Inert Gas Research Articles

Performance analysis of various fluxes in different variants of the TIG welding process on the quality of welding

The tungsten inert gas (TIG) welding process is widely used in various industries for its ability to produce high-quality welds at a low cost. However, TIG welding struggles with welding thick stainless steel in a single pass, reducing production efficiency. To address this, new TIG variants such as activated TIG (A-TIG), flux bound TIG (FB-TIG), and flux zone TIG (FZ-TIG) have been developed to enhance penetration in austenitic stainless steel. This study investigates the effects of TiO2 and Fe2O3 flux on 304 stainless steels welded using A-TIG, FB-TIG, and FZ-TIG processes. Results show a slight increase in the depth-to-width (d/w) ratio for A-TIG and FB-TIG, while FZ-TIG achieved a 59% higher d/w ratio compared to autogenous TIG welding. The increased penetration is attributed to the reversal Marangoni convection and arc constriction. Microstructural analysis reveals a higher delta ferrite content in A-TIG and FZ-TIG welds due to increased heat input. Additionally, FZ-TIG welds exhibited an 11.5% higher microhardness compared to autogenous TIG welds. FZ-TIG welding enhances penetration and mechanical properties effectively.

Research on Process Characteristics and Properties in Deep-Penetration Variable-Polarity Tungsten Inert Gas Welding of AA7075 Aluminum Alloy

In this study, a new deep-penetration variable-polarity tungsten inert gas (DP-VPTIG) welding process, which is performed by a triple-frequency-modulated pulse, was employed in the welding fabrication of 8 mm AA7075 aluminum plates. The electric signal, arc shape, and weld pool morphology of the welding process were obtained by means of high-speed photography and an electric signal acquisition system under varying parameters of the intermediate frequency (IF) pulse current. The principle of the arc characteristics and the dynamic mechanism of the weld melting during the process are explained. In addition, the macroforming, microstructure, and microhardness of the welded joints were investigated. The results indicate that, with an intermediate frequency pulse of 750 Hz, the arc displayed a higher energy density and a more effective arc contraction, which improved weld appearance and penetration. Moreover, the impact and stirring action of the arc refined the microstructure grains of the weld center. Therefore, this new welding method is feasible for welding medium-thickness aluminum alloy plates without a groove.

Characterization and optimization of TIG welding parameters for AISI 304 and AISI 316 stainless steel dissimilar joints

This study explores the impact of tungsten inert gas (TIG) welding parameters on the mechanical properties and microstructure of dissimilar welds between AISI 304 and AISI 316 austenitic stainless steels. Given the growing industrial demand for these materials, the research focuses on optimizing welding current, shielding gas flow rate, and voltage to enhance tensile strength, hardness, and impact toughness. Using the L9 orthogonal array based on Taguchi’s methodology, the experiments revealed that Relatively highs currents and voltages significantly improved the ultimate tensile strength (up to 673.67 MPa) and impact energy absorption (up to 36.5 J). Microstructural analysis indicated refined grain structures in the heat-affected zones, with pronounced grain growth in AISI 316 due to its thermal sensitivity. The micro-hardness analysis revealed that the highest hardness occurred in the HAZ of AISI 304, with samples 5 and 6 exhibiting the optimal hardness profile, reflecting the most favorable welding parameters. The study concludes that a current range of 80-90 A and a voltage range of 10-11 V and a shielding gas flow rate of 12-16 L/min provide optimal welding conditions, offering robust guidelines for industrial applications requiring high-performance dissimilar welds.

