TIG粉末堆焊反应合成FeAl金属间化合物层的工艺优化

采用正交试验法研究了堆焊工艺对FeA l金属间化合物堆焊层成形质量的影响,通过极差分析和方差分析,评价了堆焊工艺参数对成形质量影响的显著程度,并对堆焊工艺参数进行了优化。结果表明,堆焊电流、堆焊速度与电流之间的交互作用对堆焊层成形的影响最显著,堆焊速度对堆焊层成形质量影响较小,而粉末涂敷厚度的影响程度最小。对于Fe∶A l(原子比)为1∶2的混合粉末而言,本试验条件下能够获得较好成形的堆焊工艺参数是电流130 A、堆焊速度0.9 mm/s、粉末涂敷厚度2 mm。

Investigation on the process parameters of TIG-welded aluminum alloy through mechanical and microstructural characterization

Multi-pass TIG welding was conducted on plates(15×300×180 mm^(3))of aluminum alloy Al-5083 that usually serves as the component material in structural applications such as cryogenics and chemical processing industries.Porosity formation and solidification cracking are the most common defects when TIG welding Al-5083 alloy,which is sensitive to the welding heat input.In the experiment,the heat input was varied from 0.89 kJ/mm to 5 kJ/mm designed by the combination of welding torch travel speed and welding current.Tensile,micro-Vicker hardness and Charpy impact tests were executed to witness the impetus response of heat input on the mechanical properties of the joints.Radiographic inspection was performed to assess the joint’s quality and welding defects.The results show that all the specimens displayed inferior mechanical properties as compared to the base alloy.It was established that porosity was progressively abridged by the increase of heat input.The results also clinched that the use of medium heat input(1-2 kJ/mm)offered the best mechanical properties by eradicating welding defects,in which only about 18.26% of strength was lost.The yield strength of all the welded specimens remained unaffected indica ted no influence of heat input.Partially melted zone(PMZ)width also affected by heat input,which became widened with the increase of heat input.The grain size of PMZ was found to be coarser than the respective grain size in the fusion zone.Charpy impact testing revealed that the absorbed energy by low heat input specimen(welded at high speed)was greater than that of high heat input(welded at low speed)because of low porosity and the formation of equiaxed grains which induce better impact toughness.Cryogenic(-196℃)impact testing was also performed and the results corroborate that impact properties under the cryogenic environment revealed no appreciable change after welding at designated heat input.Finally,Macro and micro fractured surfaces of tensile and impact specimens were analyzed using Stereo and Scanning Electron Microscopy(SEM),which have supported the experimental findings.

Sliding Wear Behavior of a Grey Cast Iron Surface Remelted by TIG

The sliding wear behavior of a grey cast iron surface remelted by tungsten inert gas （TIG） was studied and compared with the unremelted one in the current work. To evaluate the wear behavior a Pin-on-Disk wear test machine was used. Pins which were prepared from the samples with the remelted layers of different thicknesses of 1.2, 1.8, 2.5 and 3 turn were worn on an AISID3 steel counterface having a hardness of 63HRC under the applied loads of 54, 76 and gg N at a constant sliding velocity of 0.45 m/s. Scanning electron microscopy （SEM） equipped with energy dispersive X-ray analysis （EDS） and X-ray diffraction （XRD） techniques were used to characterize worn surface and subsurface and also wear debris obtained from the wear tests under different test conditions. Results showed that surface remelted grey cast iron have better wear properties for all applied normal loads in comparison with unremelted ones. Microscopic studies on the worn surfaces and subsurfaces of samples revealed that dominant wear mechanism for surface remelted samples was mild oxidative, while it was severe for unremelted samples. Increasing remelted layer thickness and then forming grosser microstructure lead to a decline of wear properties, whereas lower thickness of remelted layer with finer microstructure due to having higher cooling rate through remelting process can withstand better against wear.

