National Library of Energy BETA

Sample records for welded tuff layer

  1. Infiltration and Seepage Through Fractured Welded Tuff

    SciTech Connect (OSTI)

    T.A. Ghezzehei; P.F. Dobson; J.A. Rodriguez; P.J. Cook

    2006-06-20

    The Nopal I mine in Pena Blanca, Chihuahua, Mexico, contains a uranium ore deposit within fractured tuff. Previous mining activities exposed a level ground surface 8 m above an excavated mining adit. In this paper, we report results of ongoing research to understand and model percolation through the fractured tuff and seepage into a mined adit both of which are important processes for the performance of the proposed nuclear waste repository at Yucca Mountain. Travel of water plumes was modeled using one-dimensional numerical and analytical approaches. Most of the hydrologic properly estimates were calculated from mean fracture apertures and fracture density. Based on the modeling results, we presented constraints for the arrival time and temporal pattern of seepage at the adit.

  2. Bond strength of cementitious borehole plugs in welded tuff

    SciTech Connect (OSTI)

    Akgun, H.; Daemen, J.J.K.

    1991-02-01

    Axial loads on plugs or seals in an underground repository due to gas, water pressures and temperature changes induced subsequent to waste and plug emplacement lead to shear stresses at the plug/rock contact. Therefore, the bond between the plug and rock is a critical element for the design and effectiveness of plugs in boreholes, shafts or tunnels. This study includes a systematic investigation of the bond strength of cementitious borehole plugs in welded tuff. Analytical and numerical analysis of borehole plug-rock stress transfer mechanics is performed. The interface strength and deformation are studied as a function of Young`s modulus ratio of plug and rock, plug length and rock cylinder outside-to-inside radius ratio. The tensile stresses in and near an axially loaded plug are analyzed. The frictional interface strength of an axially loaded borehole plug, the effect of axial stress and lateral external stress, and thermal effects are also analyzed. Implications for plug design are discussed. The main conclusion is a strong recommendation to design friction plugs in shafts, drifts, tunnels or boreholes with a minimum length to diameter ratio of four. Such a geometrical design will reduce tensile stresses in the plug and in the host rock to a level which should minimize the risk of long-term deterioration caused by excessive tensile stresses. Push-out tests have been used to determine the bond strength by applying an axial load to cement plugs emplaced in boreholes in welded tuff cylinders. A total of 130 push-out tests have been performed as a function of borehole size, plug length, temperature, and degree of saturation of the host tuff. The use of four different borehole radii enables evaluation of size effects. 119 refs., 42 figs., 20 tabs.

  3. Air-injection testing in vertical boreholes in welded and nonwelded Tuff, Yucca Mountain, Nevada

    SciTech Connect (OSTI)

    LeCain, G.D.

    1997-12-31

    Air-injection tests, by use of straddle packers, were done in four vertical boreholes (UE-25 UZ-No.16, USW SD-12, USW NRG-6, and USW NRG-7a) at Yucca Mountain, Nevada. The geologic units tested were the Tiva Canyon Tuff, nonwelded tuffs of the Paintbrush Group, Topopah Spring Tuff, and Calico Hills Formation. Air-injection permeability values of the Tiva Canyon Tuff ranged from 0.3 x 10{sup -12} to 54.0 x 10{sup -12} m{sup 2}(square meter). Air-injection permeability values of the Paintbrush nonwelded tuff ranged from 0.12 x 10{sup -12} to 3.0 x 10{sup -12} m{sup 2}. Air-injection permeability values of the Topopah Spring Tuff ranged from 0.02 x 10{sup -12} to 33.0 x 10{sup -12} m{sup 2}. The air-injection permeability value of the only Calico Hills Formation interval tested was 0.025 x 10{sup -12} m{sup 2}. The shallow test intervals of the Tiva Canyon Tuff had the highest air-injection permeability values. Variograms of the air-injection permeability values of the Topopah Spring Tuff show a hole effect; an initial increase in the variogram values is followed by a decrease. The hole effect is due to the decrease in permeability with depth identified in several geologic zones. The hole effect indicates some structural control of the permeability distribution, possibly associated with the deposition and cooling of the tuff. Analysis of variance indicates that the air-injection permeability values of borehole NRG-7a of the Topopah Spring Tuff are different from the other boreholes; this indicates areal variation in permeability.

  4. Multiple pass and multiple layer friction stir welding and material enhancement processes

    DOE Patents [OSTI]

    Feng, Zhili [Knoxville, TN; David, Stan A. [Knoxville, TN; Frederick, David Alan [Harriman, TN

    2010-07-27

    Processes for friction stir welding, typically for comparatively thick plate materials using multiple passes and multiple layers of a friction stir welding tool. In some embodiments a first portion of a fabrication preform and a second portion of the fabrication preform are placed adjacent to each other to form a joint, and there may be a groove adjacent the joint. The joint is welded and then, where a groove exists, a filler may be disposed in the groove, and the seams between the filler and the first and second portions of the fabrication preform may be friction stir welded. In some embodiments two portions of a fabrication preform are abutted to form a joint, where the joint may, for example, be a lap joint, a bevel joint or a butt joint. In some embodiments a plurality of passes of a friction stir welding tool may be used, with some passes welding from one side of a fabrication preform and other passes welding from the other side of the fabrication preform.

  5. The Hydrogeologic Character of the Lower Tuff Confining Unit and the Oak Springs Butte Confining Unit in the Tuff Pile Area of Central Yucca Flat

    SciTech Connect (OSTI)

    Drellack, Jr., Sigmund L.; Prothro, Lance B.; Gonzales, Jose L.; Mercadante, Jennifer M.

    2010-07-30

    The lower tuff confining unit (LTCU) in the Yucca Flat Corrective Action Unit (CAU) consists of a monotonous sequence of pervasively zeolitized volcanic tuff (i.e., mostly bedded with lesser nonwelded to poorly welded tuff; not fractured) (Bechtel Nevada, 2006). The LTCU is an important confining unit beneath Yucca Flat because it separates the alluvial and volcanic aquifers, where many underground nuclear tests were conducted, from the regional lower carbonate aquifer. Recent sub-CAU-scale modeling by Los Alamos National Laboratory in the Tuff Pile area of Yucca Flat (Boryta, et al., in review) includes postulated low-porosity, high-permeability zones (i.e., fractured welded-tuff aquifers) within the LTCU. This scenario indicates that such postulated low-porosity, high-permeability zones could provide fast-path lateral conduits to faults, and eventually to the lower carbonate aquifer. A fractured and faulted lower carbonate aquifer is postulated to provide a flow path(s) for underground test-derived contaminants to potential offsite receptors. The ramifications of such a scenario are obvious for groundwater flow and contaminant migration beneath Yucca Flat. This paper describes the reasoning for not including postulated low-porosity, high-permeability zones within the LTCU in the Tuff Pile area or within the LTCU in the Yucca Flat CAU-scale model. Both observational and analytical data clearly indicate that the LTCU in the Tuff Pile area consists of pervasively zeolitic, nonwelded to poorly welded tuffs that are classified as tuff confining units (i.e., high-porosity, low-permeability). The position regarding the LTCU in the Tuff Pile area is summarized as follows: • The LTCU in the Tuff Pile area consists of a monotonous sequence of predominantly zeolitic nonwelded to poorly welded tuffs, and thus is accurately characterized hydrogeologically as a tuff confining unit (aquitard) in the Yucca Flat-Climax Mine hydrostratigraphic framework model (Bechtel Nevada, 2006). • No welded-tuff (or lava-flow aquifers), referred to as low-porosity, high-permeability zones in Boryta et al. (in review), are present within the LTCU in the Tuff Pile area. • Fractures within the LTCU are poorly developed, a characteristic of zeolitic tuffs; and fracture distributions are independent of stratigraphic and lithologic units (Prothro, 2008). • Groundwater flow and radionuclide transport will not be affected by laterally extensive zones of significantly higher permeability within the LTCU in the Tuff Pile area. Although not the primary focus of this report, the hydrogeologic character of the Oak Spring Butte confining unit (OSBCU), located directly below the LTCU, is also discussed. The OSBCU is lithologically more diverse, and does include nonwelded to partially welded ash-flow tuffs. However, these older ash-flow tuffs are poorly welded and altered (zeolitic to quartzofeldspathic), and consequently, would tend to have properties similar to a tuff confining unit rather than a welded-tuff aquifer.

  6. STRONTIUM ISOTOPE EVOLUTION OF PORE WATER AND CALCITE IN THE TOPOPAH SPRING TUFF, YUCCA MOUNTAIN , NEVADA

    SciTech Connect (OSTI)

    B.D. Marshall; K. Futa

    2001-02-07

    Yucca Mountain, a ridge of Miocene volcanic rocks in southwest Nevada, is being characterized as a site for a potential high-level radioactive waste repository. One issue of concern for the future performance of the potential repository is the movement of water in and around the potential repository horizon. Past water movement in this unsaturated zone is indicated by fluid inclusions trapped in calcite coatings on fracture footwall surfaces and in some lithophysal cavities. Some of the fluid inclusions have homogenization temperatures above the present-day geotherm (J.F. Whelan, written communication), so determining the ages of the calcite associated with those fluid inclusions is important in understanding the thermal history of the potential repository site. Calcite ages have been constrained by uranium-lead dating of silica polymorphs (opal and chalcedony) that are present in most coatings. The opal and chalcedony ages indicate that deposition of the calcite and opal coatings in the welded part of the Topopah Spring Tuff (TSw hydrogeologic unit) spanned nearly the entire history of the 12.8-million-year-old rock mass at fairly uniform overall long-term rates of deposition (within a factor of five). Constraining the age of a layer of calcite associated with specific fluid inclusions is complicated. Calcite is commonly bladed with complex textural relations, and datable opal or chalcedony may be millions of years older or younger than the calcite layer or may be absent from the coating entirely. Therefore, a more direct method of dating the calcite is presented in this paper by developing a model for strontium evolution in pore water in the TSw as recorded by the strontium coprecipitated with calcium in the calcite. Although the water that precipitated the calcite in fractures and cavities may not have been in local isotopic equilibrium with the pore water, the strontium isotope composition of all water in the TSw is primarily controlled by water-rock interaction in the overlying nonwelded and essentially unfractured Paintbrush Group tuffs (PTn). The method of dating secondary minerals from known strontium evolution rates in rocks cannot be used in this study because it assumes the water that deposited the minerals was in isotopic equilibrium with the rock, which is not the case for the pore water in the TSw. Therefore, the evolution of the strontium isotope composition of the water that deposited the calcite, as recorded by the strontium coprecipitated with calcium in the calcite, was used to develop a model for determining the age of the calcite.

  7. Laboratory studies of radionuclide migration in tuff

    SciTech Connect (OSTI)

    Rundberg, R.S.; Mitchell, A.J.; Ott, M.A.; Thompson, J.L.; Triay, I.R.

