Shielding Gas Research Articles

Fabrication of boron carbide ceramics reinforced with silicon carbide fibers

In the present study, the boron carbide ceramics reinforced with silicon carbide fibers (B4C-SiCf) were fabricated by incorporating various contents of SiCf ranging from 2.5 to 10 wt%. The B4C-SiCf powder mixtures were sintered using the Field Assisted Sintering Technique (FAST), also known as Spark Plasma Sintering (SPS), at temperatures of 1800 °C and 2000 °C for 5 min by applying a pressure of 70 MPa in argon atmosphere, while heating and cooling rates were maintained at 100 °C/min and 50 °C/min, respectively. The influence of the initial powder ratio on the sintering behavior, relative density, microstructural development, and mechanical properties of the obtained B4C-SiCf composites was investigated. The results indicated that the sintered ceramic materials contained only the initial compounds, i.e. B4C and SiC phases. Scanning Electron Microscopy (SEM) showed that the sintered composites consisted of densely compacted B4C grains. The highest relative density (>99 %) was achieved for the sample with 95 wt%B4C and 5 wt%SiCf, sintered at 2000 °C. Depending on the constituent content and the densification temperature the obtained composites demonstrated hardness values ranging from 29 to 43 GPa. The maximal hardness was attained in the composite with 95 wt%B4C sintered at 2000 °C. To assess the performance of the composites under extreme conditions, the ablation resistance was evaluated using a flowing oxyacetylene torch test. The material containing 5 wt%SiCf exhibited superior ablation resistance when compared to the other compositions. The attained results of this study showed that the SPS technique is a highly effective method for the densification of additive-free B4C-SiCf ceramic composites, showcasing promising properties for applications in extreme environments.

The electrochemical corrosion performance of aluminum alloys grade 6082-T6 weld repair

This research investigated the corrosion behavior of standard current metal inert gas weld repair for 6082-T6 aluminum alloy using ER5356 filler metal. The new and repaired (NW and RW) welds were studied. The welds comprised the weld metal (WM), the heat affected zone (HAZ) (solid solution and softened zones), and the base metal (BM). The study focused on investigating electrochemical corrosion using polarization and electrochemical impedance spectroscopy (EIS) methods in 3.5% NaCl solutions, especially in HAZ, including metallurgical and mechanical examinations. The BM containing an α-Al matrix with Al(Fe,Mn)Si and Mg2Si phases exhibited the maximum hardness (70–104 HV0.1). The WM hardness decreased (67–76 HV0.1) with the α-Al, β-Mg3Al2, and Mg2Si phases. Despite having comparable phases to BM, HAZs showed lower hardness (Solid HAZ: 70–82 HV0.1) due to more intermetallic phases. The RW’s softened HAZ revealed the minimum hardness (52–63 HV0.1) compared to that of the NW (55–70 HV0.1). Besides, the tensile strength of the RW (179.7 MPa) was also lower than that of the NW (174.4 MPa) because of the reheating effect. The electrochemical corrosion results indicated that the BM exhibited the maximum corrosion resistance (the lowest corrosion current density (icorr), the highest corrosion potential (Ecorr), and the charge transfer resistance (Rct)), followed by the HAZ and the WM, respectively. The softened HAZ demonstrated better corrosion resistance than the solid solution HAZ. Conversely, the over-aging effect reduced the softened zone’s pitting corrosion resistance (Ep) compared to the solid solution zone. The RW exhibited inferior corrosion resistance compared to the NW due to increased intermetallic phases, which was consistent with the mechanical results. However, the RW’s softened HAZ corrosion characteristics were inconsistent with its mechanical properties; its hardness and tensile strength were the lowest, but its corrosion resistance was not. Pitting corrosion was observed on the weld surfaces using the SEM.

