Solid State Welding and Application in Aeronautical Industry
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Study and Characterization of EN AW 6181/6082-T6 and EN AC
metals Article Study and Characterization of EN AW 6181/6082-T6 and EN AC 42100-T6 Aluminum Alloy Welding of Structural Applications: Metal Inert Gas (MIG), Cold Metal Transfer (CMT), and Fiber Laser-MIG Hybrid Comparison Giovanna Cornacchia * and Silvia Cecchel DIMI, Department of Industrial and Mechanical Engineering, University of Brescia, via Branze 38, 25123 Brescia, Italy; [email protected] * Correspondence: [email protected]; Tel.: +39-030-371-5827; Fax: +39-030-370-2448 Received: 18 February 2020; Accepted: 26 March 2020; Published: 27 March 2020 Abstract: The present research investigates the effects of different welding techniques, namely traditional metal inert gas (MIG), cold metal transfer (CMT), and fiber laser-MIG hybrid, on the microstructural and mechanical properties of joints between extruded EN AW 6181/6082-T6 and cast EN AC 42100-T6 aluminum alloys. These types of weld are very interesting for junctions of Al-alloys parts in the transportation field to promote the lightweight of a large scale chassis. The weld joints were characterized through various metallurgical methods including optical microscopy and hardness measurements to assess their microstructure and to individuate the nature of the intermetallics, their morphology, and distribution. The results allowed for the evaluation of the discrepancies between the welding technologies (MIG, CMT, fiber laser) on different aluminum alloys that represent an exhaustive range of possible joints of a frame. For this reason, both simple bar samples and real junctions of a prototype frame of a sports car were studied and, compared where possible. The study demonstrated the higher quality of innovative CMT and fiber laser-MIG hybrid welding than traditional MIG and the comparison between casting and extrusion techniques provide some inputs for future developments in the automotive field. -
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E.O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine International Scientific-Technical and Production Journal Issue 06 2019 Published Monthly Since 2000 English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948 EDITORIAL BOARD CONTENTS Editor-in-Chief B.E. Paton Plenary Papers for International Conference Scientists of PWI, Kyiv S.I. Kuchuk-Yatsenko (vice-chief ed.), «Consumables for Welding, Surfacing V.N. Lipodaev (vice-chief ed.), and Coating Deposition and 3D Technologies», Yu.S. Borisov, G.M. Grigorenko, A.T. Zelnichenko, V.V. Knysh, Kyiv, PWI, 4–5 June 2019 I.V. Krivtsun, Yu.N. Lankin, L.M. Lobanov, V.D. Poznyakov, Bonnel J.-M., Maurer M. and Rosert R. Submerged arc surfacing of high-alloy I.A. Ryabtsev, K.A. Yushchenko steels by flux-cored wires .................................................................................. 3 Scientists of Ukrainian Universities Golovko V.V., Stepanyuk S.N. and Ermolenko D.Yu. Dispersion modification V.V. Dmitrik, NTU «KhPI», Kharkov V.V. Kvasnitsky, NTUU «KPl», Kyiv of dendrite structure of weld metal .................................................................... 13 E.P. Chvertko, NTUU «KPl», Kyiv Yushchenko K.A., Gakh I.S., Zadery B.A., Zvyagintseva A.V. and Foreign Scientists Karasevskaya O.P. Repair surfacing of gas turbine engine blades from N.P. Alyoshin high-temperature nickel alloys with surface defects and damage ..................... 19 N.E. Bauman MSTU, Moscow, Russia Guan Qiao Goncharov I.O., Sudavtsova V.S., Mishchenko D.D., Duchenko A.M. and Beijing Aeronautical Institute, China M. Zinigrad Sokolsky V.E. Influence of refractory dispersed phases on physical-chemical Ariel University, Israel properties of slag metls of MgO–Al2O3–SiO2–CaF2 system .............................. -
Welding Technology a Suncam Continuing Education Course
