Simulation and experiments of ultrasonic propagation in nickel-based alloy weldments

In order to obtain good understanding of complicated beam propagation behaviors in nickel-based alloy weldments , ray tracing simulation is established to predict the ultrasonic beam path in a special welded structure of dissimilar steels. Also experimental examinations are carried out to measure the ultrasonic beam paths in the weldment. Then comparisons of the modeling predictions with experimental results are presented to reveal the complicated beam propagation behaviors.

Locating flaws in anisotropic and inhomogeneous weldments using ray tracing method

Ultrasonic inspections on nickel-based alloy weldments meets some difficulties due to the curvilinear propagating paths will appear in both anisotropic and inhomogeneons welded joints. Thus, it is difficult to determine the exact location of flaws using the traditional ultrasonic testing method which is based on the assumption that the sound beam will propagate in straight lines. In order to overcome this problem, we provide a new model-based inspection approach to locate the flaws in the nickel-based alloy weldments. Furthermore, some experimental examinations are carried out to compare the locating accuracy between the traditional and the modeled-based approach. It shows that the provided model-based inspection method is more accurate than the traditional method in inspection of the nickel-based alloy weldments.

Focusing behaviors of ultrasonic phased arrays in anisotropic and inhomogeneous weldments

It meets some difficulties in the case of ultrasonic phased arrays testing for the nickel-based alloy welded joint, since the ultrasound will propagate with curvilinear paths in this kind anisotropic joint. Thus, it is hard to calculate the phased array time delays properly according to the traditional focusing approach, which is based on the assumption that the sound beam will propagate in straight lines. In order to focus the phased arrays beam in this kind anisotropic joint, we provide a modified focusing approach by combining the ray tracing method and the bisectional searching optimization. With the help of this focusing approach, the curved ray path connecting each element position in phased arrays to the expected focus point in weldments can be determined, so that it can be used to calculate the proper time delay and control the beam focusing in the anisotropic weldment. Furthermore, some experimental examinations are carried out to compare the focusing behaviors between the traditional and the modified focusing approach. It shows that the provided focusing approach is more accurate than the traditional method in the case of inspection on the nickel-based alloy weldments.

Predictability of Hardness of the Heat Affect Zone in Aluminum Weldments Cooled in Palm Oil Based on Hardness of Similarly Cooled Mild Steel and Cast Iron Weldments

The predictability of hardness of the heat affected zone (HAZ) in aluminum weldments cooled in palm oil, based on hardness of similarly cooled mild steel and cast iron weldments has been ascertained. The general model: α = 1.2769? indicates that HAZ hardness of aluminium weldment is dependant on the ratio of product to sum of HAZ hardness of mild steel and cast iron weldments cooled in palm oil under the same conditions. The maximum deviations of the model-predicted HAZ hardness values α, μ and β from the corresponding experimental values αexp, μexp and βexp were less than 0.04% indicating the reliability and validity of the model.

PROPERTIES, WELDABILITY AND APPLICATIONS OF ADVANCED WROUGHT SUPERALLOYS FOR GAS TURBINE ENGINES

Alloy selection and alloy design both require consideration of an array of material attributes, including in-service properties, weldability and fabricability. Critical properties of advanced wrought superalloys for gas turbine applications include high temperature strength, thermal stability, oxidation resistance and fatigue resistance. In this paper, the properties of twelve wrought solid-solution-strengthened and six age-hardenable superalloys are compared. Weldability is an important attribute and can be a major limiting factor in the use of certain alloys. Weldability test methods are discussed and the resistance of alloys to solidification cracking and strain-age cracking is compared. The use of weldability testing in the development of modern wrought su-peralloys is discussed with several examples cited. Finally, alloy selection for gas turbine components is outlined, taking into account both alloy properties and fabricability.

