Transient liquid phase bonding of DD5 superalloy using a designed interlayer: microstructure and mechanical properties

Nickel based single crystal superalloy is currently widely used as the material for turbine blades in aerospace engines.However,metallurgical defects during the manufacturing process and damage during harsh environmental service are inevitable challenges for turbine blades.Therefore,bonding techniques play a very important role in the manufacturing and repair of turbine blades.The transient liquid phase(TLP)bonding of DD5 Ni-based single crystal superalloy was performed using the designed H1 interlayer.A new third-generation Ni-based superalloy T1 powder was mixed with H1 powder as another interlayer to improve the mechanical properties of the bonded joints.The res-ults show that,such a designed H1 interlayer is beneficial to the improvement of shear strength of DD5 alloy bonded joints by adjusting the bonding temperature and the prolongation of holding time.The maximum shear strength at room temperature of the joint with H1 interlayer reached 681 MPa when bonded at 1260℃for 3 h.The addition of T1 powder can effectively reduce holding time or relatively lower bond-ing temperature,while maintaining relatively high shear strength.When 1 wt.%T1 powder was mixed into H1 interlayer,the maximum room temperature shear strength of the joint bonded at 1260℃reached 641 MPa,which could be obtained for only 1 h.Considering the bonding temperature and the efficiency,the acceptable process parameter of H1+5 wt.%T1 interlayer was 1240℃/2 h,and the room tem-perature shear strength reached 613 MPa.

Dissimilar welding of high nitrogen stainless steel and low alloy high strength steel under different shielding gas composition:Process,microstructure and mechanical properties

Ar-N_(2)-O_(2)ternary shielding gas is employed in dissimilar welding between high nitrogen steel and low alloy steel.The effect of O_(2)and N_(2)is investigated based on the systematical analysis of the metal transfer,nitrogen escape phenomenon,weld appearance,nondestructive detection,nitrogen content distribution,microstructure and mechanical properties.There are two nitrogen sources of the nitrogen in the weld:high nitrogen base material and shielding gas.The effect of shielding gas is mainly reflected in these two aspects.The change of the droplet transfer mode affects the fusion ratio,N2in the shielding gas can increase nitrogen content and promote the nitrogen uniform distribution.The addition of 2%O_(2)to Ar matrix can change the metal transfer from globular transfer to spray transfer,high nitrogen base material is thereby dissolved more to the molten pool,making nitrogen content increase,ferrite decrease and the mechanical properties improve.When applying N2-containing shielding gas,arc stability becomes poor and short-circuiting transfer frequency increases due to the nitrogen escape from droplets and the molten pool.Performance of the joints is improved with N_(2)increasing,but internal gas pores are easier to appear because of the poor capacity of low alloy steel to dissolve nitrogen,The generation of pores will greatly reduce the impact resistance.4-8%N2content in shielding gas is recommended in this study considering the integrated properties of the dissimilar welded joint.

Bonding mechanisms of SiO_(2) glass and 1060 Al by ultrasonic assisted active metal soldering process

In this work,the ultrasonic assisted active metal soldering of SiO_(2) glass and Al was successfully achieved using Sn-2Ti solder filler at a low soldering temperature of 250℃in ambient atmosphere.A nano-crystallineα-Al2O3 layer with the average thickness of 13.9 nm and a nano-crystalline R-TiO_(2) layer with the average thickness of 16.2 nm are formed at the interface of Al/Sn and SiO_(2)/Sn respectively because Al elements did not diffuse from Al alloy side to SiO_(2) side,which verified that a sono-oxidation reaction had occurred during the ultrasonic assisted active metal soldering process.The soldered butt joints exhibited an average tensile strength of 25.31 MPa.

