Low temperature friction stir welding of P91 steel

Bead-on-plate friction stir welds were made on P91 alloy with low and high rotational speeds(100 and 1000 RPM) to study their effects on weld microstructural changes and impression creep behavior. Temperatures experienced by the stir zone were recorded at the weld tool tip. Different zones of welds were characterized for their microstructural changes, hardness and creep behavior(by impression creep tests). The results were compared with submerged arc fusion weld. Studies revealed that the stir zone temperature with 100 RPM was well below A_(c1) temperature of P91 steel while it was above A_(c3) with 1000 RPM. The results suggest that the microstructural degradation in P91 welds can be controlled by low temperature friction stir welding technique.

Evaluating location specific strain rates, temperatures,and accumulated strains in friction welds through microstructure modeling

A microstructural simulation method is adopted to predict the location specific strain rates, temperatures, grain evolution, and accumulated strains in the Inconel 718 friction welds. Cellular automata based 2D microstructure model was developed for Inconel 718 alloy using theoretical aspects of dynamic recrystallization. Flow curves were simulated and compared with experimental results using hot deformation parameter obtained from literature work. Using validated model, simulations were performed for friction welds of Inconel 718 alloy generated at three rotational speed i.e., 1200, 1500, and1500 RPM. Results showed the increase in strain rates with increasing rotational speed. These simulated strain rates were found to match with the analytical results. Temperature difference of 150 K was noticed from center to edge of the weld. At all the rotational speeds, the temperature was identical implying steady state temperature(0.89 T_m) attainment.

Friction assisted solid state lap seam welding and additive manufacturing method

This paper describes results of seam welding of relatively high temperature melting materials, AISI 304, C-Mn steels, Ni-based alloys, CP Cu, CP Ni, Ti6Al4V and relatively low temperature melting material, AA6061. It describes the seam welding of multi-layered similar and dissimilar metallic sheets. The method described and involved advancing a rotating non-consumable rod(CP Mo or AISI 304) toward the upper sheet of a metallic stack clamped under pressure. As soon as the distal end of the rod touched the top portion of the upper metallic sheet, an axial force was applied. After an initial dwell time, the metallic stack moved horizontally relative to the stationery non-consumable rod by a desired length, thereby forming a metallurgical bond between the metallic sheets. Multi-track and multi-metal seam welds of high temperature metallic sheets, AISI 304, C-Mn steel,Nickel-based alloys, Cp Cu, Ti6Al4V and low temperature metallic sheets, AA6061 were obtained. Optical and scanning electron microscopy examination and 180 degree U-bend test indicated that defect free seam welds could be obtained with this method. Tensile- shear testing showed that the seam welds of AISI 304, C-Mn steel, Nickel-based alloy were stronger than the starting base metal counterparts while AA6061 was weaker due to softening. The metallurgical bonding at the interface between the metallic sheets was attributed to localized stick and slip at the interface, dynamic recrystallization and diffusion. The method developed can be used as a means of welding, cladding and additive manufacturing.

Plasmonic-enhanced electrochemical detection of volatile biomarkers with gold functionalized TiO_2 nanotube arrays

Titania nanotubular arrays （TNA） synthesized via electrochemical anodization is a stable and versatile material, widely studied for photocatalytic and sensing applications, whereas nano-sized gold particles are a known plasmonic material. Semiconductor-metal nanocomposites in isolated, embedded, or encapsulated form, when irradiated with proper light frequency can exhibit localized surface plasmon resonance （LSPR） effect. This effect can result in improved light adsorption and electrical properties of a material. In this study, we report the enhanced visible light photo-response of LSPR induced volatile organic biomarker vapor sensing at room temperature using a Au-embedded TNA electrochemical sensor. Two mechanisms are proposed. One based on classical physics （band theory）, which explains operation under non-irradiated conditions. The second mechanism is based on the coupling of classical and quantum physics （molecular orbitals）, and explains sensor operation under irradiated conditions.

Development of a field enhanced photocatalytic device for biocide of coliform bacteria

A field enhanced flow reactor using bias assisted photocatalysis was developed for bacterial disinfection in lab-synthesized and natural waters. The reactor provided complete inactivation of contaminated waters with flow rates of 50 mL/min. The device consisted of titanium dioxide nanotube arrays, with an externally applied bias of up to 6 V. Light intensity, applied voltage, background electrolytes and bacteria concentration were all found to impact the device performance. Complete inactivation of Escherichia coli W3110（- 8 × 10^3CFU/mL） occurred in 15 sec in the reactor irradiated at 25 mW/cm^2 with an applied voltage of 4 V in a 100 ppm NaCl solution. Real world testing was conducted using source water from Emigration Creek in Salt Lake City, Utah. Disinfection of natural creek water proved more challenging, providing complete bacterial inactivation after 25 sec at 6 V. A reduction in bactericidal efficacy was attributed to the presence of inorganic and organic species, as well as the increase in robustness of natural bacteria.