Plume active control in high-power fiber laser welding based on high-speed shielding gas microbeam

Plume is an inherent physical phenomenon in fiber laser keyhole welding, negatively affecting welding quality. This paper proposes a new type of high-speed shielding gas microbeam (HSGM) based on the limitation of conventional shielding gas regulating plumes. The gas flow characteristics of the HSGM on the molten pool surface were explored using numerical simulation. Then, the coaxial double-layer shielding nozzle was trial-manufactured to clarify the regulation law for the HSGM on the plume. The gas velocity and pressure produced by the HSGM on the molten pool surface were positively correlated with the shielding gas flow rate, and the gas flow pattern was an acute triangle shape. The suitable HSGM can significantly restrain plume formation, improve the weld surface forming quality, increase the weld penetration depth (about 15.4%), and reduce the mass loss of the weld (about 58.7%). The significant blowing pressure effect of HSGM on plumes and splashes was the key to regulating the welding process. Compared with conventional shielding gas, the use of HSGM was significantly reduced.

Effect of double-pulse frequency and post-weld heat treatment on microstructure and mechanical properties of metal-inert gas welded Al–Mg–Si alloy joints

The Al–Mg–Si alloy welded structure is widely used in aerospace, marine ship, automotive and other industries. However, the mechanical properties of welded joint were seriously weakened due to the microstructure coarsening and heat affected zone (HAZ) softening, making its service life decayed. In this paper, in order to enhance the mechanical properties of Al–Mg–Si alloy welded joint, a coupled method including double pulsed Metal Inert Gas (DP-MIG) welding technology and post-weld heat treatment (PWHT) were applied on the joining process of Al–Mg–Si alloy. With the increase of DP frequency from 2 Hz to 5 Hz, the average grain size of fusion zone decreased from 113.7 μm to 88.4 μm. And the tensile strength of welded joint was at the interval of 180∼190 MPa. After a suitable heat treatment (solution treatment at 530 °C for 2 h and aging treatment at 180 °C for 8 h), the tensile strength of welded joint increased to 318.3–333.8 MPa, which exceeds 90 % of the base metal (BM). Under the comprehensive effect of solid solution strengthening, fine grain strengthening, and precipitation strengthening, the mechanical properties of Al–Mg–Si alloy welded joint were significantly improved. And the research results in this paper can provide a research basis for high quality connection of Al–Mg–Si alloys.

Keyhole critical failure criteria and variation rule under different thicknesses and multiple materials in K-TIG welding

The stability of keyhole was important to determine both the process and welding quality in keyhole tungsten inert gas (K-TIG) welding. In this study, the welding experiments were conducted on three kinds of materials (TC4 alloy, 304 stainless steel, Q235 carbon steel) with four kinds of thicknesses (2 mm, 4 mm, 6 mm and 8 mm). The keyhole critical failure criteria of K-TIG welding for different materials and thicknesses was established based on Gibbsian surface thermodynamics and regression analysis. Critical stability coefficient Kc was calculated by the values of upper width (Wf) of fusion zone and lower width (Wr) of fusion zone. When Kc>G/WfWr, the keyhole collapse failure would occur. Otherwise, a stable penetration could be obtained. On the other hand, the values of Kc increase with the increase of plate thickness, which meant the keyhole stable range would be smaller. The Kc values of TC4 alloy were smallest and the corresponding stable penetration range was largest. While the values and range of Q235 carbon steel were the largest. This was consistent with the rule reflected by the fitting curves of critical heat input. Furthermore, the difference in criteria variation rule of different materials and different thicknesses were discussed.

Intelligent seam tracking in foils joining based on spatial–temporal deep learning from molten pool serial images

Vision-based weld seam tracking has become one of the key technologies to realize intelligent robotic welding, and weld deviation detection is an essential step. However, accurate and robust detection of weld deviations during the microwelding of ultrathin metal foils remains a significant challenge. This challenge can be attributed to the fusion zone at the mesoscopic scale and the complex time-varying interference (pulsed arcs and reflected light from the workpiece surface). In this paper, an intelligent seam tracking approach for foils joining based on spatial–temporal deep learning from molten pool serial images is proposed. More specifically, a microscopic passive vision sensor is designed to capture molten pool and seam trajectory images under pulsed arc lights. A 3D convolutional neural network (3DCNN) and long short-term memory (LSTM)-based welding torch offset prediction network (WTOP-net) is established to implement highly accurate deviation prediction by capturing long-term dependence of spatial–temporal features. Then, expert knowledge is further incorporated into the spatio-temporal features to improve the robustness of the model. In addition, the slime mould algorithm (SMA) is used to prevent local optima and improve accuracy, efficiency of WTOP-net. The experimental results indicate that the maximum error detected by our method fluctuates within ± 0.08 mm and the average error is within ± 0.011 mm when joining two 0.12 mm thickness stainless steel diaphragms. The proposed approach provides a basis for automated robotic seam tracking and intelligent precision manufacturing of ultrathin sheets welded components in aerospace and other fields.