Improving the corrosion properties of magnesium AZ31 alloy GTA weld metal using microarc oxidation process

In this work, the morphology, phase composition, and corrosion properties of microarc oxidized (MAO) gas tungsten arc (GTA) weldments of AZ31 alloy were investigated. Autogenous gas tungsten arc welds were made as full penetration bead-on-plate welding under the alternating-current mode. A uniform oxide layer was developed on the surface of the specimens with MAO treatment in silicate-based alkaline electrolytes for different oxidation times. The corrosion behavior of the samples was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy. The oxide film improved the corrosion resistance substantially compared to the uncoated specimens. The sample coated for 10 min exhibited better corrosion properties. The corrosion resistance of the coatings was concluded to strongly depend on the morphology, whereas the phase composition and thickness were concluded to only slightly affect the corrosion resistance.

Models for Assessment and Computational Analysis of Hardness of the Heat Affected Zone in Water Cooled Aluminum Weldment

Models have been derived for assessment and computational analysis of the hardness of the heat affected zone (HAZ) in aluminum weldment. The general model;γ = 1.2714[(αβ/α + β)] was found to predict the HAZ hardness of aluminum weldment cooled in water as a function of the HAZ hardness of both mild steel and cast iron welded and cooled under the same conditions. The maximum deviations of the model-predicted HAZ hardness values γ, α and β from the corresponding experimental values γexp, αexp and βexp were less than 0.02% respectively.

EFFECT OF CRACK DEPTH ON ROTATION FACTOR AND FRACTURE TOUGHNESS OF WELDED JOINT

Single edge notched bend (SENB) specimens were prepared from steel weldments and crack tip opening displacement (CTOD) tests were carried out at different temperatures. Two specimen geometries, square (B×B) and rectangular (B×2B) were used with a/W ratio ranging from 0.1 to 0.5 to investigate the effect of notch depth on plastic rotation factor and CTOD toughness. The CTOD values at initiation ( δ i) and maximum load ( δ m) for shallow cracked specimens were found to be significantly higher than those for the deep notched specimens. The plastic rotation factor was experimentally determined for shallow cracked specimens and found to be about 0.2.

Optimization of gas tungsten arc welding parameters for the dissimilar welding between AISI 304 and AISI 201 stainless steels

This present study applied gas tungsten arc welding in order to join AISI 304 and AISI 201 stainless steels.The objective was to find the optimum welding condition that gave a weld bead in accordance with DIN EN ISO 25817 quality level B, pitting corrosion potential of the weld metal of not less than that of the AISI304 base metal and a ratio of delta-ferrite in austenite matrix of the weld metal of not lower than 3%.Such a ratio is a criterion widely accepted to protect the weld metal from solidification cracking. At the welding current of 75 A and by using pure argon as a shielding gas 0 to 8 vol.% and applying a welding speed in the range of 2-3.5 mm·s^(-1) was found to give a complete weld bead with an increased depthper-width ratio(promote weldability). For welding speed in the range of 3 and 3.5 mm·s^(-1)(promote corrosion resistance). Increasing the welding speed in such a range decreased the amount of delta-ferrite in the austenite matrix, and increased the pitting corrosion potential of the weld metal to be 302 mV_(SCE).This value was still lower than the pitting corrosion potential of the AISI 304 base metal. Mixing nitrogen in argon shielding gas increased the nitrogen content in the weld. The optimum condition was found when using a welding speed of 3 mm· s^(-1) and mixing 1 vol.% of nitrogen in the argon shielding gas(promote weldability and corrosion resistance). Pitted areas after potentiodynamic test were observed in the austenite in which its Cr content was relatively low.

Improvement in hot corrosion resistance of dissimilar alloy 825 and AISI 321 CO2-laser weldment by HVOF coating in aggressive salt environment at 900℃

This study investigated the hot corrosion performance of a dissimilar weldment of Ni-based superalloy and stainless steel joined by CO2-laser welding and improved by high-velocity oxy-fuel(HVOF)coating in a Na2SO4-60wt%V2O5 environment at 900℃.A dissimilar butt joint of AISI 321 and alloy 825 was fabricated by CO2-laser welding with low heat input after obtaining the optimum welding parameters by bead-on-plate trials.The metallurgical and mechanical properties of the laser weldment were evaluated.The tensile test results indicated the occurrence of fracture in the base metal AISI 321 side.The HVOF process was employed to coat Ni-20wt%Cr on the weldment.To evaluate the surface morphology of the corrosion products formed on the uncoated and Ni-20wt%Cr-coated weldments,scanning electron microscopy(SEM)analysis was performed.Energy-dispersive spectroscopy(EDS)was used to determine the different elements present on the surface scales.The existence of oxide phases on the weldments was determined by X-ray diffraction(XRD).The cross sections of the weldments were characterized by SEM with EDS line mapping analysis.The results indicated that the Ni-20wt%Cr-coated weldment exhibited superior hot corrosion resistance due to the development of Cr2O3 and NiCr2O4 protective oxide scales.