Rational design of the temperature-responsive nonflammable electrolyte for safe lithium-ion batteries

The development of nonflammable electrolytes is critical for breaking the trade-off between the safety and energy density in Li-ion batteries (LIBs). Here, a rational design strategy of temperature-responsive nonflammable electrolytes (TRNEs) is proposed which are capable to prevent the heat accumulation and extinguish the fire efficiently during thermal runaway. Compared to the conventional phosphate- or halogen-based flame retardants, the TRNE based on low-cost and multifunctional methylurea (MU) was demonstrated with the lowest volatility (11.6 % weight loss) below 250 °C, and the highest efficacy to extinguish the fire at >210.4 °C through heat absorption, inert gases generation and char layer formation. In addition, the developed MU-based TRNEs enable higher stability and rate capability of LIBs compared to various nonflammable electrolytes. A Li||LiFePO4 (LFP) cell employing MU-based TRNE achieved higher stability (94.9 % capacity retention for 1500 cycles) than commercial electrolyte. A Ni-rich Li||LiNi0.8Mn0.1Co0.1O2 (NMC811) system was demonstrated with superior rate capability and high stability for 700 cycles (2.72 months) with the capacity retention of 89.9 %. Combining low cost and volatility, as well as high stability, rate capability and fire extinguishing efficacy, we demonstrate a promising design strategy to improve the battery safety for high-energy-density LIBs.

Numerical Simulation of Thermal–Mechanical Coupling in Laser–Metal Inert Gas Hybrid Welding Considering Grain Heterogeneity and Study of Phase Field Method during Solidification Process

Numerical Simulation of Thermal–Mechanical Coupling in Laser–Metal Inert Gas Hybrid Welding Considering Grain Heterogeneity and Study of Phase Field Method during Solidification Process

Phenomenological Study of the Atomization Process in Pre‐Filming Nozzles Typically Used for Steel Atomization

Liquid steel atomization using close‐coupled nozzles is highly dependent on the relationship between momentum flux ratio, gas–liquid ratio, aspiration pressure, and operating pressure of inert gases. A strong correlation between these parameters and the final powder must be assumed. Understanding these parameters, their influence on the process, and their interactions with each other is indispensable for efficient powder production. In particular, the industrial application of close‐coupled atomization nozzles, which develop a thin pre‐film on the nozzle tip, is not yet fully understood. A model experiment is presented to investigate interactions between the flow conditions of the gaseous and liquid phases, focusing on recirculation phenomena inside the atomization zone. The experiments show the influence of liquid and gas flow conditions on the spray geometry and the liquid core length, as well as the strong dependence of the liquid mass flux on the gas flow. The aspiration pressure below the liquid nozzle is sensitive to gas pressure and has a major influence on the development of the liquid core and the pre‐film, as it increases the liquid mass flux. For practical application, the results confirm an optimal operating point of interacting system parameters, which leads to high‐quality atomization with minimal use of resources.

Investigations on the Heat Balance of the Melt Pool during PBF-LB/M under Various Process Gases

During the powder bed fusion of metals using a laser beam (PBF-LB/M), an inert atmosphere is maintained in the build chamber to avoid reactions of the liquid metal with ambient air leading to the creation of oxides or nitrides, which alter the mechanical properties of the processed part. A continuous gas flow is guided over the process zone to remove spatters and fumes. This flow induces a convective heat transfer from the molten metal to the gas, which, depending on the level of the heat flow, may alter the melt pool dimensions by influencing the cooling rate. The present work investigated these phenomena with single-line trials, both experimentally and numerically. For this reason, a smoothed-particle hydrodynamics model was utilized to investigate the temperatures of the melt pool, cooling rates, and the integral heat balance with various gas atmospheres. In parallel, an on-axis pyrometer was set up on an experimental PBF-LB/M machine to capture the surface emissions of the melt pool. The atmosphere in the simulations and experiments was varied between argon, helium, and two mixtures thereof. The results showed a slight increase in the cooling rates with an increasing fraction of helium in the process gas. Consistently, a slight decrease in the melt pool temperatures and dimensions was found.