Penetration state recognition for tungsten inert gas welding via an alternating cusp-shaped magnetic field-assisted molten pool-oscillation

To ensure optimal penetration in direct current (DC) argon tungsten arc welding, a method was proposed to recognize the molten pool penetration during molten pool oscillation under alternating cusp-shaped magnetic field (ACSMF). An arc discharge model is established to analyze the oscillation mechanism of the molten pool under ACSMF. The periodic variation of arc shape induces the periodic oscillation to establish a mapping relationship with the fluctuation of arc voltage waveform. At the excitation current of 3 A and frequency of 10 Hz, the arc voltage waveform undergoes abrupt changes at 1.26 V and 1.37 V, corresponding to the critical and the full penetration states, respectively. The errors in identifying moving penetration are 0.8 % and 0.7 %, with a full penetration weld, demonstrating a penetration rate of 100 %, indicating effective penetration recognition. Arc sensing technology for tungsten inert gas (TIG) welding under ACSMF is poised for gradual application in single-side welding and double-side forming of medium and thick plates. It is anticipated to evolve towards real-time identification technology for molten pool penetration monitoring.

Effect of oxygen in shielding gas on weldability in plasma-GMA hybrid welding process of high-tensile strength steel

This study aims to clarify the effect of oxygen in shielding gas on weldability in the plasma-GMA (Gas Metal Arc) hybrid welding process of high-tensile strength steel plates. The difference in keyhole profile and bead formation, when the GMA shielding gas was pure Ar, Ar + 2% O2, or Ar + 20% CO2, was investigated for plate thicknesses of 6 and 9 mm for the first time. It was found that the weld beads were in good condition for 6 mm thickness plates for all shielding gases, which implied that the window of welding conditions for this thickness is wide. In contrast, for 9 mm thickness plates, a fully penetrated weld bead was achieved only in Ar + 20% CO2, and weld bead penetration in Ar + 20% CO2 is higher than in pure Ar and Ar + 2% O2 in the same welding condition. Due to decreased surface tension caused by sufficiently increased oxygen absorbed into the weld pool, the keyhole diameter increased to penetrate the bottom side of the plate, and the depressing weld pool surface under GMA allowed the heat input from the GMA to be directly applied to a deeper position. Consequently, the plasma-GMA hybrid welding process with Ar + 20% CO2 achieved a complete penetration for a plate of 9 mm thickness, owing to the effects of both phenomena. It proved a potential to increase penetrability in welding thicker plates by controlling oxygen content in shielding gas of GMA adequately.

Microstructural evolution and mechanical behavior of activated tungsten inert gas welded joint between P91 steel and Incoloy 800HT

This study examines the welded joint between P91 steel and Incoloy 800HT using the activated tungsten inert gas (A-TIG) welding process. The focus is on analyzing the microstructure and evaluating the mechanical properties of joints made with different compositions of activating flux. Owing to the reversal of the Marangoni effect in which the conventional direction of molten metal flow in the weld pool is reversed due to the application of oxide-based fluxes, a complete depth of penetration of 8 mm was successfully achieved. Conducting mechanical tests, such as microhardness, tensile, and Charpy impact toughness tests, elucidates the behavior of the welded specimens under different loading conditions. The findings highlight the effects of grain size, dislocations, and the evolution of fine-sized precipitates in the high-temperature matrix. This study highlights the importance of choosing suitable flux compositions to achieve consistent penetration and dilution in the base metals. Insights into different failure modes and the influence of temperature on the tensile strength were evaluated. Beneficial mechanical properties of the joints (meeting the criteria of ISO and ASTM standards) were found: ultimate tensile strength of 585 ± 5 MPa, elongation 38 ± 2%, impact toughness of 96 ± 5 J, and maximum microhardness of 345 ± 5 HV.

