Welding Electrode Research Articles

ПРИМЕНЕНИЕ УЛЬТРАЗВУКОВЫХ КОЛЕБАНИЙ ПРИ ДУГОВОЙ СВАРКЕ (ОБЗОР)

The paper describes various methods of using ultrasonic vibrations in arc welding based on the analysis of literature data. The main attention is paid to the recently developed method of ultrasound action on the arc. The advantages and disadvantages of existing methods of using ultrasonic vibrations in non-consumable electrode welding are shown.

Welding techniques and manganese concentrations in blood and brain: Results from the WELDFUMES study

This study used whole-brain mapping to investigate the effect of different welding processes on manganese (Mn) accumulation in the brain. Exposure measurements were performed at the welders’ workplaces about 3 weeks before a magnetic resonance imaging (MRI) examination. The welders were categorized into three main groups based on welding method, and the T1-relaxation rate (R1) was measured using quantitative MRI (qMRI). Welders using shielded metal arc welding (SMAW) were found to have lower accumulations of total Mn in clusters encompassing white matter, thalamus, putamen, pallidum, and substantia nigra compared with welders using inert gas tungsten arc welding (GTAW) or continuous consumable electrode arc welding (CCEAW). A positive correlation was found between Mn in red blood cells (Mn-RBC) and R1 in a region encompassing pre-and post-central gyri. The results of this study show that the accumulation of free, bound, or compartmentalized Mn ions in the brain differed depending on the welding method used. These differences were predominately located in the basal ganglia but were also found in regions encompassing white matter. The level of Mn-RBC was correlated to the deposition of Mn in the left primary somatosensory and motor cortex and may therefore be linked to neurological and neurobehavioral symptoms.

Dissimilar joining of aluminum alloy and low-alloy carbon steel by resistance spot welding

In this work, the resistance spot welding (RSW) process was performed to join aluminum alloy and low-alloy carbon steel plates. The macro characteristics including nugget diameters and indentation rates, microstructure and tensile-shear strength of RSW joints were investigated. The results showed that the nugget of the RSW joints comprises a ‘bowl’ shape nugget on the aluminum side and an elliptical shape nugget on the steel side. Also, the intermetallic compound (IMC) layers containing Fe4Al13 and Fe2Al5 were formed around the aluminum/steel interface with the steel side having a tongue-shape and the aluminum side having a needle-shape. According to metallurgical evaluation and temperature distribution of RSW joints analyzed by the finite element method, the nugget on the aluminum side contained the dendritic grains and equiaxed dendritic grains. The nugget on the steel side consisted of a large amount of bainite and a small amount of coarse lath martensite. The nugget diameters and the indentations rates of RSW joints increased when increasing either welding current or welding time, and decreased when increasing the electrode pressure. The maximum values of nugget diameter and indentation rate of RSW joints were 9.076 mm and 4.144% when using the welding current of 16 kA, welding time of 450 ms and electrode force of 3 kN. In tensile-shear tests, the RSW joints showed a shear-off fracture mode. When increasing the welding current, welding time or electrode force, the tensile-shear strength of RSW joints increased first, and then reached a maximum, and finally decreased. The welding current of 16 kA, the welding time of 300 ms, and the electrode pressure of 3 kN were considered as the optimal welding parameters in the present study which resulted in the maximum tensile-shear strength of 2.24 kN. In addition, the IMC layers of the RSW joints exhibited a uniform and continuous appearance with a thickness of approximately 1.9 μm, and the IMC layer in the central area was thicker than that in the edge area.

The High-Cycle Tensile-Shear Fatigue Properties and Failure Mechanism of Resistance Spot-Welded Advanced High-Strength Steel with a Zn Coating.