Microstructure and Hardness Properties of Additively Manufactured AISI 316L Welded by Tungsten Inert Gas and Laser Welding Techniques

Microstructure and Hardness Properties of Additively Manufactured AISI 316L Welded by Tungsten Inert Gas and Laser Welding Techniques

The establishment of superlubricity in engineering field for H-DLC composite in multi-environments

The application of hydrogenated diamond-like carbon (H-DLC) with superlubricity can significantly decrease friction and largely save energy dissipation in mechanical systems. Thus, the realization of the near-frictionless state at the engineering scale in both inert and active atmospheres for H-DLC film is of interest. However, the film can achieve the state only under inert and vacuum conditions, while it fails in active atmospheres, such as oxygen and moist air, which seriously hinders wide application of the superlow friction. In previous studies, we have successfully solved this challenge by combining H-DLC film with MoS2 flakes. Nevertheless, the life of the superlubricity achieved by the MoS2/H-DLC composite in an inert gas was extremely short, which was attributed to the failure of MoS2-rich transfer films. To establish the near-frictionless state in various atmospheres, graphene oxide with numerous oxygen-containing groups was used to prepare a GO/MoS2/H-DLC triple composite in this study. The tribological performances were investigated systematacially. The results demonstrated that the triple composite could establish superlubricity in inert gases and ultralow friction in active atmosphere by forming robust transfer films at sliding interfaces. The structures at frictional interfaces including wear tracks and scars were thoroughly investigated. This work provides a valuable approach for the H-DLC composite to achieve an extremely low friction in various atmospheres and can guide the application of superlow friction in engineering fields.

Reactive formation of C3N4 as a by-product of AISI 1070 parts produced by laser powder bed fusion in N2 atmosphere

AbstractIn metal additive manufacturing (AM), inert gases are traditionally used to achieve a controlled atmosphere and mitigate the effects of residual reactive gases. However, the interaction between gases and laser processes, particularly in reactive laser powder bed fusion (RL-PBF) technology, offers the possibility of opening up new avenues for material synthesis. In this experimental work, the authors observed the presence of C3N4 in the residual powder during the manufacture of AISI 1070 steel parts by L-PBF, indicating a reactive process occurred during parts production. This investigation revealed the formation in the working chamber of a waste product containing C3N4 carbon nitride, due to the reaction between the carbon released from the steel and the nitrogen in the chamber. Remarkably, despite carbon depletion, the final product of AISI 1070 steel complies with the specifications of use. Hence, the L-PBF machine was modified to allow black powder sampling from various locations in the chamber. Authors attempted to enhance the production of the C3N4 material by increasing the SED up to 7143 J/mm2 to sublimate a pure graphite rod and concurrently manufacture parts in AISI 1070, in a nitrogen atmosphere. The results obtained at higher SED values showed that in both cases (graphite rod or AISI 1070 steel) a C3N4 compound in the black powder is formed in the investigated atmosphere by reaction of nitrogen atoms with the carbon atoms vaporized by the laser beam. Thus, the study highlights the novel achievement of synthesizing carbon nitride as a high-value by-product while producing functional AISI 1070 steel parts via L-PBF through reaction with nitrogen atmosphere.

Characterization of CrMnNi Steel Powders Obtained via Gas Atomization

To obtain a successful product during additive manufacturing, the powder as a raw material must have the high quality. The purpose of this work is to investigate CrMnNi steel powders obtained by inert gas atomization with nickel content: 3, 6, and 9 wt% and to identify dependencies between the powder size and morphology, solidification structure, and change in chemical composition and thermophysical properties. Particle size distribution is measured by a laser scattering analyzer: d50 value are 82.02, 69.32, and 75.54 μm for powders with 3, 6, and 9 wt%, respectively. Surface tension (ST) measurements are made by maximum bubble pressure method: for steels with 3, 6, and 9 wt% at temperature 1500 °C, ST is 1.01, 1.07, and 1.15 mN m−1, respectively. It is found that the change in particle size affects the chemical composition, the content of the ferromagnetic phase and secondary dendritic arm‐spacing. Changes in the content of elements such as S, O, N, and Mn are determined, depending on the diameter of the particles. The influence of changes in content of S, O, and N on the thermophysical properties such as ST is investigated.