033.pdf Welding Technology A SunCam Continuing Education Course Welding Technology By Roger Cantrell www.SunCam.com Page 1 of 35 033.pdf Welding Technology A SunCam Continuing Education Course Learning Objectives This course introduces the student to the concept of developing procedures for welding and brazing. Welding and brazing variables are introduced and some example concepts for applying each variable are highlighted to pique the student’s interest and perhaps lead to further study. Upon completion of this course, the student should be able to: • Understand the concept of creating a welding/brazing procedure • Identify several commonly used welding/brazing processes • Identify the more common welding/brazing variables • Appreciate some of the considerations for applying each variable 1.0 INTRODUCTION This course highlights the basic concepts of developing a welding or brazing procedure specification (WPS/BPS). There are a number of ways to approach this subject such as by process, base material, etc. It will be convenient to organize our thoughts in the format of ASME Section IX. The various factors that might influence weld quality are identified in ASME Section IX as "Welding Variables". "Brazing Variables" are treated in a separate part of Section IX in a manner similar to welding variables. The listing of variables for welding procedures can be found in ASME Section IX, Tables QW-252 through QW-265 (a table for each process). The layout of each table is similar to Figure No. 1. www.SunCam.com Page 2 of 35 033.pdf Welding Technology A SunCam Continuing Education Course Process Variable Variation (Description) Essential Supplementary Essential Nonessential Joint Backing X Root Spacing X Base P Number X Metal G Number X Filler F Number X Metal A Number X Continued in this fashion until all relevant variables for the subject process are listed. -
Guidelines for the Welded Fabrication of Nickel-Containing Stainless Steels for Corrosion Resistant Services
NiDl Nickel Development Institute Guidelines for the welded fabrication of nickel-containing stainless steels for corrosion resistant services A Nickel Development Institute Reference Book, Series No 11 007 Table of Contents Introduction ........................................................................................................ i PART I – For the welder ...................................................................................... 1 Physical properties of austenitic steels .......................................................... 2 Factors affecting corrosion resistance of stainless steel welds ....................... 2 Full penetration welds .............................................................................. 2 Seal welding crevices .............................................................................. 2 Embedded iron ........................................................................................ 2 Avoid surface oxides from welding ........................................................... 3 Other welding related defects ................................................................... 3 Welding qualifications ................................................................................... 3 Welder training ............................................................................................. 4 Preparation for welding ................................................................................. 4 Cutting and joint preparation ................................................................... -
Magnetically Impelled Arc Butt (MIAB) Welding of Chrome Plated Steel
MAGNETICALLY IMPELLED ARC BUTT (MIAB) WELDING OF CHROMIUM- PLATED STEEL TUBULAR COMPONENTS UTILIZING ARC VOLTAGE MONITORING TECHNIQUES DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By David H. Phillips, M.S.W.E ***** The Ohio State University 2008 Dissertation Committee: Professor Charley Albright, Advisor Approved by Professor Dave Dickinson _________________________________ Professor John Lippold Advisor Welding Engineering Graduate Program ABSTRACT Magnetically Impelled Arc Butt (MIAB) welding is a forge welding technique which generates uniform heating at the joint through rapid rotation of an arc. This rotation results from forces imposed on the arc by an external magnetic field. MIAB welding is used extensively in Europe, but seldom utilized in the United States. The MIAB equipment is robust and relatively simple in design, and requires low upset pressures compared to processes like Friction welding. In the automotive industry, tubular construction offers many advantages due to the rigidity, light weight, and materials savings that tubes provide. In the case of automotive suspension components, tubes may be chromium-plated on the ID to reduce the erosive effects of a special damping fluid. Welding these tubes using the MIAB welding process offers unique technical challenges, but with potential for significant cost reduction vs. other welding options such as Friction welding. Based on published literature, this research project represented the first attempt to MIAB weld chromium-plated steel tubes, and to utilize voltage monitoring techniques to assess weld quality. ii Optical and SEM microscopy, tensile testing, and an ID bend test technique were all used to assess the integrity of the MIAB weldments. -