Advanced high-strength steels (AHSSs) with Zn coatings are commonly joined by the resistance spot welding (RSW) technique. However, Zn coatings could possibly cause the formation of liquid metal embrittlement (LME) cracks during the RSW process. The role of a Zn coating in the tensile-shear fatigue properties of a welding joint has not been systematically explored. In this study, the fatigue properties of tensile-shear RSW joints for bare and Zn-coated advanced high-strength steel (AHSS) specimens were comparatively studied. In particular, more severe LME cracks were triggered by employing a tilted welding electrode because much more stress was caused in the joint. LME cracks had clearly occurred in the Zn-coated steel RSW joints, as observed via optical microscopy. On the contrary, no LME cracks could be found in the RSW joints prepared with the bare steel sheets. The fatigue test results showed that the tensile-shear fatigue properties remained nearly unchanged, regardless of whether bare or Zn-coated steel was used for the RSW joints. Furthermore, Zn mapping adjacent to the crack initiation source was obtained by an electron probe micro-analyzer (EPMA), and it showed no segregation of the Zn element. Thus, the failure of the RSW joints with the Zn coating had not initiated from the LME cracks. It was concluded that the fatigue cracks were initiated by the stress concentration in the notch position between the two bonded steel sheets.

Microstructure and mechanical properties of similar and dissimilar resistance spot welded DC04 and HRP6222 (DD11) steels

Abstract Low carbon steels are frequently preferred in the automotive industry. The most preferred welding method in vehicle body manufacturing is resistance spot welding (RSW). In this study, RSW joints of DC04 and HRP6222 steels were carried out at two different electrode forces (2.1 kN, 2.4 kN) and three different welding currents (4 kA, 6 kA, 8 kA). The effects of different welding parameters on microstructure, tensile shear force, failure mode and microhardness were investigated. So, the focus was on optimizing the welding parameters. As a result, the RSW process caused the formation of three different regions in the microstructure (the base metal, the heat affected zone and the weld metal). It was observed that the tensile shear force increased as the welding current and electrode force increased. After the tensile shear tests, two different failure modes occurred (interface and pull-out type). Hardness values showed a linear relationship with tensile shear force results. In addition, a significant increase in hardness values was observed from the base metal to the weld metal in all welding parameters.

MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED RESISTANCE-SPOT-WELDED JOINTS

To advance automotive lightweighting, a study was conducted on steady-state magnetic-field-assisted resistance spot welding of 6082 aluminum alloy (1.0 mm thick) and 7075 aluminum alloy (1.5 mm thick) with thermal compensation. The influence of varying magnetic induction intensity on the microstructure and tensile properties of welded joints was assessed under the same welding current, time and electrode pressure. The results revealed that the Lorentz force induced by magnetic induction intensity ranging from 0 mT to 60 mT could promote an outward circumferential movement of molten metal within the weld nugget. This movement, at the same time, led to an increase in the weld-nugget size and improved the efficiency of thermal resistance. At a magnetic induction intensity of 80 mT, no weld-nugget formation occurred in the welded joint. Microstructural observations at magnetic induction intensities of 0 mT and 60 mT revealed equiaxed grains at the nugget center and columnar dendrite grains at the nugget edge in the welded joints. The Lorentz force accelerated the weld cooling rates after the addition of magnetic field, refining the weld grain structure. Tensile properties of the welded joints gradually improved with increasing the magnetic induction intensity from 0 mT to 60 mT, driven by the weld nugget size expansion and weld grain refinement. Overall, the present study indicated that the magnetic induction intensity of 60 mT resulted in the most favorable comprehensive mechanical properties of the investigated welded joints.

Influence of submerged arc welding process parameters and metallurgical behaviour in a thick carbon steel section for boiler application

AbstractThe aim of the research is to investigate the weldability of thick sections of carbon steel using submerged arc welding with varying process parameters. The experimental design for joining thick carbon steel involves manipulating input weld process parameters such as current (A), voltage (V), weld speed (mm/h), and weld electrode diameter (mm). The quality of the weld material is assessed based on transformations in microstructure, weld hardness measured by Brinell hardness number, and tensile strength (MPa). It is crucial to note that the grain structure and metallurgical behavior of other hard materials may differ significantly. The presence of carbon in the ferrite phase has led to the formation of bainite, martensite, and composites of martensite and austenite within the weld zone, as confirmed by high‐resolution microscopy. The weldment‘s hardness has increased from 242.5 HV 30 in the base metal to 316.4 HV 30 in the weldment due to metallurgical alterations in the microstructure. Weld energy input emerges as the primary factor influencing weld quality. With increasing weld current and voltage, there is a corresponding increase in the joined metal, resulting in improved characteristics in the weld structure, particularly at maximal energy input and welding speed. In the context of boiler applications, understanding the weldability of thick carbon steel sections is paramount for ensuring structural integrity and longevity under high‐temperature and high‐pressure conditions. The optimized welding parameters identified in this study can contribute to enhancing the reliability and performance of boilers, thereby promoting safety and efficiency in industrial settings.