    1989-10-01

    The movement of selected radionuclides has been observed in crushed tuff, intact tuff, and fractured tuff columns. Retardation factors and dispersivities were determined from the elution profiles. Retardation factors have been compared with those predicted on the basis of batch sorption studies. This comparison forms a basis for either validating distribution coefficients or providing evidence of speciation, including colloid formation. Dispersivities measured as a function of velocity provide a means of determining the effect of sorption kinetics or mass transfer on radionuclide migration. Dispersion is also being studied in the context of scaling symmetry to develop a basis for extrapolating from the laboratory scale to the field. 21 refs., 6 figs., 2 tabs.

  8. WELDING PROCESS

    DOE Patents [OSTI]

    Zambrow, J.; Hausner, H.

    1957-09-24

    A method of joining metal parts for the preparation of relatively long, thin fuel element cores of uranium or alloys thereof for nuclear reactors is described. The process includes the steps of cleaning the surfaces to be jointed, placing the sunfaces together, and providing between and in contact with them, a layer of a compound in finely divided form that is decomposable to metal by heat. The fuel element members are then heated at the contact zone and maintained under pressure during the heating to decompose the compound to metal and sinter the members and reduced metal together producing a weld. The preferred class of decomposable compounds are the metal hydrides such as uranium hydride, which release hydrogen thus providing a reducing atmosphere in the vicinity of the welding operation.

  9. Unsaturated fractured rock characterization methods and data sets at the Apache Leap Tuff Site

    SciTech Connect (OSTI)

    Rasmussen, T.C.; Evans, D.D.; Sheets, P.J.; Blanford, J.H. [Arizona Univ., Tucson, AZ (USA). Dept. of Hydrology and Water Resources

    1990-08-01

    Performance assessment of high-level nuclear waste containment feasibility requires representative values of parameters as input, including parameter moments, distributional characteristics, and covariance structures between parameters. To meet this need, characterization methods and data sets for interstitial, hydraulic, pneumatic and thermal parameters for a slightly welded fractured tuff at the Apache Leap Tuff Site situated in central Arizona are reported in this document. The data sets include the influence of matric suction on measured parameters. Spatial variability is investigated by sampling along nine boreholes at regular distances. Laboratory parameter estimates for 105 core segments are provided, as well as field estimates centered on the intervals where the core segments were collected. Measurement uncertainty is estimated by repetitively testing control samples. 31 refs., 10 figs., 21 tabs.

  10. Episodic potassic alteration of Ordovician tuffs in the Upper Mississippi Valley

    SciTech Connect (OSTI)

    Lee, M.; Hay, R.L.; Kolata, D.R.

    1985-01-01

    Tuffs of middle and late Ordovician age are altered to mixed-layer illite-smectite (I/S) and to K-feldspar in the Upper Mississippi Valley in northeast Iowa, southeast Minnesota, and southwest Wisconsin. Some and perhaps much of the I/S replaces previously feldspathized tuff, as shown by field and petrographic relationships. Samples for K-Ar dating were collected over a 200 km southeast-northwest traverse. Dates from authigenic K-feldspar are early Devonian and range from 397 +/- 13 to 406 +/- 18, averaging 400 m.y. in three samples, including a middle Ordovician tuff in Iowa and Minnesota and a late Ordovician tuff in Minnesota. Ages of illite layers in I/S are late Devonian and early Mississippian and range from 356 +/- 16 to 371 +/- 17, averaging 366 m.y. in 5 samples including 4 from two middle Ordovician tuffs in Minnesota and Iowa and the late Ordovician tuff in Minnesota. Oxygen-isotopic composition of the K-feldspar and I/S shows that the two minerals crystallized under different conditions and probably reflect introduction of waters of varying chemistry and temperature. K-feldspar very likely crystallized under higher temperatures and possibly lower salinity than the I/S. Introduction of these pore waters may have been caused by groundwater movements resulting from recharge in distal areas undergoing tectonic uplift. K-feldspar alteration was concurrent with early Devonian uplift on the Northeast Missouri Arch and possibly the Transcontinental Arch. Age of the illite layers corresponds to movements on the Sangamon Arch and possibly the Wisconsin Arch.

  11. On the physics of unstable infiltration, seepage, and gravity drainage in partially saturated tuffs

    SciTech Connect (OSTI)

    Faybishenko, B.; Bodvarsson, G.S.; Salve, R.

    2002-04-01

    To improve understanding of the physics of dynamic instabilities in unsaturated flow processes within the Paintbrush nonwelded unit (PTn) and the middle nonlithophysal portion of the Tonopah Spring welded tuff unit (TSw) of Yucca Mountain, we analyzed data from a series of infiltration tests carried out at two sites (Alcove 4 and Alcove 6) in the Exploratory Studies Facility, using analytical and empirical functions. The analysis of infiltration rates measured at both sites showed three temporal scales of infiltration rate: (1) a macro-scale trend of overall decreasing flow, (2) a meso-scale trend of fast and slow motion exhibiting three-stage variations of the flow rate (decreasing, increasing, and [again] decreasing flow rate, as observed in soils in the presence of entrapped air), and (3) micro-scale (high frequency) fluctuations. Infiltration tests in the nonwelded unit at Alcove 4 indicate that this unit may effectively dampen episodic fast infiltration events; however, well-known Kostyakov, Horton, and Philip equations do not satisfactorily describe the observed trends of the infiltration rate. Instead, a Weibull distribution model can most accurately describe experimentally determined time trends of the infiltration rate. Infiltration tests in highly permeable, fractured, welded tuff at Alcove 6 indicate that the infiltration rate exhibits pulsation, which may have been caused by multiple threshold effects and water-air redistribution between fractures and matrix. The empirical relationships between the extrinsic seepage from fractures, matrix imbibition, and gravity drainage versus the infiltration rate, as well as scaling and self-similarity for the leading edge of the water front are the hallmark of the nonlinear dynamic processes in water flow under episodic infiltration through fractured tuff. Based on the analysis of experimental data, we propose a conceptual model of a dynamic fracture flow and fracture-matrix interaction in fractured tuff, incorporating the time dependent processes of water redistribution in the fracture-matrix system.

  12. Explosive shaped charge penetration into tuff rock

    SciTech Connect (OSTI)

    Vigil, M.G.

    1988-10-01

    Analysis and data for the use of Explosive Shaped Charges (ESC) to generate holes in tuff rock formation is presented. The ESCs evaluated include Conical Shaped Charges (CSC) and Explosive Formed Projectiles (EFP). The CSCs vary in size from 0.158 to 9.1 inches inside cone diameter. The EFPs were 5.0 inches in diameter. Data for projectile impact angles of 30 and 90 degrees are presented. Analytically predicted depth of penetration data generally compared favorably with experimental data. Predicted depth of penetration versus ESC standoff data and hole profile dimensions in tuff are also presented. 24 refs., 45 figs., 6 tabs.

  13. Uranium transport in Topopah spring tuff; An ion-microscope investigation

    SciTech Connect (OSTI)

    McKeegan, K.D.; Phinney, D.; Oversby, V.M.; Buchholtz-tenBrink, M.; Smith, D.K.

    1989-12-31

    The authors discuss their investigation of the effect of different methods of surface preparation on ion-microscope profiles of uranium concentration (added to the sample by diffusion from an aqueous solution) vs depth in a welded, devitrified, tuffaceous rock from Yucca Mountain. The concentration profiles were used to study transport of uranium in the tuff. Four wafers of rock were prepared from primary drill core material and finished by polishing with increasingly finer abrasive material. Final polishes were made with 400 grit SiC, 600 grit SiC, 0.3{mu}m alumina, and 0.05{mu}m alumina. The polished tuff wafers were exposed for eight hours to a solution of groundwater doped with 2 ppm 235-U. The wafers were then examined by SEM and the ion microscope was used to measure the lateral and depth distributions of 235-U and other isotopes in the wafer. No systematic correlation of the measured 235-U concentration- vs-depth profiles with the degree of surface finish was observed, indicating that the polishing does not affect the measurable transport of U in the tuff.

  14. Fracture-coating minerals in the Topopah Spring Member and upper tuff of Calico Hills from drill hole J-13

    SciTech Connect (OSTI)

    Carlos, B.

    1989-02-01

    Fracture-lining minerals from drill core in the Topopah Spring Member of the Paintbrush Tuff and the tuff of Calico Hills from water well J-13 were studied to identify the differences between these minerals and those seen in drill core USW G-4. In USW G-4 the static water level (SWL) occurs below the tuff of Calico Hills, but in J-13 the water table is fairly high in the Topopah Spring Member. There are some significant differences in fracture minerals between these two holes. In USW G-4 mordenite is a common fracture-lining mineral in the Topopah Spring Member, increasing in abundance with depth. Euhedral heulandite >0.1 mm in length occurs in fractures for about 20 m above the lower vitrophyre. In J-13, where the same stratigraphic intervals are below the water table, mordenite is uncommon and euhedral heulandite is not seen. The most abundant fracture coating in the Topopah Spring Member in J-13 is drusy quartz, which is totally absent in this interval in USW G-4. Though similar in appearance, the coatings in the vitrophyre have different mineralogy in the two holes. In USW G-4 the coatings are extremely fine grained heulandite and smectite. In J-13 the coatings are fine-grained heulandite, chabazite, and alkali feldspar. Chabazite has not been identified from any other hole in the Yucca Mountain area. Fractures in the tuff of Calico Hills have similar coatings in core from both holes. In J-13, as in USW G-4, the tuff matrix of the Topopah Spring Member is welded and devitrified and that of the tuff of Calico Hills is zeolitic. 11 refs., 10 figs., 5 tabs.

  15. WELDING TORCH

    DOE Patents [OSTI]

    Correy, T.B.

    1961-10-01

    A welding torch into which water and inert gas are piped separately for cooling and for providing a suitable gaseous atmosphere is described. A welding electrode is clamped in the torch by a removable collet sleeve and a removable collet head. Replacement of the sleeve and head with larger or smaller sleeve and head permits a larger or smaller welding electrode to be substituted on the torch. (AEC)

  16. WELDING METHOD

    DOE Patents [OSTI]

    Cornell, A.A.; Dunbar, J.V.; Ruffner, J.H.

    1959-09-29

    A semi-automatic method is described for the weld joining of pipes and fittings which utilizes the inert gasshielded consumable electrode electric arc welding technique, comprising laying down the root pass at a first peripheral velocity and thereafter laying down the filler passes over the root pass necessary to complete the weld by revolving the pipes and fittings at a second peripheral velocity different from the first peripheral velocity, maintaining the welding head in a fixed position as to the specific direction of revolution, while the longitudinal axis of the welding head is disposed angularly in the direction of revolution at amounts between twenty minutas and about four degrees from the first position.

  17. Uranium transport in Topopah Spring tuff: An ion-microscope investigation

    SciTech Connect (OSTI)

    McKeegan, K.D.; Phinney, D.; Oversby, V.M.; Buchholtz-ten Brink, M.; Smith, D.K.