Part 2, Materials and Welding
RULE REQUIREMENTS FOR MATERIALS AND WELDING 2002 PART 2 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2001 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Rule Change Notice (2002) The effective date of each technical change since 1993 is shown in parenthesis at the end of the subsection/paragraph titles within the text of each Part. Unless a particular date and month are shown, the years in parentheses refer to the following effective dates: (2000) and after 1 January 2000 (and subsequent years) (1996) 9 May 1996 (1999) 12 May 1999 (1995) 15 May 1995 (1998) 13 May 1998 (1994) 9 May 1994 (1997) 19 May 1997 (1993) 11 May 1993 Listing by Effective Dates of Changes from the 2001 Rules EFFECTIVE DATE 1 January 2001 (based on the contract date for construction) Part/Para. No. Title/Subject Status/Remarks 2-1-1/15.1 Permissible Variations in To clarify that mill scale is to be considered when the Dimensions – Scope plate is produced for compliance with the specified under tolerance Section 2-4-4 Piping To align ABS requirements with IACS UR P2 regarding fabrication of piping and non-destructive examinations, and to outline the requirements for the heat treatment of piping. This Section is applicable only to piping for installation on vessels to be built in accordance with the Rules for Building and Classing Steel Vessels. ii ABS RULE REQUIREMENTS FOR MATERIALS AND WELDING . 2002 PART 2 Foreword For the 1996 edition, the “Rules for Building and Classing Steel Vessels – Part 2: Materials and Welding” was re-titled “Rule Requirements for Materials and Welding – Part 2.” The purpose of this generic title was to emphasize the common applicability of the material and welding requirements in “Part 2” to ABS-classed vessels, other marine structures and their associated machinery, and thereby make “Part 2” more readily a common “Part” of the various ABS Rules and Guides, as appropriate. -
Electroslag Welding: the Effect of Slag Composition
ELECTROSLAG WELDING: THE EFFECT OF SLAG COMPOSITION ON MECHANICAL PROPERTIES by JAMES S. MITCHELL B.Sc, Queens University at Kingston, 1973 A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF APPLIED SCIENCE In the Department of METALLURGY We accept this thesis as conforming to the required standard THE UNIVERSITY OF BRITISH COLUMBIA August 1977 © James Mitchell, 1977 In presenting this thesis in partial fulfilment of the requirements for an advanced degree at the University of British Columbia, I agree that the Library shall make it freely available for reference and study. I further agree that permission for extensive copying of this thesis for scholarly purposes may be granted by the Head of my Department or by his representatives. It is understood that copying or publication of this thesis for financial gain shall not be allowed without my written permission. Department of The University of British Columbia 2075 Wesbrook Place Vancouver, Canada V6T 1W5 Date 7 ABSTRACT Previous studies of the properties of electroslag weld metal have been done using electroslag remelted ingots made under welding conditions. This procedure assumes the electrical and thermal regimes of these pro• cesses to be equivalent. To test this assumption an experimental program was devised in which the remelted metal of an ingot and weld made with each of three slag systems was analysed and the mechanical properties examined. The results show that each process imparted different properties to the remelted metal by alloy and inclusion modification. Consequently the above assumption was proved invalid. Special consideration was given to the effect of inclusion composition and overall distribution toward mechanical properties. -