Comparative study of electrogas and shielded metal arc welding processes on steel A537 welded joints

In this research, the electro-gas welding process was compared with a shielded metal arc welding process for welding steel A573 from a mechanical properties point of view. Visual and radiographic inspections confirmed the soundness of weldments produced by electro-gas welding and shielded metal arc welding techniques. Various assessments were performed, including hardness, tensile strength, V-notch impact toughness, macrostructure, microstructure, and electrochemical tests. The mechanical properties of the two welding processes were closely matched, with an average tensile strength of 590 MPa for electro-gas welding and 585 MPa for shielded metal arc welding. Furthermore, the influence of welding variables, such as groove design and heat input, on the welded joints’ quality, mechanical properties, and electrochemical behavior was thoroughly examined. Dilution estimates, particularly for the electro-gas welding process, were around 35%, and a significant similarity was observed between the chemical composition determined through dilution calculations and that obtained from chemical analysis using an arc spark emission spectrometer. Notably, the electro-gas welding process demonstrated exceptional productivity, surpassing the shielded metal arc welding process by more than elevenfold. The optimum welding parameters for the electro-gas welding process were identified to achieve superior mechanical properties, low corrosion rates, and reduced consumption of the welding electrodes. This included adopting a single V type and groove angle of 30° instead of 60°, resulting in a 23% reduction in economic costs. Selecting an appropriate heat input within the range of 12 to 14 kJ/mm further contributed to enhancing overall welding efficiency.

PROGRAM AND ANALYTICAL COMPLEX OF THE INDUSTRIAL SAFETY AND HEALTH ANALYSIS SYSTEM

Aim. To investigate the quantitative characteristics of magnetic fields created during electric contact welding by various methods: contact point, arc-contact, capacitor point, contact-contact continuous and pulsating reflow. The problem being solved is the lack of necessary information on the electromagnetic safety of the specified welding methods. Methodology. A description of the proposed methodical approaches to determining the levels of magnetic fields, means of measuring them, and methods of assessing their impact on the welder's body is provided. Based on the analysis and processing of the received oscillograms and spectrograms of magnetic fields, measurements of their quantitative characteristics were performed. To determine the general level of the multifrequency magnetic field that occurs during contact welding, the proposed generalized indicator of the level of the magnetic field was used. Implications of research. It was established that during contact spot welding with a stationary machine, the magnetic field level exceeds the maximum permissible value at the workplace in the range of 50-1000 Hz at a distance of 0.3 m from the welding electrodes. During manual welding by this method, the level of the magnetic field exceeds the permissible level in the frequency ranges of 5-50, 50-1000 Hz directly near the electric cable. Condenser spot welding with direct current is characterized by exceeding the maximum allowable MP at the workplace in the high-frequency range of 1000–10000 Hz. During arc-joint welding at the workplace, exceeding the maximum allowable levels of the magnetic field was not detected. Practical implications. It is shown that the spectral composition and magnitude of the magnetic field signal is determined by the welding method itself and the initial parameters of the power sources. The obtained results can be used in the field of welding production and labor protection for the improvement of contact welding technologies and the development of measures to protect welders from the magnetic field.

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.

Consumable and nonconsumable electrode welding of high-strength 2219-T31 aluminium alloy

Consumable and nonconsumable electrode welding of high-strength 2219-T31 aluminium alloy

Digital twin-based tig welding quality prediction using electrode tip angle degradation influencing Industry 5.0 in manufacturing sector