A STUDY OF ELECTROCHEMICAL BEHAVIOUR OF VARIOUS THERMAL HISTORY ZONES AND DIFFERENT PHASE STRUCTURES ON THE WELDMENT FOR LOW ALLOY STEEL 16Mn IN NITRAfE SOLUTION

The electrochemical behaviour, including free corrosion potential, free corrosion current density and polarization curve, of various thermal history zones on the weldment was measured in this paper. The weldment consisted of matrix, tempering zone. incomplete normalized zone, normalized zone, overtemperature zone, fusion line zone and weld metal zone. The electrochemical behaviour of the ferrite, pearlite and mixed structure in various zones have successfully measured. The results showed that there was a difference of free corrosion potential which is smaller than ca. 200mV between various zones and about 20-150mV potential difference between ferrite and pearlite in every zone. The free cormsion potential of fusion line zone was the most negative between various zones. The free corrosion potential of pearlite was some dozens mV more negative than ferrite. The corrosion course of various zones and of different phase structures on the weldment and their effect on corrosion attack of weldment were discussed.

A NEW METHOD FOR MEASURING LONG-TERMCREEP DEFORMATION IN A SMALL REGION

Creep deformation localization is generally found in structures at high temperamture,typically in weldments. As the heat affected zone (HAZ) in a weldment is very narrow, deformation in HAZ region can hardly be measured by conventional displacement gauge. A new method for measuring long-term local creep deformation was developed by quartz optical fiber and technique of digital image analysis. The creep deformations of base metal, weld metal and HAZ in weldments are thereby determined with crossweld specimens.

Defect detection in brazed weldment with lattice structure using ultrasonic Lamb wave technique

In this paper, defects detection in brazed weldment with lattice structure is studied using ultrasonic Lamb wave. Based on the ultrasonic guided wave theory, the frequency dispersion curves for phase and group velocity of I Cr18Ni9Ti are obtained by solving the Rayleigh-Lamb equation. The incident angles of different modes are determined through theoretical calculation and experimental analyses. Artificial defects of through-wall slots with different dimensions are made and tested. Experimental scattering effects of the fundamental symmetric mode S2 and asymmetric modes A1 and A0 are analysed and compared. The results show that mode Ao is suitable for detecting artificial defect, and the amplitude of the received signals are in good agreement with the defect size. Brazed weldment specimen containing lack of brazing with certain dimensions is made. Using the same methodology, scattering effects produced by weld defects are measured. The results show that the clutter wave brought about by the filler metal will certainly disturbs the identification of defect signal. But, when the defect is 3.0 mm in width, the presented mode Ao could be used potentially.

Experimental Study of Inducing Compressive Stress by Anti-welding Heating Treatment in a Thin Plate Weldment with Variant Temperatures

Significant compressive stress may be induced in thin plate weldment by anti-welding heating treatment (AWHT) with a temperature difference above 350℃, and an interesting phenomenon of obvious residual stress reduction on non-treated surface was discovered. The method of AWHT has no great effect on the mechanical properties including hardness, strength and toughness of the metal material. The results in the paper prompt a possibility application in shipbuilding industry.

Distribution of Inherent Strains and Residual Stressesin Medium Thickness Plate Weldment

A fundamental theory for the analysis of residual welding stresses and deformation based on the inherent strain distribution along the welded joint is introduced. Distribution of inherent strains and longitudinal residual stresses in medium thickness plate weldment is calculated and analyzed. A new method of calculating inherent strains and longitudinal residual stresses is proposed.

