-destructive evaluation relies on the scattering of waves from defects. In the material microstructure, ultrasound waves are also scattered at the grain boundaries as grain noise. The work presents a study on the influence of heterogeneous microstructure in WAAM on defect detectability during ultrasonic inspections. The study used a 2D finite element model to simulate ultrasound wave propagation in the material microstructure represented by a surface element from electron backscatter diffraction scans. Side-drilled holes were introduced in the material as defects. Phased array was used to perform full matrix capture and obtain ultrasound image through total focusing method, with dynamic focusing capability to inspect the heterogeneous microstructure. The study analysed the defect echoes and noises using the signal-to-noise ratio (SNR) to assess its defect detectability. While defects were well detected, the SNR values differ by 10% for defects at various positions along the building and transverse directions in the heterogeneous microstructure.

HOMERUN: A new approach to photoionization modeling

We present HOMERUN (Highly Optimized Multi-cloud Emission-line Ratios Using photo-ionizatioN), a new approach to modeling emission lines from photoionized gas that can simultaneously reproduce all observed line intensities from a wide range of ionization levels with high accuracy. Our approach is based on the weighted combination of multiple single-cloud photoionization models, and contrary to previous works, the novelty of our approach consists of using the weights as free parameters of the fit and constraining them with the observed data. One of the main applications of HOMERUN is the accurate determination of gas-phase metallicities, and we show that a critical point is to allow for a variation of the N/O and S/O abundance ratios, as this can significantly improve the quality of the fit and the accuracy of the results. Moreover, our approach provides a major improvement compared to the single-cloud constant-pressure models commonly used in the literature. By using high-quality spectra from the literature of H II regions, where 10 to 20 emission lines (including several auroral lines) are detected with a high signal-to-noise ratio, we show that all lines are reproduced by the model with an accuracy better than 10%. In particular, the model is able to simultaneously reproduce [O I]λλ6300, 6363; [O II]λλ3726, 3729; [O III]λλ4959, 5007; [S II]λλ6717, 6731; and [S III]λλ9069, 9532 emission lines, which to our knowledge is an unprecedented result. Finally, we show that the gas metallicities estimated with our models for HII regions in the Milky Way are in better agreement with the stellar metallicities than the estimates based on the Te method. Overall, our method provides a new accurate tool to estimate the metallicity and the physical conditions of the ionized gas. It can be applied to many different science cases, from HII regions to active galactic nuclei, and wherever there are emission lines from photoionized gas.

Residual mechanical properties of corroded ultra-high-strength steels and weld metals

This paper presents an in-depth investigation into the residual mechanical properties of ultra-high-strength steels and weld metals after exposure to corrosive environment. The tensile specimens of weld metals were fabricated using ER100S-G, ER110S-G, ER120S-G feedstock wires by robotic gas metal arc welding, whilst ultra-high-strength steel tensile coupon specimens were machined from the Q890 and Q960 steel plates. The high-strength steel and weld metal tensile specimens were exposed to neutral salt spray accelerated corrosion conditions. Six exposure durations were designed to achieve different corrosion degrees of specimens. A total of 23 corroded ultra-high-strength steel tensile coupon specimens and 19 corroded high-strength weld metal specimens were included. The geometric profiles of corroded steel specimens were determined via non-contact 3D laser scanning. Monotonic tensile tests were conducted to determine the stress-strain responses and key mechanical properties of corroded steel and weld specimens. Mechanical properties deterioration of corroded ultra-high-strength steels and weld metals are reported and discussed. Prediction equations on the residual mechanical properties regarding the tensile loading capacity, yield stress and ultimate tensile stress of ultra-high-strength steels and weld metals after exposure to corrosive environment were established.

Effect of filler wires on microstructure and mechanical properties of Inconel 718 welded joints by double pulse metal inert gas welding

ABSTRACT Inconel 718 possesses issues like microsegregation of Nb, Mo leads to the formation of Laves phase which degrades the mechanical properties of the welded joints. This study aims to investigate the mechanical properties and microstructural characteristics of Inconel 718 welded joints using the double pulse metal inert gas (DP-MIG) process by the combined effect of filler wires, such as ERNiFeCr-2, ERNiCrCoMo-1, and 9Cr-1Mo. All the weldments were found to have columnar dendrites with coarser grain morphology. Liquated grain boundaries, secondary phases, unmixed zones at the heat affected zone (HAZ) and segregation of Nb (21.3%) and Mo (10.4%) at the weld zone were identified for ERNiFeCr-2 and ERNiCrCoMo-1 fillers. From EBSD findings, the formation of peninsula and island at the HAZ and segregation of Fe (68%) in the weld zone of 9Cr-1Mo filler weldment was noticed. Even though the ultimate tensile strength (UTS) of all the weldments was found to be inferior to that of base metal (788.9MPa), the 9Cr-1Mo filler weldment shows better tensile strength of 403.5MPa with a joint efficiency of (51.14%). From the fractography results, the void formation due to secondary phases along with dimple networks ensures the ductility mode of fracture for all the weldments.

Follow-up Biomonitoring Study of Metal Exposure in Apprentice Welders in Montreal, Quebec, During Gas Metal Arc Welding (GMAW).