    1988-10-01

    We investigated the effect of different methods of surface preparation on ion-microscope profiles of uranium concentration (added to the sample by diffusion from an aqueous solution) vs depth in a welded, devitrified, tuffaceous rock from Yucca Mountain. The concentration profiles were used to study transport of uranium in the tuff. Four wafers of rock were prepared from primary drill core material and finished by polishing with increasingly finer abrasive material. Final polishes were made with 400 grit SiC, 600 grit SiC, 0.3 um alumina, and 0.05 um alumina. The polished tuff wafers were exposed for eight hours to a solution of groundwater doped with 2 ppM 235-U. The wafers were then examined by SEM and the ion microscope was used to measure the lateral and depth distributions of 235-U and other isotopes in the wafer. No systematic correlation of the measured 235-U concentration- vs-depth profiles with the degree of surface finish was observed, indicating that the polishing does not affect the measurable transport of U in the tuff. A zone of enhanced 235-U concentration was observed in the upper few microns, which we attribute to sorption onto surfaces of exposed pores. Concentrations of 235-U were elevated above background to depths >15 um, indicating that rapid transport paths exist. When the uranium distribution near the surface of the wafer was modelled by an error function, an upper limit for a slower transport path was defined by an apparent diffusion coefficient of approximately 10{sup {minus}13} cm{sup 2}/s. 5 refs., 5 figs., 1 tab.

  18. Wonder Weld

    SciTech Connect (OSTI)

    2012-01-01

    Engineers at the U.S. Department of Energy's Princeton Plasma Physics Laboratory are using the process shown here to create a super-strong weld for the upgrade of a key component of the Lab's experimental nuclear fusion reactor.

  19. Bulk and mechanical properties of the Paintbrush tuff recovered from boreholes UE25 NRG-2, 2A, 2B, and 3: Data report

    SciTech Connect (OSTI)

    Boyd, P.J.; Martin, R.J.; Noel, J.S. [New England Research, Inc., White River Junction, VT (United States); Price, R.H. [Sandia National Labs., Albuquerque, NM (United States)

    1996-09-01

    An integral part of the licensing procedure for the potential nuclear waste repository at Yucca Mountain, Nevada, involves characterization of the in situ rheology for the design and construction of the facility and the emplacement of canisters containing radioactive waste. The data used to model the thermal and mechanical behavior of the repository and surrounding lithologies include dry and saturated bulk densities, average grain density, porosity, compressional and shear wave velocities, elastic moduli, and compressional and tensional fracture strengths. In this study, a suite of experiments was performed on cores recovered from boreholes UE25 NRG-2, 2A, 2B, and 3 drilled in support of the Exploratory Studies Facility (ESF) at Yucca Mountain. The holes penetrated the Timber Mountain tuff and two thermal/mechanical units of the Paintbrush tuff. The thermal/mechanical stratigraphy was defined by Ortiz to group rock horizons of similar properties for the purpose of simplifying modeling efforts. The relationship between the geologic stratigraphy and the thermal/mechanical stratigraphy for each borehole is presented. The tuff samples in this study have a wide range of welding characteristics (usually reflected in sample porosity), and a smaller range of mineralogy and petrology characteristics. Generally, the samples are silicic, ash-fall tuffs that exhibit large variability in their elastic and strength properties.

  20. Narrow gap laser welding

    DOE Patents [OSTI]

    Milewski, J.O.; Sklar, E.

    1998-06-02

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables. 34 figs.

  1. Narrow gap laser welding

    DOE Patents [OSTI]

    Milewski, John O.; Sklar, Edward

    1998-01-01

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables.

  2. Weld pool oscillation during pulsed GTA welding

    SciTech Connect (OSTI)

    Aendenroomer, A.J.R.; Ouden, G. den

    1996-12-31

    This paper deals with weld pool oscillation during pulsed GTA welding and with the possibility to use this oscillation for in-process control of weld penetration. Welding experiments were carried out under different welding conditions. During welding the weld pool was triggered into oscillation by the normal welding pulses or by extra current pulses. The oscillation frequency was measured both during the pulse time and during the base time by analyzing the arc voltage variation using a Fast Fourier Transformation program. Optimal results are obtained when full penetration occurs during the pulse time and partial penetration during the base time. Under these conditions elliptical overlapping spot welds are formed. In the case of full penetration the weld pool oscillates in a low frequency mode (membrane oscillation), whereas in the case of partial penetration the weld pool oscillates in a high frequency mode (surface oscillation). Deviation from the optimal welding conditions occurs when high frequency oscillation is observed during both pulse time and base time (underpenetration) or when low frequency oscillation is observed during both pulse time and base time (overpenetration). In line with these results a penetration sensing system with feedback control was designed, based on the criterion that optimal weld penetration is achieved when two peaks are observed in the frequency distribution. The feasibility of this sensing system for orbital tube welding was confirmed by the results of experiments carried out under various welding conditions.

  3. Evaluation of tuff as a medium for a nuclear waste repository: interim status report on the properties of tuff

    SciTech Connect (OSTI)

    Johnstone, J.K.; Wolfsberg, K.

    1980-07-01

    This report is the second in a series of summary briefings to the National Academy of Science`s (NAS) Committee on Radioactive Waste Management dealing with feasibility of disposal of heat-producing radioactive waste in silicic tuff. The interim status of studies of tuff properties determined on samples obtained from Yucca Mountain and Rainier Mesa (G-tunnel) located on the Nevada Test Site (NTS) are discussed. In particular, progress is described on resolving issues identified during the first briefing to the NAS which include behavior of water in tuff when heated, the effect of the presence or absence of water and joints on the thermal/physical properties of tuff and the detailed/complex sorptive properties of highly altered and unaltered tuff. Initial correlations of thermal/physical and sorptive properties with the highly variable porosity and mineralogy are described. Three in-situ, at-depth field experiments, one nearly completed and two just getting underway are described. In particular, the current status of mineralogy and petrology, geochemistry, thermal and mechanical, radiation effects and water behavior studies are described. The goals and initial results of a Mine Design Working Group are discussed. Regional factors such as seismicity, volcanism and hydrology are not discussed.

  4. WELDING APPARATUS

    DOE Patents [OSTI]

    Correy, T.B.; DeWitt, D.E.; Nelson, I.V.

    1963-04-23

    This patent covers an arrangement for replacing air in a welding chamber with an inert gas. This operation usually is time-consuming because of the tendency of the inert gas to mix with the air being removed from the welding chamber. The chamber is open at the bottom and has at its top a cover and a porous plate a little below the cover. The inert gas is admitted to the chamber through two screened openings in the cover. On passing through the porous plate, the gas acts as a piston extending across the chamber and moving downwardly to expel the air through the lower open end of the chamber, with a minimum of mixing with the air being expelled. (AEC)

  5. Intraluminal tissue welding for anastomosis

    DOE Patents [OSTI]

    Glinsky, M.; London, R.; Zimmerman, G.; Jacques, S.

    1998-10-27

    A method and device are provided for performing intraluminal tissue welding for anastomosis of a hollow organ. A retractable catheter assembly is delivered through the hollow organ and consists of a catheter connected to an optical fiber, an inflatable balloon, and a biocompatible patch mounted on the balloon. The disconnected ends of the hollow organ are brought together on the catheter assembly, and upon inflation of the balloon, the free ends are held together on the balloon to form a continuous channel while the patch is deployed against the inner wall of the hollow organ. The ends are joined or ``welded`` using laser radiation transmitted through the optical fiber to the patch. A thin layer of a light-absorbing dye on the patch can provide a target for welding. The patch may also contain a bonding agent to strengthen the bond. The laser radiation delivered has a pulse profile to minimize tissue damage. 8 figs.

  6. Intraluminal tissue welding for anastomosis

    DOE Patents [OSTI]

    Glinsky, Michael; London, Richard; Zimmerman, George; Jacques, Steven

    1998-10-27

    A method and device are provided for performing intraluminal tissue welding for anastomosis of a hollow organ. A retractable catheter assembly is delivered through the hollow organ and consists of a catheter connected to an optical fiber, an inflatable balloon, and a biocompatible patch mounted on the balloon. The disconnected ends of the hollow organ are brought together on the catheter assembly, and upon inflation of the balloon, the free ends are held together on the balloon to form a continuous channel while the patch is deployed against the inner wall of the hollow organ. The ends are joined or "welded" using laser radiation transmitted through the optical fiber to the patch. A thin layer of a light-absorbing dye on the patch can provide a target for welding. The patch may also contain a bonding agent to strengthen the bond. The laser radiation delivered has a pulse profile to minimize tissue damage.

  7. Creep properties of the Paintbrush tuff recovered from borehole USW NRG-7/7A: Data report

    SciTech Connect (OSTI)

    Martin, R.J.; Noel, J.S.; Boyd, P.J.

    1997-09-01

    Experimental results are presented for seven creep experiments on welded specimens of the Paintbrush tuff recovered from borehole USW NRG-7/7A at Yucca Mountain, Nevada. The measurements were performed at differential stresses of 40, 70, 100, and 130 MPa. The confining pressure and temperature for each of the experiments was 10 MPa and 225 {degrees}C respectively. All of the specimens were tested drained, in a room dry condition. All of the experiments were terminated prior to failure. The duration of the experiments range from 2.6 x 10{sup 6} seconds to 5.9 x 10{sup 6} seconds. Creep strain is observed for those specimens tested at a stress difference. The strain rate is not constant. A primary creep stage is observed. Secondary creep does not exhibit a constant strain rate, but decreases with increasing time.

  8. Comparison Between Keyhole Weld Model and Laser Welding Experiments...

    Office of Scientific and Technical Information (OSTI)

    Technical Report: Comparison Between Keyhole Weld Model and Laser Welding Experiments Citation Details In-Document Search Title: Comparison Between Keyhole Weld Model and Laser...

  9. Bulk and mechanical properties of the Paintbrush tuff recovered from borehole USW NRG-7/7A: Data report. Yucca Mountain Site Characterization Project

    SciTech Connect (OSTI)

    Martin, R.J.; Boyd, P.J.; Noel, J.S. [New England Research, Inc. White River Junction, VT (United States); Price, R.H. [Sandia National Labs., Albuquerque, NM (United States)

    1995-05-01

    An integral part of the licensing procedure for the potential nuclear waste repository at Yucca Mountain, Nevada, involves prediction of the in situ rheology for the design and construction of the facility and the emplacement of canisters containing radioactive waste. The data used to model the thermal and mechanical behavior of the repository and surrounding lithologies include dry and saturated bulk densities, average grain density, porosity, compressional and shear wave velocities, elastic moduli, and compressional and tensional fracture strengths. In this study, a suite of experiments was performed on cores recovered from the USW NRG-717A borehole drilled in support of the Exploratory Studies Facility (ESF) at Yucca Mountain. USW NRG-7/7A was drilled to a depth of 1,513.4 feet through five thermal/mechanical units of Paintbrush tuff and terminating in the tuffaceous beds of the Calico IEUS. The thermal/mechanical stratigraphy was defined by Orfiz et al. to group rock horizons of similar properties for the purpose of simplifying modeling efforts. The relationship between the geologic stratigraphy and the thermal/mechanical stratigraphy is presented. The tuff samples in this study have a wide range of welding characteristics, and a smaller range of mineralogy and petrology characteristics. Generally, the samples are silicic, ash-fall tuffs that exhibit large variability in their elastic and strength properties.