Direct conversion of CO_(2)to graphene via vapor–liquid reaction for magnesium matrix composites with structural and functional properties

Converting CO_(2)to valuable materials is attractive in environmental protection and resource utilization.In this study,a vapor-liquid interface reaction system for mass production of high-quality graphene is reported.The graphene obtained has high crystallinity and few defects during the reaction of CO_(2)and Mg melt.The growth mechanism of graphene is demonstrated in vapor-liquid interface area by combining the CO_(2)bubbles as a soft template to guide growth with the confinement effect of dense MgO nanoparticles.The quality of the graphene is verified by epoxy composites with high electromagnetic shielding effectiveness.Additionally,the V-L reaction method ingeniously solves the dispersion of graphene in metal,providing a preparation strategy of Mg matrix composites with structure and function integration.

Microstructure and microhardness of aluminium alloy with underwater and in-air wire-feed laser deposition

This study carried out the underwater and in-air wire-feed laser deposition of an aluminium alloy with a thin-walled tubular structure. For both the underwater and in-air deposition layers, both were well-formed and incomplete fusion, cracks, or other defects did not exist.Compared with the single-track deposition layer in air, the oxidation degree of the underwater single-track deposition layer was slightly higher.In both the underwater and in-air deposition layers, columnar dendrites nucleated close to the fusion line and grew along the direction of the maximum cooling rate in the fusion region(FR), while equiaxed grains formed in the deposited region(DR). As the environment changed from air to water, the width of DR and height of FR decreased, but the deposition angle and height of DR increased. The grain size and ratio of the high-angle boundaries also decreased due to the large cooling rate and low peak temperature in the water environment.Besides, the existence of a water environment benefitted the reduction of magnesium element burning loss in the DR. The microhardness values of the underwater deposition layer were much larger than those of the in-air layer, owing to the fine grains and high magnesium content.

An integrated machine learning model for accurate and robust prediction of superconducting critical temperature

Discovering new superconductors via traditional trial-and-error experimental approaches is apparently a time-consuming process,and the correlations between the critical temperature(Tc) and material features are still obscure.The rise of machine learning(ML) technology provides new opportunities to speed up inefficient exploration processes,and could potentially uncover new hints on the unclear correlations.In this work,we utilize open-source materials data,ML models,and data mining methods to explore the correlation between the chemical features and Tcvalues of superconducting materials.To further improve the prediction accuracy,a new model is created by integrating three basic algorithms,showing an enhanced accuracy with the coefficient of determination(R2) score of 95.9 % and root mean square error(RMSE) of 6.3 K.The average marginal contributions of material features towards Tcvalues are estimated to determine the importance of various features during prediction processes.The results suggest that the range thermal conductivity plays a critical role in Tcprediction among all element features.Furthermore,the integrated ML model is utilized to screen out potential twenty superconducting materials with Tcvalues beyond 50.0 K.This study provides insights towards Tcprediction to accelerate the exploration of potential high-Tcsuperconductors.

Effects of Ni on microstructure and properties of aluminum- stainless steel TIG welding-brazing joint with AI-Si filler

Effects of Ni on microstructure and properties of aluminum-stainless steel TIG welding-brazing joint with Al-Si filler were studied. Different mass percentage of Ni powder was added in the flux separately. Results of tensile tests show that a significant improvement on mechanical properties of the butt joint is obtained using the modified flux. Moreover, obvious differences on microstructures of the interfaces were observed with Ni addition, that two intermetallic compound （IMC） layers at the interface change to one layer and the IMC thickness also decreases. Finally, effect mechanism of Ni was analyzed and discussed. Ni addition leads to an enrichment of element Si at the brazing interface, and furthermore suppresses the formation of intermetaUic compound. The reduction of IMC thickness is the main reason for the improvement of joint properties.

Microstructure and mechanical properties of E36 steel joint welded by underwater wet welding

The microstructure and mechanical properties of E36 steel joint welded by underwater welding using flux-cored wire are comprehensively investigated. The welding depth, welding current and welding voltage is 4 m, 130 A and 32 V, respectively. The weld metal is ferrite which varies in size, with carbide particles distributed on it, while the microstructure of HAZ is mixture of martensite of different size and some tempered structure. The microhardness of the weld metal is 190 HV. Almost all the tensile specimens fracture in weld metal and the average tensile strength of joint is 390 MPa, which is equal to 80% that of base metal. The tensile fracture morphology of joint presents obviously the characterization of brittle fracture, which displays the features of cleavage fracture and intergranular fracture.