Annealing Time Dependence on Creation of SiV, GeV, and SnV in Diamond by Atmospheric Annealing at 1800 °C

The creation of SiV−, GeV−, and SnV− are presented by the atmospheric annealing in the argon flow. Compared to high‐pressure annealing, in which gas cannot flow, atmospheric annealing with an inert gas flow not only causes less degradation of the sample surface but also has the advantage of reducing equipment cost and preparation time. Excessive annealing time has been shown to reduce the amount of centers created. The optimal annealing time that maximizes formations depends on the type of diamond sample and the implanted ions. Furthermore, inspired by the split‐vacancy structure of the group IV–V centers, atmospheric pre‐annealing at 600 °C to increase the amount of di‐vacancy is demonstrated, followed by annealing at 1800 °C for 1 min. A shorter duration of high‐temperature annealing is expected to qualitatively reduce stress and deterioration of the crystallinity of the diamond sample.

New cobalt complex with dihydroxycoumarin: synthesis and kinetics of its redox-activated dissociation

A new redox-active cobalt(III) complex containing the 2-oxo-2Н-chromene-6,7-diolate dianion and 4,4ʹ-dimethoxy-2,2ʹ-bipyridine as ligands is synthesized. The reduction of the sythesized complex with ascorbic acid in an inert atmosphere is studied in situ by NMR spectrocopy. The reduction is shown to result in the release of 6,7-dihydrocycoumarin acting as a model drug. This process has the first order with respect to the initial complex.

THIOL‐ENE COUPLING REACTION FOR FUNCTIONALIZATION OF NON‐ACTIVATED ALKENES: AN EXPERIMENTAL STUDY ON THE CHEMISTRY OF THE METHYL OLEATE AMINATION

This work investigates the functionalization of molecules with non‐activated internal double bonds via thiol‐ene coupling (TEC) reaction. A comprehensive study of the reaction between cysteamine hydrochloride (CAHC) and methyl oleate (MO) was carried out. A series of reactions were conducted under different operating conditions in order to assess their effect on conversion and selectivity. Different conditions were considered like the type of atmospheres and solvents, a portionwise addition of CAHC, reagents concentrations, and excess of CAHC. Maximum conversion and selectivity were reached under inert atmosphere, diluted conditions, ethanol as solvent, and the addition of CAHC at the beginning of the reaction with a molar ratio of CAHC/MO of 3/1. This provides an approach for analyzing more complex reaction systems..

Macroscopic behavior and kinetic mechanism of ammonium dihydrogen phosphate for suppressing polyethylene dust deflagration

In this paper, the inhibition effect of ammonium dihydrogen phosphate (NH4H2PO4) on the deflagration of polyethylene dust (C100H202) is studied by combining experimental tests with reaction molecular dynamics simulation (ReaxFF MD). The mechanism by which NH4H2PO4 inhibits C100H202 deflagration is revealed at the microscopic level. The experimental results demonstrate that the inhibition effect of NH4H2PO4 on C100H202 deflagration is positively correlated with its concentration, and the addition of NH4H2PO4 equivalent to 50 % of the mass of C100H202 can completely suppress the deflagration. The apparent activation energies for the decomposition of C100H202 and C100H202/50 %NH4H2PO4 are calculated using ReaxFF MD to be 97.11 kJ/mol and 124.78 kJ/mol, respectively, which are in agreement with the results obtained from thermogravimetric tests. Furthermore, ReaxFF MD is employed to calculate the types and quantities of deflagration products and free radicals before and after the addition of NH4H2PO4. The results indicate that the number of the main intermediate C2H4 decreases with the increasing addition of NH4H2PO4. Based on this, the generation and consumption pathways of C2H4 are traced. It is found that phosphorous groups such as HOPO and PO2 scavenge active free radicals like ·O and ·OH, thereby altering the formation and consumption pathways of C2H4, leading to a reduction in both its formation and consumption. Additionally, H2O and inert gases produced by the thermal decomposition of NH4H2PO4 also contribute to inhibiting the progression of C100H202 deflagration.