  10. Laser weld jig

    DOE Patents [OSTI]

    Van Blarigan, Peter (Livermore, CA); Haupt, David L. (Livermore, CA)

    1982-01-01

    A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  11. Fusion welding process

    DOE Patents [OSTI]

    Thomas, Kenneth C.; Jones, Eric D.; McBride, Marvin A.

    1983-01-01

    A process for the fusion welding of nickel alloy steel members wherein a ferrite containing pellet is inserted into a cavity in one member and melted by a welding torch. The resulting weld nugget, a fusion of the nickel containing alloy from the members to be welded and the pellet, has a composition which is sufficiently low in nickel content such that ferrite phases occur within the weld nugget, resulting in improved weld properties. The steel alloys encompassed also include alloys containing carbon and manganese, considered nickel equivalents.

  12. Estimation of Fracture Porosity in an Unsaturated Fractured Welded Tuff Using Gas Tracer Testing

    SciTech Connect (OSTI)

    B.M. Freifeild

    2001-10-18

    Kinematic fracture porosity is an important hydrologic transport parameter for predicting the potential of rapid contaminant migration through fractured rock. The transport velocity of a solute moving within a fracture network is inversely related to the fracture porosity. Since fracture porosity is often one or two orders of magnitude smaller than matrix porosity, and fracture permeability is often orders of magnitude greater than matrix permeability, solutes may travel significantly faster in the fracture network than in the surrounding matrix. This dissertation introduces a new methodology for conducting gas tracer tests using a field portable mass spectrometer along with analytical tools for estimating fracture porosity using the measured tracer concentration breakthrough curves. Field experiments were conducted at Yucca Mountain, Nevada, consisting of air-permeability transient testing and gas-tracer-transport tests. The experiments were conducted from boreholes drilled within an underground tunnel as part of an investigation of rock mass hydrological behavior. Air-permeability pressure transients, recorded during constant mass flux injections, have been analyzed using a numerical inversion procedure to identify fracture permeability and porosity. Dipole gas tracer tests have also been conducted from the same boreholes used for air-permeability testing. Mass breakthrough data has been analyzed using a random walk particle-tracking model, with a dispersivity that is a function of the advective velocity. The estimated fracture porosity using the tracer test and air-injection test data ranges from .001 to .015. These values are an order of magnitude greater than the values estimated by others using hydraulically estimated fracture apertures. The estimates of porosity made using air-permeability test data are shown to be highly sensitive to formation heterogeneity. Uncertainty analyses performed on the gas tracer test results show high confidence in the parameter estimates made.

  13. Repository site data report for unsaturated tuff, Yucca Mountain, Nevada

    SciTech Connect (OSTI)

    Tien, P.L.; Updegraff, C.D.; Siegel, M.D.; Wahi, K.K.; Guzowski, R.V.

    1985-11-01

    The US Department of Energy is currently considering the thick sequences of unsaturated, fractured tuff at Yucca Mountain, on the southwestern boundary of the Nevada Test Site, as a possible candidate host rock for a nuclear-waste repository. Yucca Mountain is in one of the most arid areas in the United States. The site is within the south-central part of the Great Basin section of the Basin and Range physiographic province and is located near a number of silicic calderas of Tertiary age. Although localized zones of seismic activity are common throughout the province, and faults are present at Yucca Mountain, the site itself is basically aseismic. No data are available on the composition of ground water in the unsaturated zone at Yucca Mountain. It has been suggested that the composition is bounded by the compositions of water from wells USW-H3, UE25p-1, J-13, and snow or rain. There are relatively few data available from Yucca Mountain on the moisture content and saturation, hydraulic conductivity, and characteristic curves of the unsaturated zone. The available literature on thermomechanical properties of tuff does not always distinguish between data from the saturated zone and data from the unsaturated zone. Geochemical, hydrologic, and thermomechanical data available on the unsaturated tuffs of Yucca Mountain are tabulated in this report. Where the data are very sparse, they have been supplemented by data from the saturated zone or from areas other than Yucca Mountain. 316 refs., 58 figs., 37 tabs.

  14. Penetration in GTA welding

    SciTech Connect (OSTI)

    Heiple, C.R.; Burgardt, P.

    1990-01-01

    The size and shape of the weld bead produced in GTA welding depends on the magnitude and distribution of the energy incident on the workpiece surfaces as well as the dissipation of that energy in the workpiece. The input energy is largely controllable through the welding parameters selected, however the dissipation of that energy in the workpiece is less subject to control. Changes in energy dissipation can produce large changes in weld shape or penetration. Heat transport away from the weld pool is almost entirely by conduction, but heat transport in the weld pool is more complicated. Heat conduction through the liquid is an important component, but heat transport by convection (mass transport) is often the dominant mechanism. Convective heat transport is directional and changes the weld pool shape from that produced by conduction alone. Surface tension gradients are often the dominant forces driving fluid flow in GTA weld pools. These gradients are sensitive functions of weld pool chemistry and the energy input distribution to the weld. Experimental and theoretical work conducted primarily in the past decade has greatly enhanced our understanding of weld pool fluid flow, the forces which drive it, and its effects on weld pool shape. This work is reviewed here. While less common, changes in energy dissipation through the unmelted portion of the workpiece can also affect fusion zone shape or penetration. These effects are also described. 41 refs., 9 figs.

  15. Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

    SciTech Connect (OSTI)

    Hovanski, Yuri; Carsley, John; Carlson, Blair; Hartfield-Wunsch, Susan; Pilli, Siva Prasad

    2014-01-15

    A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

  16. The Otowi Member of the Bandelier Tuff, Valles Caldera, New Mexico...

    Open Energy Info (EERE)

    sheet sections around the caldera. The underlying assumption is that, given the zoned nature of the tuff, time-synchronous tephra (fallout or ignimbrite) erupted from a single...

  17. WeldBraze Program

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    white2 ES&H Manual Welding & Brazing Program Supplement 1.0 Purpose This document has been written for all groups at Jefferson Lab that perform or contract welding and brazing operations in order to develop a single welding and brazing program that meets minimum requirements derived from national consensus standards. The safety of welders and brazers is covered in the body of ES&H Manual Chapter 6122 Hot Work (Welding, Cutting, Brazing, and Grinding) Safety Program whereas each weld

  18. Method for welding beryllium

    DOE Patents [OSTI]

    Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

    1997-01-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

  19. Radionuclide release from PWR fuels in a reference tuff repository groundwater

    SciTech Connect (OSTI)

    Wilson, C.N.; Oversby, V.M.

    1985-03-01

    The Nevada Nuclear Waste Storage Investigations Project (NNWSI) is studying the suitability of the welded devitrified Topopah Spring tuff at Yucca Mountain, Nye County, Nevada, for potential use as a high-level nuclear waste repository. In support of the Waste Package task of NNWSI, tests have been conducted under ambient air environment to measure radionuclide release from two pressurized water reactor (PWR) spent fuels in water obtained from the J-13 well near the Yucca Mountain site. Four specimen types, representing a range of fuel physical conditions that may exist in a failed waste canister containing a limited amount of water were tested. The specimen types were: fuel rod sections split open to expose bare fuel particles; rod sections with water-tight end fittings with a 2.5-cm long by 150-{mu}m wide slit through the cladding; rod sections with water-tight end fittings and two 200-{mu}m-diameter holes through the cladding; and undefected rod segments with water-tight end fittings. Radionuclide release results from the first 223-day test runs on H.B. Robinson spent fuel specimens in J-13 water are reported and compared to results from a previous test series in which similar Turkey Point reactor spent fuel specimens were tested on deionized water. Selected initial results are also given for Turkey Point fuel specimens tested on J-13 water. Results suggest that the actinides Pu, Am, Cm and Np are released congruently with U as the UO{sub 2} spent fuel matrix dissolves. Fractional release of {sup 137}Cs and {sup 99}Tc was greater than that measured for the actinides. Generally, lower radionuclide releases were measured for the H.B. Robinson fuel in J-13 water than for Turkey Point Fuel in deionized water. 8 references, 7 figures, 9 tables.

  20. Comparison Between Keyhole Weld Model and Laser Welding Experiments...

    Office of Scientific and Technical Information (OSTI)

    the effects that changes in incident power and various welding parameters had on weld geometry were investigated. In this report, the fusion zones of the laser welds are compared...

  1. Computerized tomographic analysis of fluid flow in fractured tuff

    SciTech Connect (OSTI)

    Felice, C.W.; Sharer, J.C.; Springer, E.P.

    1992-05-01

    The purpose of this summary is to demonstrate the usefulness of X-ray computerized tomography to observe fluid flow down a fracture and rock matrix imbibition in a sample of Bandelier tuff. This was accomplished by using a tuff sample 152.4 mm long and 50.8 mm in diameter. A longitudinal fracture was created by cutting the core with a wire saw. The fractured piece was then coupled to its adjacent section to that the fracture was not expected. Water was injected into a dry sample at five flow rates and CT scanning performed at set intervals during the flow. Cross sectional images and longitudinal reconstructions were built and saturation profiles calculated for the sample at each time interval at each flow rate. The results showed that for the test conditions, the fracture was not a primary pathway of fluid flow down the sample. At a slow fluid injection rate into the dry sample, the fluid was imbibed into the rock uniformly down the length of the core. With increasing injection rates, the flow remained uniform over the core cross section through complete saturation.

  2. Computerized tomographic analysis of fluid flow in fractured tuff

    SciTech Connect (OSTI)

    Felice, C.W.; Sharer, J.C. ); Springer, E.P. )

    1992-01-01

    The purpose of this summary is to demonstrate the usefulness of X-ray computerized tomography to observe fluid flow down a fracture and rock matrix imbibition in a sample of Bandelier tuff. This was accomplished by using a tuff sample 152.4 mm long and 50.8 mm in diameter. A longitudinal fracture was created by cutting the core with a wire saw. The fractured piece was then coupled to its adjacent section to that the fracture was not expected. Water was injected into a dry sample at five flow rates and CT scanning performed at set intervals during the flow. Cross sectional images and longitudinal reconstructions were built and saturation profiles calculated for the sample at each time interval at each flow rate. The results showed that for the test conditions, the fracture was not a primary pathway of fluid flow down the sample. At a slow fluid injection rate into the dry sample, the fluid was imbibed into the rock uniformly down the length of the core. With increasing injection rates, the flow remained uniform over the core cross section through complete saturation.