Research on the Influence of HMFI and PWHT Treatments on the Properties and Stress States of MAG-Welded S690QL Steel Joints.

The aim of this study was to analyze the effect of the HFMI (high-frequency mechanical impact) treatment of each weld bead on the properties of a butt joint with a ceramic backing welded by robotic method 135 (MAG-metal active gas welding method) and to determine the effect of HMFI on the stress level. This analysis was based on a comparison of three butt joints made of a S690QL plate, in the as-welded condition, with the HFMI of each bead and with the heat treatment carried out with PWHT stress relief annealing. The high-frequency (90 Hz) peening of each weld bead was linked with a stress reduction in the weld via the implementation of compressive stresses into the joint. The HFMI pneumatic hammer was used for this. The correctness of treatment was achieved when 100% of the surface of each bead including the face was treated. As part of the post-welding tests, basic tests were carried out based on the standards for the qualification of welding technology, and as a supplementary test, a stress state analysis using the Barkhausen effect was carried out. The tests carried out showed that the use of high-frequency peening after each pass did not affect the negative results of all the required tests when qualifying the welding technology of S690QL sheet metal compared to the test plates in the as-welded condition and after heat treatment-stress relief annealing. Inter-pass peening of the welded face and HAZ (heat-affected zone) resulted in a reduction in post-weld residual stresses at a distance of 12 mm from the joint axis compared to the stress measurement result for the sample in the as-welded condition. This allowed for a positive assessment of peening in the context of reducing the notch, which is the concentration of tensile stresses in the area of the fusion line and HAZ. The tests carried out showed that the peening process does not reduce the strength properties of welded joints, and the results obtained allow the technology to be qualified based on applicable standards.

New Technique to Repair Keyhole of 2195 Al-Li Alloy Friction Stir Welding Joints.

Aiming at the repairing of keyhole defects after friction stir welding of complex structures, a new method combined with tungsten inert gas welding (TIG) and friction stir processing (FSP) was proposed. The results showed that the pre-filling wire of TIG can completely fill the volumetric keyhole. FSP can refine the coarse grain area into equiaxial grains due to dynamic recrystallization, while some pore defects are eliminated. The interface bonding quality is high. The microhardness of the repairing zone with FSP is significantly stronger than that of the untreated parts. Compared to direct TIG repairing, the introduction of FSP transformed the fracture from brittle fracture to ductile fracture, and the tensile strength of the joint was increased by 131.7%, realizing the high-quality repairing of keyhole defects in 2195 Al-Li alloy.

Active control effect of shielding gas flow on high-power fiber laser welding plume

Plume are common physical phenomena in fiber laser keyhole welding and have serious negative effects on the welding process. Based on this, this paper explores the regulation law of conventional shielding gas flow on plume. The results show that the shielding gas has a very significant effect on the suppression of the slender part of the plume, and the greater the gas flow rate, the better the plume removal effect. The addition of the shielding gas makes the welding process more stable, the molten pool flows stably, and the frequency of spatter eruption is reduced. Under the experimental conditions, the optimal shielding gas flow rate is around 15 l/min, and the penetration depth and width are increased by about 10% and decreased by about 22%, respectively, compared with that without adding the shielding gas. Based on the gas flow simulation, the gas flow pressure (about 132 Pa) generated by an appropriate amount of shielding gas (about 15 l/min) can press the liquid column and spatter near the keyhole mouth into the molten pool to avoid the spatter eruption. Excessive shielding gas flow will interfere with the flow of the molten pool excessively, and the weld surface will show a serious undercut phenomenon.

Microstructure and mechanical properties of double pulse TIG welded super austenitic stainless steel butt joints

Abstract The primary objective of this study is to analyze the effect of double pulse tungsten inert gas (DP-TIG) welding on microstructure and mechanical properties of super austenitic SMO 254 stainless steel joints. The butt joints of SMO 254 steel were made using ERNiCrMo-10 filler metal. The microstructural characteristics of different regions of joint were analyzed using optical microscope, scanning electron microscope, X-ray diffraction analysis, and energy dispersive spectroscopy. The micrograph of weld metal showed finer equiaxed grains at the middle of weld metal and columnar grains near the weld interface. The SMO 254 steel joints showed the tensile strength of 636 MPa, ductility of 35 %, and impact toughness of 52 J. The fractured surfaces showed ductile mode of failure of joints.