Prevention of carbon migration in 9% Cr/CrMoV dissimilar welded joint by adding tungsten inert gas overlaying layer

High chromium （9-12% Cr） steels with excellent heat resistance and CrMoV steels with good toughness were potential candidates for combined rotor for steam turbine operated over 620℃. Two welding techniques were used to fabricate 9% Cr and CrMoV dissimilar welded joint. The results show that the carbon migration only appears in the specimen using narrow gap submerged arc welding （NG-SAW） technique, yet it can be effectively prevented by adding tungsten inert gas （TlG） overlaying process before the NG-SAW. The carbon migration occurred in NG-SAW resulting from the sharp transition of the strong carbide-forming element Cr between the weld （-2.7 wt%） and the base metal （- 9 wt%）. On the contrary, the application of TIG overlaying layers can promote the diffusion of Cr element, and therefore result in its much smaller concentration gradient. That is to say, a gentle transition zone of Cr element can be created among the SAW weld, TIG overlaying layers and the base metal, which effectively prevents the carbon migration and therefore produces a decreased carbon concentration adjacent to the fusion line.

Acoustic Emission Studies on Weld Bead Defects in Nuclear Grade SS 316L Materials

This paper contributes about the behaviour of Acoustic Emission (AE) signatures of implanted weld defects of SS 316L materials. Lack of penetration and lack of side fusion defects were implanted in weld bead region of the materials. Tungsten Inert Gas Welding (TIG) is adopted to weld the Stainless Steel (SS316L) nuclear grade materials. The material is fabricated with dimensions of 140 × 16 × 10 mm and AE signatures are studied under preload conditions. Mechanical Jig is fabricated to maintain constant load in concentrated weld region. When external load is applied on the weld region, the deformed specimen experiences acoustic emission signals form the weld defect region which are potential source of releasing stress energy. Liner Location Technique (LLT) is adopted for AE singal studies and the generated signal is processed by 2-channel USB—AE node and AE-WIN software. The tests are conducted on two different samples having each defect. A conventional NDT method i.e. X-ray Radiography is conducted on the samples to know the defect ranging and correlated with AE signatures. This study will be helpful to standardize the AE signals for different implanted weld defects of SS 316L materials and it is found that, the parameter “counts vs. amplitude” has given the widest distinction with respect to the type of defects.

Cavitation Erosion Behavior of as-Welded Cu12Mn8Al3Fe2Ni Alloy

Cavitation erosion behavior of as-welded Cu12Mn8Al3Fe2Ni alloy in 3.5% NaCl aqueous solution was studied bymagnetostrictive vibratory device for cavitation erosion. The results show that the cavitation erosion resistance ofthe as-welded Cu12Mn8Al3Fe2Ni alloy is much more superior to that of the as-cast one. The cumulative mass lossand the mass loss rate of the as-welded Cu12Mn8Al3Fe2Ni alloy are almost 1/4 that of the as-cast one. SEM analysisof eroded specimens reveals that the as-cast Cu12Mn8Al3Fe2Ni alloy is attacked more severely than the as-weldedone. Microcracks causing cavitation damage initiate at the phase boundaries.

Principles Giving High Penetration under the Double Shielded TIG Process

A new welding method named double shielded tungsten inert gas （TIG） has been developed to improve the TIG weld penetration. The main principles to increase the weld depth have been discussed. Results show that the critical oxygen content in the weld pool is around 100 × 10 -6 as the temperature coefficient of surface tension changes from negative to positive. The tracer test using pure silver shows that the direction of Marangoni convection changes as the oxygen content increases in the weld pool. The effect of arc constriction on the weld depth has been evaluated on a water-cooled copper plate, and the result indicates that the torch of double shielded can give a more powerful arc. Heavy oxide on the pool surface has undesirable impacts on the increasing of weld depth as the oxygen excessively accumulates in weld pool. It is possible to form chromium oxide in the weld process, while the iron oxide may form as the weld surface exposes to the air after the shielded gas moving away.