Defect detection in brazed weldment with lattice structure using acoustic shadow technique

Brazed weldment with lattice structure has been widely used in aerospace industry. The non-destructive testing is often difficult because of the poor inspection accessibility. The present paper illustrates how the plane-like defect lack of brazing can be detected rapidly in this kind of structure by using ultrasonic Lamb wave. Experimental weldments are prepared and weld defect are tested using S2 mode Lamb wave. Acoustic shadow technique is employed based on Lamb wave testing method. The character of the tested D-scan image and A-scan signal is studied. The experimental results show that acoustic shadow based Lamb wave testing method is effective in detecting through-wall lack of brazing. Meanwhile, the D-scan tested data can be rapidly collected and easily interpreted compared with pulse echo bused Lamb wave testing method.

Development of Fuzzy Logic System to Predict the SAW Weldment Shape Profiles

A fuzzy model was presented to predict the weldment shape profile of submerged arc welds （SAW） including the shape of heat affected zone （HAZ）. The SAW bead-on-plates were welded by following a full factorial design matrix. The design matrix consisted of three levels of input welding process parameters. The welds were cross-sectioned and etched, and the zones were measured. A mapping technique was used to measure the various segments of the weld zones. These mapped zones were used to build a fuzzy logic model. The membership functions of the fuzzy model were chosen for the accurate prediction of the weld zone. The fuzzy model was further tested for a set of test case data. The weld zone predicted by the fuzzy logic model was compared with the experimentally obtained shape profiles and close agreement between the two was noted. The mapping technique developed for the weld zones and the fuzzy logiemodel earl be used for on-line control of the SAW process. From the SAW fuzzy logic model an estimation of the fusion and HAZ can also be developed.

Effect of Hydrogen Charging on the Tensile and Constant Load Properties of an Austenitic Stainless Steel Weldment

The effect of cathodic hydrogen charging on the tensile and constant load properties was deter- mined for an austenitic stainless steel weldment comprising a 304L steel in the solution treated condition as a base metal and a 308L filler steel as a weld metal. Part of the 304L solution treated steel was separately given additional sensitization treatment to simulate the microstructure that would develop in the heat affected zone. Tests were performed at room temperature on notched round bar specimens. Hydrogen charging resulted in a pronounced embrittlement of the tested materials. This was manifested mainly as a considerable loss in the ductility of tensile specimens and a decrease in the time to failure and threshold stress of constant load specimens. The 308L weld metal exhibited the highest, and the 304L solution treated steel the lowest, resistance to hydrogen embrittlement. Hydrogen embrittlement was associated with the formation of strain induced martensite as well as a transition from brittle to ductile fracture morphology onwards the centre of the specimens.

An Exact Solution on the Stress Analysis of Fillet Welds

An exact solution on the stress distribution of fillet welds is obtained in this paper This solution can be used not only for estimating the accuracy of the present design method of fillet welds but also for establishing a new design method

Creep Behavior and Life Assessment of a Novel Heat-Resistant Austenite Steel and Its Weldment

In the present study, creep activation energy for rupture was obtained as 221-348 kJ/mol for 22Cr15Ni3.5 CuNbN due to the precipitation-hardening mechanism. The extrapolation strength of creep rupture time of 10~5 h at 923 K for22 Cr15 Ni3.5 CuNbN is more valid(83.71 MPa) predicted by the Manson-Haferd method, which is superior to other commercial heat-resistant steels. The tensile creep tests ranging from 180 to 240 MPa at 923 K were conducted to investigate creep deformation behavior of welded joint between a novel heat-resistant austenite steel 22Cr15Ni3.5 CuNbN and ERNiCrCoMo-1 weld metal. Apparent stress exponent value of 6.54 was obtained, which indicated that the ratecontrolled creep occurred in weldment during creep. A damage tolerance factor of 6.4 in the weldment illustrates that the microstructural degradation is the dominant creep damaging mechanism in the alloy. Meanwhile, the welded joints perform two types of deformation behavior with the variation in applied stress, which resulted from the different parts that govern the creep processing. Also, the morphology evolution of the fracture surfaces confirms the effects of stress level and stress state.