An approach to robot welding path autonomous planning of the intersection weldment based on 3D visual perception

To improve the accuracy, an approach to robot welding path planning of the intersection weldment based on 3D visual perception is proposed. It adopts the two-stage location scheme of “global 3D reconstruction + local scanning correction”. First, this paper proposes an improved K-means clustering method based on the geometric features of workpiece point-cloud, to achieve accurate and fast point-cloud segmentation. Second, the intersection parameters of workpiece can be quickly calculated by the proposed parameter identification method. Third, this paper plans the scanning path of laser scanner according to the identified parameters, and puts forward an algorithm of weld path points recognition combined with the actual weldments state. Then, the pose of robot welding torch is obtained by using spline fitting algorithm and welding torch attitude estimation algorithm. Finally, the experiments show the path planning error is about 0.3 mm, which has increased a lot than the published methods.

Experimental study of laser powder bed fusion (L-PBF) gas shield inlet optimization and its effects on part quality

Experimental study of laser powder bed fusion (L-PBF) gas shield inlet optimization and its effects on part quality

Influence of shielding gas flow on the TIG welding process using stainless steel 304 material

A common issue encountered with main heat exchanger equipment is improper operation, which can lead to the development of cracks in the stainless-steel pipes. The welding process alters the metal microstructure in the heat-affected zone, thereby affecting the mechanical properties of the welded joint. To mitigate this issue, TIG welding with argon shielding gas is employed. This method helps prevent oxidation and ensures the formation of a stable welding arc in 304 stainless steel, which is renowned for its excellent mechanical properties and corrosion resistance. The objective of this study is to evaluate the impact of variations in shielding gas flow on the mechanical properties of 304 stainless steel plates during the TIG welding process. The aim is to determine the optimal settings for producing robust and long-lasting welded joints. To assess the hardness of the welded joints, we employed a Brinell-type Hardness Tester FB-3000LC machine. A Brinell steel ball indenter measuring 5 mm on the HBW scale and applying a load of 125 Kgf was utilized. At a protective gas flow rate of 8 L/min, the average tensile stress was 44.72 N/mm², strain was 0.177, modulus of elasticity was 2518 MPa, and hardness was 99.712 HBW. Increasing the gas flow rate to 13 L/min resulted in an average tensile stress of 47.50 N/mm², strain of 0.189, elastic modulus of 2525 MPa, and hardness of 105.522 HBW. Further increasing the gas flow rate to 18 L/min led to an average tensile stress of 49.69 N/mm², strain of 0.192, modulus of elasticity of 2597 MPa, and hardness of 106.704 HBW. Based on the research findings, it was observed that the weld area exhibited an increase in hardness values due to the heat generated during the welding process. The use of protective gas flow during welding is deemed effective in producing well-formed welded joints, as it prevents fractures from occurring within the weld area during the tensile test process. The choice of protective gas is determined by the dimensions of the material plate.

Microstructure and properties of metal inert gas welded joints in a novel Al–Mg–Zn–Er–Zr alloy

Metal inert gas (MIG) welding of a novel Al-5.82Mg-0.61Zn-0.14Er-0.11Zr alloy was performed using ER5E61 and ER5B71 filler wires. The effect of the two filler wires on microstructures and mechanical properties of MIG welded joints was investigated. The study shows that fully penetrated joints are obtained by MIG welding process filled with ER5E61 and ER5B71 wires. Compared with ER5B71, the weld metal (WM) with ER5E61 exhibits a coarse structure and high solid solution of Mg and Mn elements. After the tensile test, the WM with ER5E61 and ER5B71 wires is composed of elongated coarse grains with a higher proportion of low angle grain boundaries (LAGBs). In addition, the lattice rotation occurring within the grains, indicating that single grain has an unevenly plastic deformation after the tensile test. The average microhardness of the WM is 83.4 HV and 82.9 HV for ER5E61 and ER5B71 wire, which is the lowest microhardness in the MIG welded joint. The average ultimate tensile strength (UTS) and elongation index (EI) of the MIG joints are 327.7 MPa and 8.5% for ER5E61 wire, and 314.3 MPa and 8.2% for ER5B71 wire, suggesting the MIG welded joint with ER5E61 wire achieves a good combination of strength and ductility. Quantitative assessments of the effects of different strengthening mechanisms on the strength reveal that dislocation strengthening and solid solute strengthening are the main factors to obtain a higher strength of welded joints with ER5E61.