Welding Process Reference Guide
Welding Process Reference Guide gas arc welding…………………..GMAW -pulsed arc…………….……….GMAW-P atomic hydrogen welding……..AHW -short circuiting arc………..GMAW-S bare metal arc welding…………BMAW gas tungsten arc welding…….GTAW carbon arc welding……………….CAW -pulsed arc……………………….GTAW-P -gas……………………………………CAW-G plasma arc welding……………..PAW -shielded……………………………CAW-S shielded metal arc welding….SMAW -twin………………………………….CAW-T stud arc welding………………….SW electrogas welding……………….EGW submerged arc welding……….SAW Flux cord arc welding…………..FCAW -series………………………..…….SAW-S coextrusion welding……………...CEW Arc brazing……………………………..AB cold welding…………………………..CW Block brazing………………………….BB diffusion welding……………………DFW Diffusion brazing…………………….DFB explosion welding………………….EXW Dip brazing……………………………..DB forge welding…………………………FOW Flow brazing…………………………….FLB friction welding………………………FRW Furnace brazing……………………… FB hot pressure welding…………….HPW SOLID ARC Induction brazing…………………….IB STATE BRAZING WELDING Infrared brazing……………………….IRB roll welding…………………………….ROW WELDING (8) ultrasonic welding………………….USW (SSW) (AW) Resistance brazing…………………..RB Torch brazing……………………………TB Twin carbon arc brazing…………..TCAB dip soldering…………………………DS furnace soldering………………….FS WELDING OTHER electron beam welding………….EBW induction soldering……………….IS SOLDERING PROCESS WELDNG -high vacuum…………………….EBW-HV infrared soldering…………………IRS (S) -medium vacuum………………EBW-MV iron soldering……………………….INS -non-vacuum…………………….EBW-NV resistance soldering…………….RS electroslag welding……………….ESW torch soldering……………………..TS -
Arc Welding and Implanted Medical Devices
A Closer Look SUMMARY Arc Weldi ng and Implanted Medical Devices Electromagnetic Interference (EMI) is the disruption of normal operation of an electronic device when it is in the vicinity of Description an electromagnetic field created by another The electrical signals generated by arc welders may interfere with the proper electronic device. function of ICDs, S-ICDs, CRT-Ds, CRT-Ps or pacing systems. This Electric arc welding refers to a process that interference may have the potential to be interpreted by the device as uses a power supply to create an electric electrical noise or as electrical activity of the heart. Such interference may arc between two metals. result in temporary asynchronous pacing (loss of coordination between the This article describes the potential heart and the device), inhibition of pacing and/or shock therapy (therapy not interaction between the arc welder and delivered when required), or inappropriate tachyarrhythmia therapy (therapy Boston Scientific implantable pacemakers and defibrillators. It also provides delivered when not required). This article refers to Gas Metal Arc Welding— suggestions to minimize potential including Metal Inert Gas (MIG) and Metal Active Gas (MAG)—Manual Metal interactions. Arc (MMA),Tungsten Inert Gas (TIG) welding, and plasma cutting. For questions regarding inductive or spot welding, or welding using current Products Referenced All CRM ICDs, S-ICDs, CRT-Ds, greater than 160 amps, please contact Technical Services. CRT-Ps, and Pacing Systems Products referenced are unregistered or Potential EMI interactions registered trademarks of Boston Scientific Corporation or its affiliates. All other trademarks Electromagnetic interference (EMI) may occur when electromagnetic waves are the property of their respective owners. -
Metal Casting and Welding (17ME45A)
[METAL CASTING AND WELDING – 17M45-A] Metal Casting and Welding (17ME45A) Prepared by: Prof. Sachin S Pande Dept of Mechanical Engineering, SECAB I E T-586109 Page 1 [METAL CASTING AND WELDING – 17M35-A] METAL CASTING AND WELDING [AS PER CHOICE ASED CREDIT SYSTEM (CBCS) SCHEME] SEMESTER – III Subject Code 17 ME 35 A IA Marks 20 Number of Lecture Hrs / Week 04 Exam Marks 80 Total Number of Lecture Hrs 50 Exam Hours 03 CREDITS – 04 COURSE OBJECTIVE 1) To provide detailed information about the moulding processes. 2) To provide knowledge of various casting process in manufacturing. 3) To impart knowledge of various joining process used in manufacturing. 