Automation in tungsten inert gas (TIG) welding is important to achieve high production rates and quality in manufacturing industries. To improve the welding process and quality inspection methodologies, the intelligent welding robot and vision-based inspection system have been researched and deployed in many engineering fields. Hence to enhance the performance and production, a digital twin-based welding system with the prediction of weld quality based on the consideration of electrode tip angle degradation. The proposed system will capture real-time electrode tip angle and weld pool temperature using a forward looking infrared (FLIR) camera along with welding current and speed correlated with tensile strength as the output parameter. To validate the analysis, support vector machine (SVM) and random forest (RF) algorithms were implemented in which the RF model performs well on the prediction of welding quality by mapping with tensile strength. RF model confirms maximum accuracy of 90% with 0.29 seconds computation time to perform prediction on the next execution of welding operation. It is inferred that if the tip angle degradation increases consecutively welding current decreases drastically impacting the weld quality from good to poor. To forecast the need for immediate or scheduled maintenance to reduce the tip angle degradation, a linear regression algorithm is implemented to enable the inspection engineer to perform maintenance without delay in production.

Monolithic 24 cm2 flexible triple-junction solar cell encapsulated module based on the ipsilateral electrode welding technology: erratum

This erratum corrects an error in Fig. 1 of the original paper, Appl. Opt. 63, 2815 (2024)APOPAI0003-693510.1364/AO.518102.

Element transfer, microhardness and metallurgical analysis of weld-bead using CaF2−CaO−Al2O3−BaO fluxes

This study investigates the influence of shielded metal arc welding electrode coating flux on microhardness, microstructure and element transfer. A series of multi-pass bead-on-plate studies were conducted using laboratory-developed electrodes. The flux composition has shown a significant effect on all the responses. An increase in [Formula: see text] and [Formula: see text] has shown a positive influence on nickel transfer, whereas an increase in [Formula: see text] reduces nickel transfer. The slag detachability was found good for ratio [Formula: see text]:: 1.76:0.73:0.51. Energy dispersive spectroscopy has shown inclusions rich in aluminum and oxygen with trace amounts of Ca, Mn, Ti and Si. Artificial neural network models have been developed and then compared to conventional regression predictions.

Monolithic 24 cm2 flexible triple-junction solar cell encapsulated module based on the ipsilateral electrode welding technology

The inverted metamorphic multi-junction solar cell is anticipated to be widely applied in stratospheric flight because of its exceptional properties of flexibility and light weight. We propose an ipsilateral welding technology based on Ti/Au electrodes to simplify the fabrication process of GaInP/GaAs/InGaAs solar cells and encapsulate large-sized flexible solar cells. After annealing at 200°C for 2 h, the Ti/Au electrode achieved a low specific contact resistivity of 2.9×10−7Ω⋅cm2. The performance of the ohmic contact remains stable after the thermal cycling tests. The Ti/Au electrode can require less heat input for welding to reduce the risk of microcrack formation of the solar cells. By employment of this electrode, a 24cm2 solar cell achieved a conversion efficiency of 34.74%. A flexible solar cell module with an efficiency of 32.82% under AM 1.5G illumination was obtained by the ipsilateral electrode welding technology.

Effect of Electrode Type and Weld Current on Service Life of Resistance Spot Weld Electrode

HSLA steels are widely preferred in the automotive industry due to their advantages of high strength, lightening of vehicle weight and formability. The fact that a lot of welding processes are carried out during the creation of the vehicle body has made the welding operations of these steels an important topic. In this study, zinc coated HX340LAD+Z sheet material was welded by RSW application in factory conditions. The welding opera-tion was carried out with different current intensities and 300 spot welds for three different electrodes, keeping the weld duration constant. After the welding trials, the shortening of the electrodes was examined and information about the electrode lifetime was obtained. The weld core diameter was measured on the sheet metal also microstructure and micro-hardness investigations were made. As a result of the findings, information was obtained about weld hardness and collapse. Determination of splashing in the HX340LAD+Z ma-terial was provided by SEM imaging and EDX studies. It was determined that F type Copper electrode was more efficient.