Ultrasonic-Assisted Tungsten Inert Gas Welding of Inconel 625 Joints to Reduce Hot Cracking and Improve Microhardness: Optimization and Prediction Methods

Abstract This research article investigated the optimized process parameters for decreasing the hot cracking phenomenon and improving the microhardness of ultrasonic vibratory-assisted tungsten inert gas (U-TIG) welding of Inconel 625 alloy. The study employed two approaches: response surface methodology (RSM) and RSM coupled with a genetic algorithm (RSM-GA). The objective was to analyze the impact of welding process parameters, including welding current, gas flow rate, presence or absence of ultrasonic vibration, and filler material, on the crack length and microhardness of the welded joints. Experimental tests were conducted using RSM with a full factorial central composite design matrix, enabling comprehensive parameter space exploration. Parametric mathematical models were developed based on the obtained experimental data. These models were then utilized as fitness functions within the GA to determine the global optimal solution, aiming to minimize crack length and maximize microhardness. Additionally, artificial neural network (ANN) models were developed to predict the responses and optimize the welding process. The comparison between the experimental and predicted data demonstrated the reliability of the ANN model in accurately estimating the crack length and microhardness of U-TIG welded Inconel 625 alloy joints. The developed models achieved a prediction accuracy of less than 5 % error.

In-situ preparation and ablative resistance of multicomponent refractory carbide ceramic gradient coatings

In this work, the gradient multicomponent carbide ceramic coatings were prepared in-situ on graphite matrix using the molten salt method, and their high temperature ablation resistance was investigated. Our results demonstrate the successful preparation of (HfTi)C, (HfTiZr)C, and (HfTiZr)C–TaC ceramic coatings with a gradient distribution on the graphite matrix by altering the types of raw materials. Thermodynamic calculations and analyses indicate that the smaller the Gibbs free energy gap between different carbides, the easier the solid solution multicomponent ceramic coating is formed. After 200 s of oxy-acetylene torch ablation, it was observed that the (HfTi)C, (HfTiZr)C, and (HfTiZr)C–TaC coatings effectively protected the graphite matrix with mass ablation rates of 6.47 mg s−1, 0.61 mg s−1, and 0.51 mg s−1, respectively. The low mass loss of (HfTiZr)C and (HfTiZr)C–TaC coatings can be attributed to the synergistic protective effect of different oxides formed by oxidation of different elements.

A Study on the Applicability of A-TIG Welding of Semi-Automatic Cold Wire Feeding Process for Cryogenic Stainless Steel Pipes

Activated Tungsten Inert Gas (A-TIG) welding with deeper penetration characteristic than manual Tungsten Inert Gas (TIG) welding is one of developed TIG welding processes for higher welding productivity. However, underfill phenomena often occurs when A-TIG welding applies to butt joints of Stainless steels with gap and misalignment. In order to complete welding, additional welding passes are needed. To prevent the underfill phenomena, A-TIG welding using semi-automatic cold wire feeding process can be one of alternatives. In this study, semi-automatic cold wire feeding condition for sound A-TIG weld profiles and characteristics of A-TIG welds were investigated. A-TIG welds without underfill were obtained by front feeding and placing the wire at the point about 1mm below from a TIG welding electrode. On the basis of mechanical and corrosion test results, A-TIG welds using semi-automatic cold wire feeding process have similar mechanical and corrosion characteristics with manual TIG welds, although slag was remained on the weld beads after the pickling process to remove heat tints of the A-TIG welds. However, the slag on the bead of A-TIG welds had no correlation with pitting corrosion.