  3. The unsaturated hydraulic characteristics of the Bandelier Tuff

    SciTech Connect (OSTI)

    Rogers, D.B.; Gallaher, B.M.

    1995-09-01

    This report summarizes the physical and, unsaturated hydraulic properties of the Bandelier Tuff determined from laboratory measurements made on core samples collected at Los Alamos National Laboratory. We fit new van Genuchten-type moisture retention curves to this data, which was categorized according to member of the Bandelier Tuff and subunit of the Tshirege Member. Reasonable consistency was observed for hydraulic properties and retention curves within lithologic units, while distinct differences were observed for those properties between units. With the moisture retention data, we constructed vertical profiles of in situ matric suction and hydraulic head. These profiles give an indication of the likely direction of liquid water movement within the unsaturated zone and allow comparison of core-scale and field-scale estimates of water flow and solute transport parameters. Our core-derived transport velocities are much smaller than values estimated from tritium, Cl, and NO{sub 3} contamination found recently in boreholes. The contaminant tracer-derived transport velocities from Los Alamos Canyon are greater than corederived values found for the Otowi Member, and for Mortandad Canyon, greater than core-derived values for that borehole. The significant difference found for Mortandad Canyon suggests that fracture or other fast-path transport may be important there. The relatively small difference between observed and predicted velocities at Los Alamos Canyon may mean that vadose zone transport there occurs by unsaturated matrix flow.

  4. Mineralogic Zonation Within the Tuff Confining Unit, Yucca Flat, Nevada Test Site

    SciTech Connect (OSTI)

    Lance Prothro

    2005-09-01

    Recently acquired mineralogic data from drill hole samples in Yucca Flat show that the tuff confining unit (TCU) can be subdivided into three mineralogic zones based on the relative abundances of primary and secondary mineral assemblages. These zones are (1) an upper zone characterized by the abundance of the zeolite mineral clinoptilolite with lesser amounts of felsic and clay minerals; (2) a middle zone with felsic minerals dominant over clinoptilolite and clay minerals; and (3) a basal argillic zone where clay minerals are dominant over felsic minerals and clinoptilolite. Interpretation of the mineralogic data, along with lithologic, stratigraphic, and geophysical data from approximately 500 drill holes, reveals a three-layer mineralogic model for the TCU that shows all three zones are extensive beneath Yucca Flat. The mineralogic model will be used to subdivide the TCU in the Yucca Flat hydrostratigraphic framework model, resulting in a more accurate and versatile framework model. In addition, the identification of the type, quantity, and distribution of minerals within each TCU layer will permit modelers to better predict the spatial distribution and extent of contaminant transport from underground tests in Yucca Flat, at both the level of the hydrologic source term and the corrective action unit.

  5. Dual wire welding torch and method

    DOE Patents [OSTI]

    Diez, Fernando Martinez; Stump, Kevin S.; Ludewig, Howard W.; Kilty, Alan L.; Robinson, Matthew M.; Egland, Keith M.

    2009-04-28

    A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

  6. Electric arc welding gun

    DOE Patents [OSTI]

    Luttrell, Edward; Turner, Paul W.

    1978-01-01

    This invention relates to improved apparatus for arc welding an interior joint formed by intersecting tubular members. As an example, the invention is well suited for applications where many similar small-diameter vertical lines are to be welded to a long horizontal header. The improved apparatus includes an arc welding gun having a specially designed welding head which is not only very compact but also produces welds that are essentially free from rolled-over solidified metal. The welding head consists of the upper end of the barrel and a reversely extending electrode holder, or tip, which defines an acute angle with the barrel. As used in the above-mentioned example, the gun is positioned to extend upwardly through the vertical member and the joint to be welded, with its welding head disposed within the horizontal header. Depending on the design of the welding head, the barrel then is either rotated or revolved about the axis of the vertical member to cause the electrode to track the joint.

  7. DC arc weld starter

    DOE Patents [OSTI]

    Campiotti, Richard H. (Tracy, CA); Hopwood, James E. (Oakley, CA)

    1990-01-01

    A system for starting an arc for welding uses three DC power supplies, a high voltage supply for initiating the arc, an intermediate voltage supply for sustaining the arc, and a low voltage welding supply directly connected across the gap after the high voltage supply is disconnected.

  8. The effect of welding parameters on penetration in GTA welds

    SciTech Connect (OSTI)

    Shirali, A.A. ); Mills, K.C. )

    1993-07-01

    The effect of various welding parameters on the penetration of GTA welds has been investigated. Increases in welding speed were found to reduce penetration; however, increases in welding current were observed to increase the penetration in high sulfur (HS) casts and decrease penetration in low sulfur (LS) steels. Plots of penetration as a function of increasing linear energy (the heat supplied per unit length of weld) revealed a similar trend with increased penetration in HS casts, but the penetration in LS casts was unaffected by increases in linear energy. These results support the Burgardt-Heiple proposition that changes in welding parameters on penetration can be explained in terms of their effect, sequentially, on the temperature gradient and the Marangoni forces operating in the weld pool. Increases in arc length were found to decrease weld penetration regardless of the sulfur concentration of the steel, and the effects of electrode geometry and welding position on weld penetration were also investigated.

  9. Method for welding beryllium

    DOE Patents [OSTI]

    Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

    1997-04-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

  10. Method development and strategy for the characterization of complexly faulted and fractured rhyolitic tuffs, Yucca Mountain, Nevada

    SciTech Connect (OSTI)

    Karasaki, K.; Galloway, D.

    1991-06-01

    The planned high-level nuclear waste repository at Yucca Mountain, Nevada, would exist in unsaturated, fractured welded tuff. One possible contaminant pathway to the accessible environment is transport by groundwater infiltrating to the water table and flowing through the saturated zone. Therefore, an effort to characterize the hydrology of the saturated zone is being undertaken in parallel with that of the unsaturated zone. As a part of the saturated zone investigation, there wells-UE-25c{number_sign}1, UE-25c{number_sign}2, and UE-25c{number_sign}3 (hereafter called the c-holes)-were drilled to study hydraulic and transport properties of rock formations underlying the planned waste repository. The location of the c-holes is such that the formations penetrated in the unsaturated zone occur at similar depths and with similar thicknesses as at the planned repository site. In characterizing a highly heterogeneous flow system, several issues emerge. (1) The characterization strategy should allow for the virtual impossibility to enumerate and characterize all heterogeneities. (2) The methodology to characterize the heterogeneous flow system at the scale of the well tests needs to be established. (3) Tools need to be developed for scaling up the information obtained at the well-test scale to the larger scale of the site. In the present paper, the characterization strategy and the methods under development are discussed with the focus on the design and analysis of the field experiments at the c-holes.

  11. Apparatus and process for ultrasonic seam welding stainless steel foils

    DOE Patents [OSTI]

    Leigh, Richard W.

    1992-01-01

    An ultrasonic seam welding apparatus having a head which is rotated to form contact, preferably rolling contact, between a metallurgically inert coated surface of the head and an outside foil of a plurality of layered foils or work materials. The head is vibrated at an ultrasonic frequency, preferably along a longitudinal axis of the head. The head is constructed to transmit vibration through a contacting surface of the head into each of the layered foils. The contacting surface of the head is preferably coated with aluminum oxide to prevent the head from becoming welded to layered stainless steel foils.

  12. Lienert named American Welding Society Fellow

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Lienert Named American Welding Society Fellow Lienert named American Welding Society Fellow Lienert was inducted into the American Welding Society's 2012 Class of Fellows during...

  13. Prediction of Weld Penetration in FCAW of HSLA steel using Artificial Neural Networks

    SciTech Connect (OSTI)

    Asl, Y. Dadgar; Mostafa, N. B.; Panahizadeh, V. R. [Department of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran (Iran, Islamic Republic of); Seyedkashi, S. M. H. [Department of Mechanical Engineering, Tarbiat Modares University, Tehran (Iran, Islamic Republic of)

    2011-01-17

    Flux-cored arc welding (FCAW) is a semiautomatic or automatic arc welding process that requires a continuously-fed consumable tubular electrode containing a flux. The main FCAW process parameters affecting the depth of penetration are welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed. Shallow depth of penetration may contribute to failure of a welded structure since penetration determines the stress-carrying capacity of a welded joint. To avoid such occurrences; the welding process parameters influencing the weld penetration must be properly selected to obtain an acceptable weld penetration and hence a high quality joint. Artificial neural networks (ANN), also called neural networks (NN), are computational models used to express complex non-linear relationships between input and output data. In this paper, artificial neural network (ANN) method is used to predict the effects of welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed on weld penetration depth in gas shielded FCAW of a grade of high strength low alloy steel. 32 experimental runs were carried out using the bead-on-plate welding technique. Weld penetrations were measured and on the basis of these 32 sets of experimental data, a feed-forward back-propagation neural network was created. 28 sets of the experiments were used as the training data and the remaining 4 sets were used for the testing phase of the network. The ANN has one hidden layer with eight neurons and is trained after 840 iterations. The comparison between the experimental results and ANN results showed that the trained network could predict the effects of the FCAW process parameters on weld penetration adequately.

  14. Weld Wire Investigation Summary

    SciTech Connect (OSTI)

    Cunningham, M.A.

    1999-03-22

    After GTA welding reservoir A production/process prove-in assemblies, X-ray examination detected a lack of sidewall fusion. After examining several possible causes, it was determined that the weld wire filler metal was responsible, particularly the wire cleaning process. The final conclusion was that the filler wire must be abrasively cleaned in a particular manner to perform as required. The abrasive process was incorporated into the wire material specification, ensuring consistency for all reservoir GTA welding at AlliedSignal Federal Manufacturing and Technologies (FM and T).

  15. APPARATUS FOR ARC WELDING

    DOE Patents [OSTI]

    Lingafelter, J.W.

    1960-04-01

    An apparatus is described in which a welding arc created between an annular electrode and a workpiece moves under the influence of an electromagnetic field about the electrode in a closed or annular path. This mode of welding is specially suited to the enclosing of nuclear-fuel slugs in a protective casing. For example, a uranium slug is placed in an aluminum can, and an aluminum closure is welded to the open end of the can along a closed or annular path conforming to the periphery of the end closure.

  16. Laser weld jig. [Patent application

    DOE Patents [OSTI]

    Van Blarigan, P.; Haupt, D.L.

    1980-12-05

    A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reusable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  17. Weld failure detection

    DOE Patents [OSTI]

    Pennell, William E.; Sutton, Jr., Harry G.

    1981-01-01

    Method and apparatus for detecting failure in a welded connection, particrly applicable to not readily accessible welds such as those joining components within the reactor vessel of a nuclear reactor system. A preselected tag gas is sealed within a chamber which extends through selected portions of the base metal and weld deposit. In the event of a failure, such as development of a crack extending from the chamber to an outer surface, the tag gas is released. The environment about the welded area is directed to an analyzer which, in the event of presence of the tag gas, evidences the failure. A trigger gas can be included with the tag gas to actuate the analyzer.