WO3 nanostructures produced from tungsten welding electrode scraps: Temperature influence on optical and morphological characteristics

Methods to produce WO3 nanostructures have become important due to the possibility of using this material in a wide range of technological applications. In this context, a hydrated WO3.2H2O structure was produced by the electrochemical dissolution of welding electrode scraps in an alkali aqueous solution, followed by acid precipitation. The thermal treatment of this precursor structure at 550, 700, 850, and 1000 °C was able to produce γ phase WO3 materials with a monoclinic crystalline structure at all the temperatures used, as demonstrated by XRD and RAMAN characterization. However, different treatment temperatures can yield materials with diverse morphologies and optoelectronic properties. For example, the material produced at 1000 °C presented an elongated nanorod shape, with dimensions, from the base, ranging between 50 and 500 nm, a length of about 4 μm, and the lowest Eg value. The spectroscopic characterization also demonstrated that above 700 °C, the thermal treatment could eliminate the crystallization water and create oxygen vacancies, mainly at 850 and 1000 °C; explaining the decrease in the Eg values with increased temperature. As proof of concept, photocatalytic degradation of the Reactive Black 5 dye demonstrated that the material produced at 1000 °C was able to discolor ca. 50% of the initial color. Broad DFT analyses were performed, carefully describing the surface properties and the influence of morphology on the material properties. Therefore, we demonstrated that a simple, fast and low-cost two-step process was successfully developed aiming at a noble reuse of residues of this important material.

Effects of post-weld heat treatment on the microstructure and properties of the matching SMAW filler metal for weld joints in MarBN steel

AbstractA detailed investigation has been carried out of the matching composition filler metal for welding MarBN steel to explore the influence of welding procedure and post-weld heat treatment (PWHT) on the microstructure and properties of the weld metal and a MarBN steel weld joint. The filler metal was in the form of a shielded metal arc welding (SMAW) electrode. With different interpass temperatures and PWHT procedures applied, the microstructure and mechanical properties, particularly toughness, of the all-weld metal deposits and welded MarBN alloy joints were examined. The differences in microstructure (grain structure, precipitates, etc.) were evaluated to provide a better understanding of how the PWHTs influence the starting conditions of the matching weld metal and welded MarBN steel joints before service. The current work found that for a 30-mm-thick all-weld metal coupon, reasonable impact toughness was achieved after PWHT of 735 °C × 8 h; longer heat treatment durations (16 h and 36 h) did not further increase the toughness. For thicker cast blocks, a PWHT of 735 °C × 16 h was needed for weld toughness comparable to the base metal, hence was considered more appropriate for actual engineering applications. Evenly distributed Laves phase precipitation was observed after 735 °C × 8 h; the precipitates gradually increased in size and area fraction as the duration increased, and appeared to be stable when approaching 36 h. Differences in the precipitation were observed between different weld regions. The weld cap region had a lower density of Laves precipitates compared to the lower weld area. From the current investigation, aspects for further investigation are also identified.

The possible solidification modes of austenitic stainless steels joints according to different chemical compositions and cooling rates

The microstructures of four welded joints of austenitic stainless steel were studied to better understand the effect of different cooling rates on the volume fraction of δ-ferrite phase, in overlay deposits obtained by SMAW process. The weld pads were carried out using E316L and E347 electrodes and adjusting welding parameters to provide high and low heat. The weld pads produced were submitted to different cooling rates, being one produced by applying higher heat input and cooling in air, and another by applying lower heat input and cooling in water. Complementary techniques of microstructural analysis were applied, such as optical emission spectrometry, optical microscopy, and quantitative image analysis. There was an increase in the volume fraction of δ-ferrite in the weld pads, executed using the welding electrode E347, as the cooling rate increased. On the other hand, it was observed the opposite effect in the weld pads manufactured with the E316L welding electrode. The results suggest that the solidification mode of E347 is ferritic-austenitic and it is austenitic-ferritic in the case of E316L.

Study of particulate emissions when using special wires for underwater welding

The article describes the study to evaluate the emissions to atmospheric air of airborne nano- and microparticles generated during underwater welding in seawater from Ajax Bay (Sea of Japan) using special wires and coated electrodes. The most commonly used underwater industrial production processes were selected: semi-automatic (mechanized) underwater welding with a welding wire, manual welding with electrodes, and semi-automatic (mechanized) underwater cutting with a welding wire for cutting. An aerosol particle counter was used to determine the mass concentration of fine aerosol particles in the air of the working area above the aquarium. The highest number of suspended particles in the atmospheric air was observed in the process of underwater welding with a welding electrode. Comparing the welding wire and the welding electrode for underwater welding, it can be concluded that the welding wire is less dangerous for people, which is confirmed by the lower amount of suspended particles emitted into the atmospheric air during its use.