3D printed SiOC architecture towards terahertz electromagnetic interference shielding and absorption

Electromagnetic interference (EMI) shielding and absorption materials can effectively mitigate the undesired pollution or noise caused by terahertz (THz) waves. The development of THz EMI shielding materials that are primarily based on absorption mechanisms to avoid secondary pollution caused by reflection is still in big demand. Herein, an absorption-dominated precursor-derived SiOC ceramic (PDC-SiOC) architecture for THz wave EMI shielding and absorption was reported. The EMI shielding properties of the bulk SiOC ceramic were studied. More than 93 % of THz EM waves were absorbed by the synthesized SiOC ceramic from 1.2 to 1.6 THz. Furthermore, lightweight honeycomb-structured SiOC architecture which was inspired by the wings of moth was fabricated by vat photopolymerization 3D printing combined with following pyrolysis. The EMI shielding properties and mechanism of the honeycomb SiOC architecture in THz bands were also discussed. The highest shielding effectiveness (SE) of the honeycomb SiOC architecture was up to 64.1 dB, and the transmissivity was below 1.4 % from 0.2 to 1.6 THz. In addition, more than 97–99.8 % of THz waves were absorbed in 0.8–1.6 THz. The excellent EMI shielding performance of the architecture was mainly attributed to its outstanding THz EM wave absorption ability. Finally, the mechanical properties and thermal stability of the architecture were further studied. The compressive and flexural strength of honeycomb architecture was 1.2 and 16.5 MPa, respectively. The result also proved that the honeycomb SiOC architecture was resistant to high temperatures up to 1100 °C under inert atmosphere. This work provides promising high-efficiency architecture towards THz EMI shielding and absorption.

Carbon fibres: Effect of various thermo-oxidative environments on structural and performance damage, both alone and in composites

This study examines the effects of heat and fire on the physical, mechanical and electrical properties of carbon fibre and those in carbon fibre reinforced composites (CFRCs). Carbon fibres were exposed to controlled heating (thermogravimetric analysis (TGA) and a tube furnace) in inert and air (oxygenated) environments and simulated fire (cone calorimetry at 35–75 kW m−2 and jet fire (propane burner) of 116 kW m−2) atmospheres. In inert atmospheres there was a minimal effect on the properties of carbon fibres, but in an oxygenated environment, significant oxidation began at temperatures ≥550 °C, resulting in a reduction in fibre diameter, which reduced further with increasing temperature and exposure duration. Tensile strength and electrical conductivity of carbon fibre decreased with reduction in fibre diameter. CFRCs exposed to 75 kW m−2 in a cone calorimeter and direct flame in a propane burner (116 kW m−2) showed varying degrees of oxidation in CFRC plies, with surface ply fibres experiencing more oxidation and consequent reductions in fibre diameter and tensile properties compared to fibres in underlying plies, where oxidation was limited due to restricted oxygen availability. Fibres exposed to the propane burner exhibited notable damage, including pitting and internal oxidation. Despite this, the overall electrical properties of residual carbon fibres did not significantly decrease, indicating that they still pose an electrical hazard if exposed during a high heat or fire event.

Effect of TIG remelting on the microstructure, mechanical properties, and corrosion behavior of 5052 aluminum alloy joints in MIG welding

In this work, the effect of tungsten inert gas (TIG) remelting on the microstructure, mechanical properties, and corrosion resistance of 5052 aluminum alloy joints produced by metal inert gas (MIG) welding is investigated. The results indicate that after TIG remelting of MIG welds, the proportion of dendrites increases in the remelted weld zone (WZ), porosity decreases by 76.9%, and the Fe elements in the second phase become coarser and more segregated. In contrast, the Mg elements form a solid solution with a decreased degree of segregation. In addition, the average grain size of the remelted structure decreases, while the proportion of sub-grain boundaries (SGBs) and the kernel average misorientation (KAM) values increase. Moreover, the heat-affected zone (HAZ) widens, and the grains become coarser. An increase of 4.5% in tensile strength and 20.0% in elongation was observed in the TIG-remelted joints after TIG remelting. Electrochemical and immersion tests on the TIG-remelted microstructure showed reduced corrosion resistance. Electrochemical tests mainly exhibited galvanic corrosion, resulting in the formation of pits. The types of corrosions observed in the immersion test differ from those in the electrochemical test, primarily exhibiting exfoliation corrosion and pitting corrosion. A higher geometric dislocation density (ρGND) in the structure increases the susceptibility to corrosion.