  18. Friction stir welding tool

    DOE Patents [OSTI]

    Tolle; Charles R. , Clark; Denis E. , Barnes; Timothy A.

    2008-04-15

    A friction stir welding tool is described and which includes a shank portion; a shoulder portion which is releasably engageable with the shank portion; and a pin which is releasably engageable with the shoulder portion.

  19. Weld braze technique

    DOE Patents [OSTI]

    Kanne, Jr., William R. (Aiken, SC); Kelker, Jr., John W. (North Augusta, SC); Alexander, Robert J. (Aiken, SC)

    1982-01-01

    High-strength metal joints are formed by a combined weld-braze technique. A hollow cylindrical metal member is forced into an undersized counterbore in another metal member with a suitable braze metal disposed along the bottom of the counterbore. Force and current applied to the members in an evacuated chamber results in the concurrent formation of the weld along the sides of the counterbore and a braze along the bottom of the counterbore in one continuous operation.

  20. Concurrent ultrasonic weld evaluation system

    DOE Patents [OSTI]

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1987-12-15

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder is disclosed. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws. 5 figs.

  1. Concurrent ultrasonic weld evaluation system

    DOE Patents [OSTI]

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1985-09-04

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  2. Concurrent ultrasonic weld evaluation system

    DOE Patents [OSTI]

    Hood, Donald W.; Johnson, John A.; Smartt, Herschel B.

    1987-01-01

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  3. Immersion studies on candidate container alloys for the Tuff Repository

    SciTech Connect (OSTI)

    Beavers, J.A.; Durr, C.L.

    1991-05-01

    Cortest Columbus Technologies (CC Technologies) is investigating the long-term performance of container materials used for high-level radioactive waste packages. This information is being developed for the Nuclear Regulatory Commission to aid in their assessment of the Department of Energy`s application to construct a geologic repository for disposal of high-level radioactive waste. This report summarizes the results of exposure studies performed on two copper-base and two Fe-Cr-Ni alloys in simulated Tuff Repository conditions. Testing was performed at 90{degrees}C in three environments; simulated J-13 well water, and two environments that simulated the chemical effects resulting from boiling and irradiation of the groundwater. Creviced specimens and U-bends were exposed to liquid, to vapor above the condensed phase, and to alternate immersion. A rod specimen was used to monitor corrosion at the vapor-liquid interface. The specimens were evaluated by electrochemical, gravimetric, and metallographic techniques following approximately 2000 hours of exposure. Results of the exposure tests indicated that all four alloys exhibited acceptable general corrosion rates in simulated J-13 well water. These rates decreased with time. Incipient pitting was observed under deposits on Alloy 825 and pitting was observed on both Alloy CDA 102 and Alloy CDA 715 in the simulated J-13 well water. No SCC was observed in U-bend specimens of any of the alloys in simulated J-13 well water. 33 refs., 48 figs., 23 tabs.

  4. Fluid Flow Phenomena during Welding

    SciTech Connect (OSTI)

    Zhang, Wei

    2011-01-01

    MOLTEN WELD POOLS are dynamic. Liquid in the weld pool in acted on by several strong forces, which can result in high-velocity fluid motion. Fluid flow velocities exceeding 1 m/s (3.3 ft/s) have been observed in gas tungsten arc (GTA) welds under ordinary welding conditions, and higher velocities have been measured in submerged arc welds. Fluid flow is important because it affects weld shape and is related to the formation of a variety of weld defects. Moving liquid transports heat and often dominates heat transport in the weld pool. Because heat transport by mass flow depends on the direction and speed of fluid motion, weld pool shape can differ dramatically from that predicted by conductive heat flow. Temperature gradients are also altered by fluid flow, which can affect weld microstructure. A number of defects in GTA welds have been attributed to fluid flow or changes in fluid flow, including lack of penetration, top bead roughness, humped beads, finger penetration, and undercutting. Instabilities in the liquid film around the keyhole in electron beam and laser welds are responsible for the uneven penetration (spiking) characteristic of these types of welds.

  5. METHOD OF OBTAINING AN IMPROVED WELD IN INERT ARC WELDING

    DOE Patents [OSTI]

    Correy, T.B.

    1962-12-11

    A method is reported for inert arc welding. An a-c welding current is applied to the workpiece and welding electrode such that the positive portion of each cycle thereof, with the electrode positive, has only sufficient energy to clean the surface of the workpiece and the negative portion of each cycle thereof, with the electrode negative, contains the energy required to weld. (AEC)

  6. Passively damped vibration welding system and method (Patent...

    Office of Scientific and Technical Information (OSTI)

    Passively damped vibration welding system and method Title: Passively damped vibration welding system and method A vibration welding system includes a controller, welding horn, an ...

  7. Weld pool oscillation during GTA welding of mild steel

    SciTech Connect (OSTI)

    Xiao, Y.H.; Ouden, G. den . Dept. of Materials Science and Engineering)

    1993-08-01

    In this paper the results are reported of a study dealing with the oscillation behavior of weld pools in the case of GTA bead-on-plate welding of mild steel, Fe 360. During welding, the weld pool was brought into oscillation by applying short current pulses, and the oscillation frequency and amplitude were measured by monitoring the arc voltage. It was found that the oscillation of the partially penetrated weld pool is dominated by one of two different oscillation modes (Mode 1 and Mode 2) depending on the welding conditions, whereas the oscillation of the fully penetrated weld pool is characterized by a third oscillation mode (Mode 3). It is possible to maintain partially penetrated weld pool oscillation in Mode 1 by choosing appropriate welding conditions. Under these conditions, an abrupt decrease in oscillation frequency occurs when the weld pool transfers from partial penetration to full penetration. Thus, weld penetration can be in-process controlled by monitoring the oscillation frequency during welding.

  8. Certification of a weld produced by friction stir welding

    DOE Patents [OSTI]

    Obaditch, Chris; Grant, Glenn J

    2013-10-01

    Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

  9. Robotic Welding and Inspection System

    SciTech Connect (OSTI)

    H. B. Smartt; D. P. Pace; E. D. Larsen; T. R. McJunkin; C. I. Nichol; D. E. Clark; K. L. Skinner; M. L. Clark; T. G. Kaser; C. R. Tolle

    2008-06-01

    This paper presents a robotic system for GTA welding of lids on cylindrical vessels. The system consists of an articulated robot arm, a rotating positioner, end effectors for welding, grinding, ultrasonic and eddy current inspection. Features include weld viewing cameras, modular software, and text-based procedural files for process and motion trajectories.

  10. Preliminary survey of tuff distribution in Esmeralda, Nye, and Lincoln Counties, Nevada

    SciTech Connect (OSTI)

    Smith, G.V.; Pink, T.S.; Lawrence, J.R.; Woodward, L.A.; Keil, K.; Lappin, A.R.

    1981-02-01

    This report inventories the surface distribution of silicic tuffs in Nye, Esmeralda, and Lincoln Counties, NV, based on a review of available literature. The inventory was taken to provide a data base in evaluating tuff sites for the disposal of high-level nuclear waste. Silicic ash-flow tuffs that are about 11 to 34 million years (my) old are widespread in these counties. These rocks are locally deformed by right-lateral movement along Walker Lane and the Las Vegas Shear Zone, and left-lateral movement along a zone from near the Nevada Test Site (NTS) to the Utah border, and are commonly offset by steeply dipping normal faults. The normal faults that bound horsts, grabens, and tilted-fault blocks of the Basin-and-Range Province began to form 30 my ago; some are still active. Tuff distribution is discussed on a regional basis. Tuff thicknesses and alterations, structural complexity, and proximity to recent faulting, recent volcanism, and mineral resources are discussed for each area. Although the literature on which it is based is often incomplete and sketchy, this report is intended to serve as a basis for future, more detailed work that includes initial field inspection, detailed field and laboratory studies, and extrapolations to the subsurface.

  11. Friction stir welding tool and process for welding dissimilar materials

    DOE Patents [OSTI]

    Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

    2013-05-07

    A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

  12. Process of welding gamma prime-strengthened nickel-base superalloys

    DOE Patents [OSTI]

    Speigel, Lyle B.; White, Raymond Alan; Murphy, John Thomas; Nowak, Daniel Anthony

    2003-11-25

    A process for welding superalloys, and particularly articles formed of gamma prime-strengthened nickel-base superalloys whose chemistries and/or microstructures differ. The process entails forming the faying surface of at least one of the articles to have a cladding layer of a filler material. The filler material may have a composition that is different from both of the articles, or the same as one of the articles. The cladding layer is machined to promote mating of the faying surfaces, after which the faying surfaces are mated and the articles welded together. After cooling, the welded assembly is free of thermally-induced cracks.

  13. Hydraulic Characterization of Overpressured Tuffs in Central Yucca Flat, Nevada Test Site, Nye County, Nevada

    SciTech Connect (OSTI)

    K.J. Halford; R.J. Laczniak; D.L. Galloway

    2005-10-07

    A sequence of buried, bedded, air-fall tuffs has been used extensively as a host medium for underground nuclear tests detonated in the central part of Yucca Flat at the Nevada Test Site. Water levels within these bedded tuffs have been elevated hundreds of meters in areas where underground nuclear tests were detonated below the water table. Changes in the ground-water levels within these tuffs and changes in the rate and distribution of land-surface subsidence above these tuffs indicate that pore-fluid pressures have been slowly depressurizing since the cessation of nuclear testing in 1992. Declines in ground-water levels concurrent with regional land subsidence are explained by poroelastic deformation accompanying ground-water flow as fluids pressurized by underground nuclear detonations drain from the host tuffs into the overlying water table and underlying regional carbonate aquifer. A hydraulic conductivity of about 3 x 10-6 m/d and a specific storage of 9 x 10-6 m-1 are estimated using ground-water flow models. Cross-sectional and three-dimensional ground-water flow models were calibrated to measured water levels and to land-subsidence rates measured using Interferometric Synthetic Aperture Radar. Model results are consistent and indicate that about 2 million m3 of ground water flowed from the tuffs to the carbonate rock as a result of pressurization caused by underground nuclear testing. The annual rate of inflow into the carbonate rock averaged about 0.008 m/yr between 1962 and 2005, and declined from 0.005 m/yr in 2005 to 0.0005 m/yr by 2300.

  14. Method and apparatus for assessing weld quality

    DOE Patents [OSTI]

    Smartt, Herschel B.; Kenney, Kevin L.; Johnson, John A.; Carlson, Nancy M.; Clark, Denis E.; Taylor, Paul L.; Reutzel, Edward W.

    2001-01-01

    Apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

  15. Method for welding chromium molybdenum steels

    DOE Patents [OSTI]

    Sikka, Vinod K.

    1986-01-01

    Chromium-molybdenum steels exhibit a weakening after welding in an area adjacent to the weld. This invention is an improved method for welding to eliminate the weakness by subjecting normalized steel to a partial temper prior to welding and subsequently fully tempering the welded article for optimum strength and ductility.