Electron beam welding of SiCp/2024 and 2219 aluminum alloy

SiCp/2024 matrix composites reinforced with SiC particles and 2219 aluminum alloy were joined via centered electron beam welding and deflection beam welding,respectively,and the microstructures and mechanical properties of these joints were investigated.The results revealed that SiC particle segregation was more likely during centered electron beam welding(than during deflection beam welding),and strong interface reactions led to the formation of many Al4C3 brittle intermetallic compounds.Moreover,the tensile strength of the joints was 104 MPa.The interface reaction was restrained via deflection electron beam welding,and only a few Al4C3 intermetallic compounds formed at the top of the joint and heat affected zone of SiCp/Al.Quasi-cleavage fracture occurred at the interface reaction layer of the base metal.Both methods yielded a hardness transition zone near the SiCp/2024 fusion zone,and the brittle intermetallic Al4C3compounds formed in this zone resulted in high hardness.

Thermo-mechanical interaction between aluminum alloy and tools with different profiles during friction stir welding

The influence of the tool profiles on the thermo-mechanical interaction between AA6061-T6 workpiece and tool during friction stir welding was investigated. A customized experimental setup was employed to measure the feature points temperature and tool spindle torque in the process of FSW. Microstructure and tensile properties of stir zone (SZ) were characterized. Results indicate that the shoulder and pin geometries were responsible for the heat generation, tool torque variation at the plunging stage as well as the cross section contour of SZ, respectively. Finer grains in SZ resulted from flutes on shoulder and grooves on pin. Flat faces on the pin resulted in inhomogeneous grain size. Weld with higher 0.2% yield strength of 173 MPa was obtained by using the cylindrical pin tool while higher elongation weld of 32.0% was produced with triflat threaded pin tool.

Wire arc additive manufacturing of a heat-resistant Al-Cu-Ag-Sc alloy:microstructures and high-temperature mechanical properties

With a high energy efficiency,low geometric limitation,and low cracking susceptivity to cracks,wire arc additive manufacturing(WAAM)has become an ideal substitute for casting in the manufacturing of load-bearing high strength aluminum components in aerospace industry.Recently,in scientific researches,the room temperature mechanical performance of additive manufactured high strength aluminum alloys has been continuously broken through,and proves these alloys can achieve comparable or even higher properties than the forged counterpart.Since the aluminum components for aerospace usage experience high-low temperature cycling due to the absence of atmosphere protection,the high temperature performances of additive manufactured high strength aluminum alloys are also important.However,few research focuses on that.A special 2319Ag Sc with 0.4 wt.%Ag and 0.2 wt.%Sc addition designed for high temperature application is deposited successfully via cold metal transfer(CMT)based on WAAM.The microstructures and high temperature tensile properties are investigated.The results show that the as-deposited 2319Ag Sc alloy presents an alternate distribution of columnar grains and equiaxed grains with no significant textures.Main second phases are Al_(2)Cu and Al3Sc,while co-growth of Al_(2)Cu and bulk Al_(3)Sc is found on the grain boundary.During manufacturing,nanoscale Al_(2)Cu can precipitate out from the matrix.Ag and Mg form nano-scaleΩphase on the Al_(2)Cu precipitates.At 260℃,average yield strengths in the horizontal direction and vertical direction are 87 MPa±2 MPa,87 MPa±4 MPa,while average ultimate tensile strengths are 140 MPa±7 MPa,141 MPa±11 MPa,and average elongations are 11.0%±2.5%,13.5%±3.0%.Anisotropy in different directions is weak.