Effect of δ Phase on Microstructure and Hardness of Heat-Affected Zone in TIG-Welded GH4169 Superalloy

The GH4169 superalloy with different content ofδ-Ni3Nb phase was welded by tungsten inert gas welding.A detailed study of microstructure and hardness of heat-affected zone(HAZ)was performed in both as-welded and aged state.The results show that the precipitation ofδphase,especially the intergranularδphase,can lead to the enrichment of Nb and Mo elements,which promote the formation ofγ/Laves eutectic constituent at grain boundaries in HAZ.In as-welded state,the hardness decreases first and then increases(exhibiting a"V"shape)with distance away from fusion line in HAZ,which is governed by grain size.After aging treatment,however,theγ″phase plays a key role in hardness and leads to the"■"shape profiles of hardness in HAZ.

Influence of Filler on the Microstructure, Mechanical Properties and Residual Stresses in TIG Weldments of Dissimilar Titanium Alloys

The influence of titanium alloy(Ti–5 Al–2.5 Sn) and commercially pure titanium(cp Ti) as fillers on dissimilar pulsed tungsten inert gas weldments of Ti–5 Al–2.5 Sn/cp Ti was investigated in terms of microstructure, mechanical/nano-mechanical properties, and residual stresses. A partial martensitic transformation was observed in the weldments for all the welding conditions due to high heat input. The microstructure evolved in the FZ/cp Ti interfacial region was observed to be the most sensitive to the proportion of α stabilizer in the filler alloy. Furthermore, the addition of filler alloy improved the tensile properties and nano-mechanical response of the weld joint owing to the increased volume of metal in the weld joint. As compared to the Ti–5 Al–2.5 Sn wire, the use of cp Ti filler wire proved to be better in terms of energy absorbed during tensile and impact tests, tensile strength and ductility of the dissimilar welds. An asymmetrical residual stresses profile was observed close to the weld centerline, with high compressive stresses on the Ti–5 Al–2.5 Sn side for both the weldments obtained with and without filler wires. This was attributed to mainly the low thermal conductivity of Ti–5 Al–2.5 Sn. The presence of residual stresses also influenced the nano-hardness profile across the weldments.

Particle Swarm Optimization of Printing Parameters for Open-source TIG-based Metal 3D Printing

Proprietary metal 3D printing is still relegated to relatively expensive systems that have been constructed over years of expensive trial-and-error to obtain optimum 3D printing settings.Low-cost open-source metal 3D printers can potentially democratize metal additive manufacturing;however,significant resources are required to redevelop optimal printing parameters for each metal on new machines.In this study,the particle swam optimization(PSO)experimenter,a free and open-source software package,is utilized to obtain the optimal printing parameters for a tungsten inert gas-based metal open source 3D printer.The software is a graphical user interface implementation of the PSO method and is designed specifically for hardware-in-loop testing.It uses the input of experimental variables and their respective ranges,and then proposes iterations for experiments.A custom fitness function is defined to characterize the experimental results and provide feedback to the algorithm for low-cost metal additive manufacturing.Four separate trials are performed to determine the optimal parameters for 3D printing.First,an experiment is designed to deposit and optimize the parameters for a single line.Second,the parameters for a single-layer plane is optimized experimentally.Third,the optimal printing parameters for a cube is determined experimentally.Fourth,the line optimization experiment is revised and reconducted using different shield gas parameters.The results and limitations are presented and discussed in the context of expanding wire arc additive manufacturing to more systems and material classes for distributed digital manufacturing.

Unveiling the Residual Stresses,Local Micromechanical Properties and Crystallographic Texture in a Ti-6Al-4V Weld Joint

In this work,the micromechanical properties,crystallographic texture,welding residual stresses and their evolution after plastic strain were investigated in a Ti-6Al-4V alloy tungsten inert gas weld joint.It was found that the welding process affected the Young modulus and microhardness values in bothαandβphases in the different regions of the weld joint.The highest microhardness and Young modulus values of a phase were recorded in the heat-affected zone,whereas the highest values of these characteristics for theβphase were found in the fusion zone(FZ).The change in the micro mechanical properties was accompanied by a change in the crystallographic texture components of the dominant a phase from(0001)<10-10>and(11-20)<10-10>components in the base material to(10-10)<11-20>and(11-20)<3-302>components in the FZ.The introduction of tensile testing resulted in a continuous stress relaxation and improved the weld joint performances.