Welding activities are known to expose workers to metal fumes, but few studies have focused on assessing the internal exposure of apprentices in learning environments. This study aimed at determining internal doses of metals in apprentices performing gas metal arc welding (GMAW) during their training course. A total of 85 apprentice welders were assessed, and multi-elements were measured in urine, hair, fingernail, and toenail samples collected at the beginning of the program, and at the beginning and end of GMAW practical training. Concentrations of welding fumes and metals were also determined in personal respirable air samples. Serial measurements of metal concentrations in urine and hair, which reflect more recent exposure, showed an increase in arsenic (As), chromium (Cr), iron (Fe), and manganese (Mn) (and to a lesser extent nickel (Ni)) levels at the end of the GMAW process. Metal concentrations in fingernails and toenails showed a time-dependent increase in Fe, Mn, and Ni (and to a lesser extent cobalt (Co)) levels, reflecting cumulative exposure. Levels of Mn and Fe were high in personal air samples with respective median concentrations (95th percentiles) of 21 (300) and 230 (1900) µg/m3. Results show that even short-term exposure to welding fumes in a learning environment leads to a significant increase in absorbed metal doses, particularly for Fe and Mn. This follow-up study confirmed the interest and usefulness of measuring multi-elements in multiple matrices to assess internal exposure to welding fumes and its applicability to occupational or even population exposure to metals.

Strength-ductility synergy in a non-equiatomic Co–Cr–Ni medium entropy alloy wall structure deposited using twin-wire arc additive manufacturing

An innovative twin-wire arc additive manufacturing (T-WAAM) has been deployed to fabricate a Co-rich non-equiatomic Co–Cr–Ni medium entropy alloy. The TWAAM-built single-wall structures of Co50Cr10Ni40 alloy were fabricated under argon gas shielding using dual gas metal arc welding sources. The microstructure studies revealed a single-phase FCC crystal structure and defect-free deposition. The slender columnar substructure and cellular substructure are formed along the build direction (BD) and scan direction (SD) respectively, which are commonly observed in the wall structures of other conventional FCC alloys. The tensile coupon SD and BD displayed a superior high strength and ductility combination. The T-WAAM-fabricated Co50Cr10Ni40 alloy showed both strength and elongation 1.4 times greater than that of the laser additive manufactured equiatomic CoCrNi wall structure. Thus, the study opens up a new avenue to tailor the mechanical properties of CoCrNi MEA by composition variation, with an added advantage of higher deposition rates of TWAAM.

Effect of Solution and Aging Heat Treatment on the Microstructure and Mechanical Properties of Inconel 625 Deposited Metal

Inconel 625 deposited metal was prepared by gas metal arc welding. The solid solution treatment temperature was set at 1140 °C for 4 h using the DSC test method, followed by secondary aging at 750 °C/4 h and 650 °C/24 h. The specimens in the prepared state and after heat treatment were subjected to high temperature tensile at 600 °C, respectively. The fracture morphology, thermal deformation behavior, and strengthening mechanism of the samples in different states were analyzed. The results showed that the stress–strain curves of the deposited metals exhibited obvious work-hardening behavior at 600 °C. The solid solution and aging heat-treated samples have higher tensile and yield strength, but the plasticity is obviously lower than that of the deposited metal. It was also found that the γ″ phase and M23C6 carbides, as well as the continuous stacking faults in the alloy, were the main reasons for the increase in tensile strength of the solution and aging heat-treated sample.

Analysis of Shielding Gases Influences 304 Gas Metal Arc Welding Microstructure, Weld Geometry, and Mechanical Properties

Analysis of Shielding Gases Influences 304 Gas Metal Arc Welding Microstructure, Weld Geometry, and Mechanical Properties

Improved accuracy of continuum surface flux models for metal additive manufacturing melt pool simulations

Computational modeling of the melt pool dynamics in laser-based powder bed fusion metal additive manufacturing (PBF-LB/M) promises to shed light on fundamental mechanisms of defect generation. These processes are accompanied by rapid evaporation so that the evaporation-induced recoil pressure and cooling arise as major driving forces for fluid dynamics and temperature evolution. The magnitude of these interface fluxes depends exponentially on the melt pool surface temperature, which, therefore, has to be predicted with high accuracy. The present work utilizes a diffuse interface finite element model based on a continuum surface flux (CSF) description of interface fluxes to study dimensionally reduced thermal two-phase problems representative for PBF-LB/M in a finite element framework. It is demonstrated that the extreme temperature gradients combined with the high ratios of material properties between metal and ambient gas lead to significant errors in the interface temperatures and fluxes when classical CSF approaches, along with typical interface thicknesses and discretizations, are applied. It is expected that this finding is also relevant for other types of diffuse interface PBF-LB/M melt pool models. A novel parameter-scaled CSF approach is proposed, which is constructed to yield a smoother temperature field in the diffuse interface region, significantly increasing the solution accuracy. The interface thickness required to predict the temperature field with a given level of accuracy is less restrictive by at least one order of magnitude for the proposed parameter-scaled approach compared to classical CSF, drastically reducing computational costs. Finally, we showcase the general applicability of the parameter-scaled CSF to a 3D simulation of stationary laser melting of PBF-LB/M considering the fully coupled thermo-hydrodynamic multi-phase problem, including phase change.