  16. Corrosion Resistant Cladding by YAG Laser Welding in Underwater Environment

    SciTech Connect (OSTI)

    Tsutomi Kochi; Toshio Kojima; Suemi Hirata; Ichiro Morita; Katsura Ohwaki

    2002-07-01

    It is known that stress-corrosion cracking (SCC) will occur in nickel-base alloys used in Reactor Pressure Vessel (RPV) and Internals of nuclear power plants. A SCC sensitivity has been evaluated by IHI in each part of RPV and Internals. There are several water level instrumentation nozzles installed in domestic BWR RPV. In water level instrumentation nozzles, 182 type nickel-base alloys were used for the welding joint to RPV. It is estimated the SCC potential is high in this joint because of a higher residual stress than the yield strength (about 400 MPa). This report will describe a preventive maintenance method to these nozzles Heat Affected Zone (HAZ) and welds by a corrosion resistant cladding (CRC) by YAG Laser in underwater environment (without draining a reactor water). There are many kinds of countermeasures for SCC, for example, Induction Heating Stress Improvement (IHSI), Mechanical Stress Improvement Process (MSIP) and so on. A YAG laser CRC is one of them. In this technology a laser beam is used for heat source and irradiated through an optical fiber to a base metal and SCC resistant material is used for welding wires. After cladding the HAZ and welds are coated by the corrosion resistant materials so their surfaces are improved. A CRC by gas tungsten arc welding (GTAW) in an air environment had been developed and already applied to a couple of operating plants (16 Nozzles). This method was of course good but it spent much time to perform because of an installation of some water-proof working boxes to make a TIG-weldability environment. CRC by YAG laser welding in underwater environment has superior features comparing to this conventional TIG method as follows. At the viewpoint of underwater environment, (1) an outage term reduction (no drainage water). (2) a radioactive exposure dose reduction for personnel. At that of YAG laser welding, (1) A narrower HAZ. (2) A smaller distortion. (3) A few cladding layers. A YAG laser CRC test in underwater environment was carried out in the different welding position, horizontal, vertical upward and downward. The soundness of cladding layers (about 3 mm) is confirmed in visual and penetration test, and cross section observation. In the application to the actual plants, it is preferable to reduce the start and end point numbers of beads with which a defect is easy to cause. Therefore a special welding equipment for a YAG laser CRC that could weld continuously was developed. (authors)

  17. Effect of oxygen on weld shape and crystallographic orientation of duplex stainless steel weld using advanced A-TIG (AA-TIG) welding method

    SciTech Connect (OSTI)

    Zou, Ying, E-mail: yingzou@jwri.osaka-u.ac.jp; Ueji, Rintaro; Fujii, Hidetoshi

    2014-05-01

    The double-shielded advanced A-TIG (AA-TIG) welding method was adopted in this study for the welding of the SUS329J4L duplex stainless steel with the shielding gases of different oxygen content levels. The oxygen content in the shielding gas was controlled by altering the oxygen content in the outer layer gas, while the inner layer remained pure argon to suppress oxidation on the tungsten electrode. As a result, a deep weld penetration was obtained due to the dissolution of oxygen into the weld metals. Additionally, the microstructure of the weld metal was changed by the dissolution of oxygen. The austenite phase at the ferrite grain boundary followed a Kurdjumov–Sachs (K–S) orientation relationship with the ferrite matrix phase at any oxide content. On the other hand, the orientation relationship between the intragranular austenite phase and the ferrite matrix phase exhibited different patterns under different oxygen content levels. When there was little oxide in the fusion zone, only a limited part of the intragranular austenite phase and the ferrite matrix phase followed the K–S orientation relationship. With the increase of the oxide, the correspondence of the K–S relationship increased and fit very well in the 2.5% O{sub 2} shielded sample. The investigation of this phenomenon was carried out along with the nucleation mechanisms of the intragranular austenite phases. - Highlights: • Weld penetration increased with the increase of the oxygen content. • Average diameter and number density of oxide were changed by the oxygen content. • K-S relationship of Widmanstätten austenite/ferrite wasn’t varied by oxide. • Orientation relationship of intragranular austenite/ferrite was varied by oxide.

  18. INERT GAS SHIELD FOR WELDING

    DOE Patents [OSTI]

    Jones, S.O.; Daly, F.V.

    1958-10-14

    S>An inert gas shield is presented for arc-welding materials such as zirconium that tend to oxidize rapidly in air. The device comprises a rectangular metal box into which the welding electrode is introduced through a rubber diaphragm to provide flexibility. The front of the box is provided with a wlndow having a small hole through which flller metal is introduced. The box is supplied with an inert gas to exclude the atmosphere, and with cooling water to promote the solidification of the weld while in tbe inert atmosphere. A separate water-cooled copper backing bar is provided underneath the joint to be welded to contain the melt-through at the root of the joint, shielding the root of the joint with its own supply of inert gas and cooling the deposited weld metal. This device facilitates the welding of large workpieces of zirconium frequently encountered in reactor construction.

  19. Lienert named American Welding Society Fellow

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Lienert named American Welding Society Fellow November 29, 2012 Thomas J. Lienert of the Lab's Metallurgy group was inducted into the American Welding Society's 2012 Class of...

  20. Edison Welding Institute | Open Energy Information

    Open Energy Info (EERE)

    Welding Institute Jump to: navigation, search Name: Edison Welding Institute Address: 1250 Arthur E. Adams Drive Place: Columbus, Ohio Zip: 43221-3585 Sector: Efficiency, Services...

  1. Microstructural characterization and mechanical properties of high power ultrasonic spot welded aluminum alloy AA6111–TiAl6V4 dissimilar joints

    SciTech Connect (OSTI)

    Zhang, C.Q. Robson, J.D.; Ciuca, O.; Prangnell, P.B.

    2014-11-15

    Aluminum alloy AA6111 and TiAl6V4 dissimilar alloys were successfully welded by high power ultrasonic spot welding. No visible intermetallic reaction layer was detected in as-welded AA6111/TiAl6V4 welds, even when transmission electron microscopy was used. The effects of welding time and natural aging on peak load and fracture energy were investigated. The peak load and fracture energy of welds increased with an increase in welding time and then reached a plateau. The lap shear strength (peak load) can reach the same level as that of similar Al–Al joints. After natural aging, the fracture mode of welds transferred from ductile fracture of the softened aluminum to interfacial failure due to the strength recovery of AA6111. - Highlights: • Dissimilar Al/Ti welds were produced by high power ultrasonic spot welding. • No visible intermetallic reaction layer was detected on weld interface. • The lap shear strength can reach the same level as that of similar Al–Al joints. • The fracture mode becomes interfacial failure after natural aging.

  2. Narrow groove welding gas diffuser assembly and welding torch

    DOE Patents [OSTI]

    Rooney, Stephen J.

    2001-01-01

    A diffuser assembly is provided for narrow groove welding using an automatic gas tungsten arc welding torch. The diffuser assembly includes a manifold adapted for adjustable mounting on the welding torch which is received in a central opening in the manifold. Laterally extending manifold sections communicate with a shield gas inlet such that shield gas supplied to the inlet passes to gas passages of the manifold sections. First and second tapered diffusers are respectively connected to the manifold sections in fluid communication with the gas passages thereof. The diffusers extend downwardly along the torch electrode on opposite sides thereof so as to release shield gas along the length of the electrode and at the distal tip of the electrode. The diffusers are of a transverse width which is on the order of the thickness of the electrode so that the diffusers can, in use, be inserted into a narrow welding groove before and after the electrode in the direction of the weld operation.

  3. Displaced electrode process for welding

    DOE Patents [OSTI]

    Heichel, L.J.

    1975-08-26

    A method is described for the butt-welding of a relatively heavy mass to a relatively small mass such as a thin-wall tube. In butt-welding heat is normally applied at the joint between the two pieces which are butt-welded together. The application of heat at the joint results in overheating the tube which causes thinning of the tube walls and porosity in the tube material. This is eliminated by displacing the welding electrode away from the seam toward the heavier mass so that heat is applied to the heavy mass and not at the butt seam. Examples of the parameters used in welding fuel rods are given. The cladding and end plugs were made of Zircalloy. The electrode used was of 2 percent thoriated tungsten. (auth)

  4. Autoclave test of inertia welded slugs

    SciTech Connect (OSTI)

    Peacock, H.B.

    1986-01-27

    Inertia welding (IW) is being evaluated as an alternative to gas-tungsten-arc (GTA) welding, for welding Mark 31 slugs. To demonstrate IW, 40 production (GTA) slugs rejected for pinholes and poor bonds were used. After welding, the slugs were autoclave tested. No autoclave failures occurred. (DLC)

  5. Method for controlling gas metal arc welding

    DOE Patents [OSTI]

    Smartt, Herschel B.; Einerson, Carolyn J.; Watkins, Arthur D.

    1989-01-01

    The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections.

  6. Method for controlling gas metal arc welding

    DOE Patents [OSTI]

    Smartt, H.B.; Einerson, C.J.; Watkins, A.D.

    1987-08-10

    The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections. 3 figs., 1 tab.

  7. Studies of the mobility of uranium and thorium in Nevada Test Site tuff

    SciTech Connect (OSTI)

    Wollenberg, H.A.; Flexser, S.; Smith, A.R.

    1991-06-01

    Hydro-geochemical processes must be understood if the movement of radionuclides away from a breached radioactive waste canister is to be modeled and predicted. In this respect, occurrences of uranium and thorium in hydrothermal systems are under investigation in tuff and in rhyolitic tuff that was heated to simulate the effects of introduction of radioactive waste. In these studies, high-resolution gamma spectrometry and fission-track radiography are coupled with observations of alteration mineralogy and thermal history to deduce the evidence of, or potential for movement of, U and Th in response to the thermal environment. Observations to date suggest that U was mobile in the vicinity of the heater but that localized reducing environments provided by Fe-Ti-Mn-oxide minerals concentrated U and thus attenuated its migration.

  8. Strontium isotope evolution of pore water and calcite in the Topopah Spring Tuff, Yucca Mountain, Nevada

    SciTech Connect (OSTI)

    Marshall, Brian D.; Futa, Kiyoto

    2001-04-29

    Pore water in the Topopah Spring Tuff has a narrow range of {delta}{sup 87}Sr values that can be calculated from the {delta}{sup 87}Sr values of the rock considering advection through and reaction with the overlying nonwelded tuffs of the PTn. This model can be extended to estimate the variation of {delta}{sup 87}Sr in the pore water through time; this approximates the variation of {delta}{sup 87}Sr measured in calcite fracture coatings. In samples of calcite where no silica can be dated by other methods, strontium isotope data may be the only method to determine ages. In addition, other Sr-bearing minerals in the calcite and opal coatings, such as fluorite, may be dated using the same model.