Role of oxidation in thermal fatigue damage mechanisms and life of X38CrMoV5 (AISI H11) hot work tool steel

Hot work tools steels, which are submitted to severe solicitations in service, are often damaged by thermal fatigue and corrosion. Interrupted Thermal Fatigue experiments were performed on X38CrMoV5 tool steel between 100 and 650 °C, in air and reduced oxygen partial pressure atmospheres after primary or secondary vacuum. A thermal and thermo-mechanical analysis by finite element method was carried out to estimate the strains and stresses undergone by the axisymmetric disc-shaped specimen during thermal cycling. The morphology, structure and phase composition of the oxide layer were analysed using scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction. It was shown that the thickness, homogeneity, structure, and compacity of the oxide multilayer formed on the specimen changed depending on test atmosphere. In air, crack initiation and propagation were strongly assisted by oxidation, leading to reduced fatigue life compared to inert atmospheres. Steel softening was highlighted in sub-surface, whatever the test atmosphere.

Study of peak Laminar Burning Velocity of several syngas compositions at different temperatures

In the context of the current energy transition, the use of biomass-derived syngas (BDS) is often recognized as a fundamental path towards decreasing fossil fuel dependency and greenhouse gas emissions. However, hydrogen-containing BDS are prone to flame instability problems. More efforts are being carried out aiming at efficiently adopting BDS in industrial combustors with CH4 co-firing or inert gas dilutions by exploring accurate knowledge of burning velocity. To do so, a deeper knowledge of the syngas combustion behaviour is strictly necessary. The objective of this study fits in this framework: in particular, a computational study has been carried out to evaluate kinetic models and present fresh insights on the effects of varying syngas mixtures such as CO/H2, CO/H2/CO2 and CO/H2/CH4 on Laminar Burning Velocity (LBV) and peak LBV location (ΦLBV=max). In-detail chemical kinetic simulations of equimolar (CO: H2 = 1:1) forestry waste syngas were systematically carried out taking advantage of the open-source CANTERA solver. Three detailed kinetic models i.e., newly released FFCM-2, USC mech II, and modified GRI mech III were implemented to report accurate flame parameters at 1 bar and different temperature levels (from 300 K up to 450 K). On comparing the results with experiments, FFCM-2 proved to be a good kinetic model for the considered syngas mixtures CO/H2, CO/H2/CO2 and especially for CO/H2/CH4 for mixtures containing a limited share of 30 % methane at normal and moderately elevated temperature at 0.4 ≤ Φ ≤ 2.1. The USC mech II performed very well for CO/H2, and CO/H2/CO2, while the modified GRI mech III model also gave agreeable predictions for CO/H2/CH4 mixture having rich methane content. Additionally, when varying syngas composition analysis was conducted at different temperatures, the progressive CO2 dilution and CH4 addition of up to 30 % reduced the peak LBV and moved the peak LBV locations (ΦLBV=max) towards lean ER conditions with 9 % and 40 % reductions, respectively; however, only the latter effect was enhanced at the elevated initial temperature. Furthermore, sensitivity analysis of respective syngas mixtures is reported at normal and elevated temperatures to explore the most sensitive intermediate reactions relative to LBV. The shift of peak LBV locations and their enhancement at elevated temperatures also open the research path to study the underlying impacts on the flame modes/regimes and structure, especially CO emissions pathways in syngas with 30 % of CH4 and CO2 additions.