Numerical analysis of thermal fluid transportation during electron beam welding of 2219 aluminum alloy plate and experimental validation

A three-dimensional mathematical model using volume-of-fluid method is developed to investigate the heat transfer, fluid flow and keyhole dynamics during electron beam welding of 2219 aluminum alloy plate. In the model, an adaptive heat source is employed to simulate the heating process of electron beam. Fluid flow is mainly driven by surface tension, thermo-capillary force, recoil pressure, hydrostatic pressure and thermal buoyancy. The thermal-fluid transport behaviors of welding pool during the drilling and backfilling stages of keyhole and the formation reason of the nail-shaped weld with an arc crater are systematically analyzed. Finally, all calculation results are validated by experiments and show good agreements.

Controlling delayed cracks in welded joints of MCQTT steel by welding with trailing impacting and rolling

30CrMnSi, one kind of the medium-carbon quenching and tempering steel（ MCQTT） , has been widely utilized in some industrial fields. However, just like some other MCQTT, this kind of steel also faces such problem as delayed cracking in its welded joints. In this paper, the delayed cracking and microstructure of the joints of 30CrMnSi steel were researched by SEM. Moreover, a method called welding with trailing impacting and rolling （WTIR） was utilized to solve the delayed cracking problem by decreasing the residual welding stress in the joint of 30CrMnSi. The crack-free joints of 30CrMnSi steel were obtained by using optimized parameters.

Understanding the changing mechanism of arc characteristics in ultrasound-magnetic field coaxial hybrid gas tungsten arc welding

Ultrasound-magnetic field coaxial hybrid Gas Tungsten Arc Welding(U-M-GTAW)is proposed as a means to control arc characteristics.The arc characteristics and the mechanism to change them,in an ultrasound-magnetic field coaxial hybrid GTAW,were studied by both experimental and theoretical analyses.The results showed that a periodic rotation and compression of the arc shape were obtained in U-M-GTAW and the arc energy was also enhanced.The most obvious compression of the arc shape in U-M-GTAW was obtained,compared with GTAW,M-GTAW and U-GTAW.At the same time,a periodic rotation of the arc was observed in U-M-GTAW.The geometric parameters of the arc shape in U-M-GTAW are reduced more than double compared with traditional GTAW.The arc voltage in the hybrid GTAW was increased,especially in the U-M-GTAW.The electromagnetic force and acoustic radiation force were the main factors for the change of arc characteristics in the U-M-GTAW.

3D FEM analysis of welding residual stress and deformation of aero-engine blisk

Aero-engine blisk welded by electron beam welding（EBW） method is a complicated structure. Fixtures were used to control the deformation of blisk during its manufacturing process. Finite element method was utilized to study the evolution of the welding residual stress and deformation of this structure. In which an attenuation function was applied to the double ellipsoid heat source model based on the characteristic of EBW, and the effects of fixtures on the welding residual stresses and deforamtion were also reserached. The simulation results showed that the temperature contour of weld cross section vertical to the weld centerline followed a ＇＂ V＂ shape. Moreover, large welding residual stress and distortion were found in the interface between blisk and fixtures. The stress concentration was reduced sufficiently in starting and end part of weldment as the fixtures were renmved after welding process, while the removing operation had almost no effects on the welding residual stress in the middle section of weld bead.

Metal transfer characteristics of tandem narrow gap GMAW for flat welding position

A series of experiments of tandem narrow gap GMAW for flat welding position were carried out. The arc behavior and metal transfer process were observed by a high-speed photography system. The effects of the welding parameters on the metal transfer were investigated. The results show that the arc behavior and metal transfer process of tandem narrow gap GMA W are different from these of bead-on-plate tandem GMA W. The arc behavior and metal transfer process are influenced by the distance between the two wires, the peak voltage, the pulse frequency and the peak time. With the increase of the distance between the two wires, the metal transfer mode gradually transforms from one pulse-multi droplets into one pulse-one droplet, and the average welding current increases. With the increase of the peak voltage, pulse frequency or peak time, the metal transfer mode transforms from one pulse-one droplet into one pulse-multi droplets, and the arc tends to occur between the wire and the sidewall.