4) To provide adequate knowledge of quality test methods conducted on welded and casted components. MODULE -1 INTRODUCTION & BASIC MATERIALS USED IN FOUNDRY Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy. Introduction to casting process & steps involved. Patterns: Definition, classification, materials used for pattern, various pattern allowances and their importance. Sand molding: Types of base sand, requirement of base sand. Binder, Additives definition, need and types Preparation of sand molds: Molding machines- Jolt type, squeeze type and Sand slinger. Study of important molding process: Green sand, core sand, dry sand, sweep mold, CO2 mold, shell mold, investment mold, plaster mold, cement bonded mold.Cores: Definition, need, types. Method of making cores, concept of gating (top, bottom, parting line, horn gate) and risering (open, blind) Functions and types. 10 hours MODULE -2 MELTING & METAL MOLD CASTING METHODS Melting furnaces: Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction furnace, electric arc furnace, constructional features & working principle of cupola furnace. -
Welding Procedure Guide
CWB Form 119E/2019-1 ® Welding Procedure Guide An easy to follow guide covering the preparation of welding procedure data sheets CWB Group - Industry Services All rights reserved. CWB Group 1-800-844-6790 www.cwbgroup.org Table of Contents 1.0 Introduction 1 2.0 Welding Procedure Specification (WPS) 1 3.0 Welding Procedure Data Sheet (WPDS) 1 3.1 BLOCK 1 (General Information) 3 3.2 BLOCK 2 (Process information) 4 3.3 BLOCK 3 (Joint information) 5 3.4 BLOCK 4 (Technical data) 8 3.5 BLOCK 5 (Joint Preparation) 10 3.6 BLOCK 6 (Base and Filler Material) 11 3.7 BLOCK 7 (Welding Details) 13 3.8 BLOCK 8 (Final Remarks) 17 4.0 Submission Of Welding Procedures 19 5.0 Review And Approval Of Welding Procedures 21 6.0 Sample Welding Procedure Data Sheets 23 WELDING PROCEDURE PREPARATION 1.0 Introduction This guide has been prepared to assist welding personnel with the preparation of welding procedures required as part of their company certification to CSA Standards W47.1, W47.2 and W186. The following two documents will be described: (a) Welding Procedure Specifications (b) Welding Procedure Data Sheets There will be a brief description of these documents; however, this guide will focus on the preparation of welding procedure data sheets. Each item on the welding procedure data sheet will be described and guidance will be provided to complete each section. 2.0 Welding Procedure Specification (WPS) All companies applying or certified to CSA Standards W47.1, W47.2 or W186 are required to prepare and submit welding procedure specifications to the CWB for acceptance. -
Lecture: 3 Classification of Welding Processes II Apart from Technical
Lecture: 3 Classification of Welding Processes II Apart from technical factors, welding processes can also be classified on the fundamental approaches used for deposition of materials for developing a joint. This chapter presents the classification of welding processes as welding processes and allied process used for developing a joint Keywords: Welding and allied processes, approach of classification, cast weld, resistance weld, fusion weld, solid state weld 3.1 Classification of welding processes There is another way of classifying welding and allied processes which is commonly reported in literature. Various positive processes involving addition or deposition of metal are first broadly grouped as welding process and allied welding processes as under: 1. Welding processes i. Cast weld processes ii. Fusion weld processes iii. Resistance weld processes iv. Solid state weld processes 2. Allied welding processes i. Metal depositing processes ii. Soldering iii. Brazing iv. Adhesive bonding v. Weld surfacing vi. Metal spraying This approach of classifying the welding process is primarily based on the way metallic pieces are united together during welding such as Availability and solidification of molten weld metal between components being joined are similar to that of casting: Cast weld process. Fusion of faying surfaces for developing a weld: Fusion weld process Heating of metal only to plasticize then applying pressure to forge them together: Resistance weld process Use pressure to produce a weld joint in solid state only: Solid state weld process 3.2 Cast welding process Those welding processes in which either molten weld metal is supplied from external source or melted and solidified at very low rate during solidification like castings.