Interface microstructure and formation mechanism of ultrasonic spot welding for Al-Ti dissimilar metals

The present study focuses on interface microstructure and joint formation.AA6061 aluminum alloy(Al)and commercial pure titanium(Ti)joints were welded by ultrasonic spot welding(USW).The welding energy was 1100-3200 J.The Al-Ti joint appearance and interface microstructure were observed mainly via optical microscopy and field emission scanning electron microscopy.Results indicated that a good joint can be achieved only with proper welding energy of 2150 J.No significant intermetallic compound(IMC)was found under all conditions.The high energy barriers of Al-Ti and difficulties in diffusion were the main reasons for the absence of IMC according to kinetic analysis.The heat input is crucial for the material plastic flow and bonding area,which plays an important role in the joint formation.

3D Printing of Tough Hydrogel Scaffolds with Functional Surface Structures for Tissue Regeneration

Hydrogel scaffolds have numerous potential applications in the tissue engineering field.However,tough hydrogel scaffolds implanted in vivo are seldom reported because it is difficult to balance biocompatibility and high mechanical properties.Inspired by Chinese ramen,we propose a universal fabricating method(printing-P,training-T,cross-linking-C,PTC&PCT)for tough hydrogel scaffolds to fill this gap.First,3D printing fabricates a hydrogel scaffold with desired structures(P).Then,the scaffold could have extraordinarily high mechanical properties and functional surface structure by cycle mechanical training with salting-out assistance(T).Finally,the training results are fixed by photo-cross-linking processing(C).The tough gelatin hydrogel scaffolds exhibit excellent tensile strength of 6.66 MPa(622-fold untreated)and have excellent biocompatibility.Furthermore,this scaffold possesses functional surface structures from nanometer to micron to millimeter,which can efficiently induce directional cell growth.Interestingly,this strategy can produce bionic human tissue with mechanical properties of 10 kPa-10 MPa by changing the type of salt,and many hydrogels,such as gelatin and silk,could be improved with PTC or PCT strategies.Animal experiments show that this scaffold can effectively promote the new generation of muscle fibers,blood vessels,and nerves within 4 weeks,prompting the rapid regeneration of large-volume muscle loss injuries.

Laser-induced combustion joining of C_(f)/Al composites and TC4 alloy

The C_(f)/Al composites were joined to the TC4 alloy via the laser-induced combustion joining method.The exothermic reaction of the interlayer provided the required energy for the joining process.By combining the theoretical calculation and experiment,the chemical composition of the Ni−Al−Zr interlayer was designed.The microstructure and mechanical properties of the joint were investigated.The results show that the addition of Zr slightly weakened the combustion reaction of exothermic interlayer but played a key role in the successful joining.Ni−Al−Zr interlayer reacted with substrates,forming a TiAl_(3)layer adjacent to TC4 alloy and NiAl_(3),Ni_(2)Al_(3)layers adjacent to the C_(f)/Al composites.Zr content dominated the microstructure and shear strength of the joint.When the Zr content was 5 wt.%under the joining pressure of 2 MPa,the joint had a maximum shear strength of 19.8 MPa.

Material flow behavior and microstructural evolution during refill friction stir spot welding of alclad 2A12-T4 aluminum alloy

In this study, we used the stop-action technique to experimentally investigate the material flow and microstructural evolution of alclad 2A12-T4 aluminum alloy during refill friction stir spot welding.There are two material flow components, i.e., the inward-or outward-directed spiral flow on the horizontal plane and the upward-or downward-directed flow on the vertical plane.In the plunge stage, the flow of plasticized metal into the cavity is similar to that of a stack, whereby the upper layer is pushed upward by the lower layer.In the refill stage, this is process reversed.As such, there is no obvious vertical plasticized metal flow between adjacent layers.Welding leads to the coarsening of S(Al2CuMg) in the thermo-mechanically affected zone and the diminishing of S in the stir zone.Continuous dynamic recrystallization results in the formation of fine equiaxed grains in the stir zone, but this process becomes difficult in the thermo-mechanically affected zone due to the lower deformation rate and the pinning action of S precipitates on the dislocations and sub-grain boundaries, which leads to a high fraction of low-angle grain boundaries in this zone.