  9. Lienert named American Welding Society Fellow

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Lienert Named American Welding Society Fellow Lienert named American Welding Society Fellow Lienert was inducted into the American Welding Society's 2012 Class of Fellows during the recent FABTECH meeting in Las Vegas, Nevada. November 29, 2012 Thomas J. Lienert Thomas J. Lienert Thomas J. Lienert has served the welding community and industry with great distinction as an individual who contributed significantly to the knowledge, science, and application of welding. Thomas J. Lienert of the Lab's

  10. Laser welding of fused quartz

    DOE Patents [OSTI]

    Piltch, Martin S.; Carpenter, Robert W.; Archer, III, McIlwaine

    2003-06-10

    Refractory materials, such as fused quartz plates and rods are welded using a heat source, such as a high power continuous wave carbon dioxide laser. The radiation is optimized through a process of varying the power, the focus, and the feed rates of the laser such that full penetration welds may be accomplished. The process of optimization varies the characteristic wavelengths of the laser until the radiation is almost completely absorbed by the refractory material, thereby leading to a very rapid heating of the material to the melting point. This optimization naturally occurs when a carbon dioxide laser is used to weld quartz. As such this method of quartz welding creates a minimum sized heat-affected zone. Furthermore, the welding apparatus and process requires a ventilation system to carry away the silicon oxides that are produced during the welding process to avoid the deposition of the silicon oxides on the surface of the quartz plates or the contamination of the welds with the silicon oxides.

  11. Control of Gas Tungsten Arc welding pool shape by trace element addition to the weld pool

    DOE Patents [OSTI]

    Heiple, C.R.; Burgardt, P.

    1984-03-13

    An improved process for Gas Tungsten Arc welding maximizes the depth/width ratio of the weld pool by adding a sufficient amount of a surface active element to insure inward fluid flow, resulting in deep, narrow welds. The process is especially useful to eliminate variable weld penetration and shape in GTA welding of steels and stainless steels, particularly by using a sulfur-doped weld wire in a cold wire feed technique.

  12. Laser welding and post weld treatment of modified 9Cr-1MoVNb steel.

    SciTech Connect (OSTI)

    Xu, Z.

    2012-04-03

    Laser welding and post weld laser treatment of modified 9Cr-1MoVNb steels (Grade P91) were performed in this preliminary study to investigate the feasibility of using laser welding process as a potential alternative to arc welding methods for solving the Type IV cracking problem in P91 steel welds. The mechanical and metallurgical testing of the pulsed Nd:YAG laser-welded samples shows the following conclusions: (1) both bead-on-plate and circumferential butt welds made by a pulsed Nd:YAG laser show good welds that are free of microcracks and porosity. The narrow heat affected zone has a homogeneous grain structure without conventional soft hardness zone where the Type IV cracking occurs in conventional arc welds. (2) The laser weld tests also show that the same laser welder has the potential to be used as a multi-function tool for weld surface remelting, glazing or post weld tempering to reduce the weld surface defects and to increase the cracking resistance and toughness of the welds. (3) The Vicker hardness of laser welds in the weld and heat affected zone was 420-500 HV with peak hardness in the HAZ compared to 240 HV of base metal. Post weld laser treatment was able to slightly reduce the peak hardness and smooth the hardness profile, but failed to bring the hardness down to below 300 HV due to insufficient time at temperature and too fast cooling rate after the time. Though optimal hardness of weld made by laser is to be determined for best weld strength, methods to achieve the post weld laser treatment temperature, time at the temperature and slow cooling rate need to be developed. (4) Mechanical testing of the laser weld and post weld laser treated samples need to be performed to evaluate the effects of laser post treatments such as surface remelting, glazing, re-hardening, or tempering on the strength of the welds.

  13. Method for enhanced control of welding processes

    DOE Patents [OSTI]

    Sheaffer, Donald A.; Renzi, Ronald F.; Tung, David M.; Schroder, Kevin

    2000-01-01

    Method and system for producing high quality welds in welding processes, in general, and gas tungsten arc (GTA) welding, in particular by controlling weld penetration. Light emitted from a weld pool is collected from the backside of a workpiece by optical means during welding and transmitted to a digital video camera for further processing, after the emitted light is first passed through a short wavelength pass filter to remove infrared radiation. By filtering out the infrared component of the light emitted from the backside weld pool image, the present invention provides for the accurate determination of the weld pool boundary. Data from the digital camera is fed to an imaging board which focuses on a 100.times.100 pixel portion of the image. The board performs a thresholding operation and provides this information to a digital signal processor to compute the backside weld pool dimensions and area. This information is used by a control system, in a dynamic feedback mode, to automatically adjust appropriate parameters of a welding system, such as the welding current, to control weld penetration and thus, create a uniform weld bead and high quality weld.

  14. Method for enhanced control of welding processes

    SciTech Connect (OSTI)

    Sheaffer, D.A.; Renzi, R.F.; Tung, D.M.; Schroder, K.

    2000-07-04

    Method and system for producing high quality welds in welding processes, in general, and gas tungsten arc (GTA) welding, in particular by controlling weld penetration are disclosed. Light emitted from a weld pool is collected from the backside of a workpiece by optical means during welding and transmitted to a digital video camera for further processing, after the emitted light is first passed through a short wavelength pass filter to remove infrared radiation. By filtering out the infrared component of the light emitted from the backside weld pool image, the present invention provides for the accurate determination of the weld pool boundary. Data from the digital camera is fed to an imaging board which focuses on a 100 x 100 pixel portion of the image. The board performs a thresholding operation and provides this information to a digital signal processor to compute the backside weld pool dimensions and area. This information is used by a control system, in a dynamic feedback mode, to automatically adjust appropriate parameters of a welding system, such as the welding current, to control weld penetration and thus, create a uniform weld bead and high quality weld.

  15. Welding arc gap ionization device

    DOE Patents [OSTI]

    Schweikhardt, George M.

    1976-01-01

    An alpha emitting isotope is positioned near the tip of a TIG welding electrode so that the alpha radiation can provide an ionized path between the electrode and the workpiece.

  16. Growth kinetics of Al–Fe intermetallic compounds during annealing treatment of friction stir lap welds

    SciTech Connect (OSTI)

    Movahedi, M., E-mail: m_movahedi@sharif.edu [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Ave., Tehran (Iran, Islamic Republic of); Kokabi, A.H., E-mail: kokabi@sharif.edu [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Ave., Tehran (Iran, Islamic Republic of); Seyed Reihani, S.M., E-mail: reihani@sharif.edu [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Ave., Tehran (Iran, Islamic Republic of); Najafi, H., E-mail: hossein.najafi@epfl.ch [Institute of Condensed Matter Physics (ICMP), EPFL, CH-1015 Lausanne (Switzerland); Farzadfar, S.A., E-mail: seyed-amir.farzadfar@mail.mcgill.ca [McGill University, Department of Materials Engineering, Montreal, QC H3A 2B2 (Canada); Cheng, W.J., E-mail: d9603505@mail.ntust.edu.tw [Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei 10607, Taiwan, ROC (China); Wang, C.J., E-mail: cjwang@mail.ntust.edu.tw [Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei 10607, Taiwan, ROC (China)

    2014-04-01

    In this study, we explored the growth kinetics of the Al–Fe intermetallic (IM) layer at the joint interface of the St-12/Al-5083 friction stir lap welds during post-weld annealing treatment at 350, 400 and 450 °C for 30 to 180 min. Optical microscope (OM), field emission gun scanning electron microscope (FEG-SEM) and transmission electron microscope (TEM) were employed to investigate the structure of the weld zone. The thickness and composition of the IM layers were evaluated using image analysis system and electron back-scatter diffraction (EBSD), respectively. Moreover, kernel average misorientation (KAM) analysis was performed to evaluate the level of stored energy in the as-welded state. The results showed that the growth kinetics of the IM layer was not governed by a parabolic diffusion law. Presence of the IM compounds as well as high stored energy near the joint interface of the as-welded sample was recognized to be the origin of the observed deviation from the parabolic diffusion law. - Highlights: • This work provided a new insight into growth kinetics of Al–Fe IM thickness. • The growth kinetics of IM layer was not governed by a parabolic diffusion law. • IM near the joint interface was the origin of deviation from the parabolic law. • High stored energy at joint interface was origin of deviation from parabolic law.

  17. Pipe weld crown removal device

    DOE Patents [OSTI]

    Sword, Charles K.; Sette, Primo J.

    1992-01-01

    A device is provided for grinding down the crown of a pipe weld joining aligned pipe sections so that the weld is substantially flush with the pipe sections joined by the weld. The device includes a cage assembly comprising a pair of spaced cage rings adapted to be mounted for rotation on the respective pipe sections on opposite sides of the weld, a plurality of grinding wheels, supported by the cage assembly for grinding down the crown of the weld, and a plurality of support shafts, each extending longitudinally along the joined pipe sections, parallel thereto, for individually mounting respective grinding wheels. Each end of the support shafts is mounted for rotation in a bearing assembly housed within a radially directed opening in a corresponding one of the cage rings so as to provide radial movement of the associated shaft, and thus of the associated grinding wheel, towards and away from the weld. A first drive sprocket provides rotation of the cage assembly around the pipe sections while a second drive unit, driven by a common motor, provides rotation of the grinding wheels.

  18. Upgraded HFIR Fuel Element Welding System

    SciTech Connect (OSTI)

    Sease, John D [ORNL

    2010-02-01

    The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. In recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.

  19. A natural analogue for high-level waste in tuff: Chemical analysis and modeling of the Valles site

    SciTech Connect (OSTI)

    Stockman, H.W.; Krumhansl, J.L.; Ho, C.K.; Kovach, L.; McConnell, V.S.

    1995-03-01

    The contact between an obsidian flow and a steep-walled tuff canyon was examined as an analogue for a high-level waste repository. The analogue site is located in the Valles Caldera in New Mexico, where a massive obsidian flow filled a paleocanyon in the Battleship Rock Tuff. The obsidian flow provided a heat source, analogous to waste panels or an igneous intrusion in a repository, and caused evaporation and migration of water. The tuff and obsidian samples were analyzed for major and trace elements and mineralogy by INAA, XRF, x-ray diffraction, and scanning electron microscopy and electron microprobe. Samples were also analyzed for D/H and {sup 39}Ar/{sup 40}Ar isotopic composition. Overall, the effects of the heating event seem to have been slight and limited to the tuff nearest the contact. There is some evidence of devitrification and migration of volatiles in the tuff within 10 m of the contact, but variations in major and trace element chemistry are small and difficult to distinguish from the natural (pre-heating) variability of the rocks.

  20. Automatic monitoring of vibration welding equipment

    DOE Patents [OSTI]

    Spicer, John Patrick; Chakraborty, Debejyo; Wincek, Michael Anthony; Wang, Hui; Abell, Jeffrey A; Bracey, Jennifer; Cai, Wayne W

    2014-10-14

    A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

  1. Repair welding of fusion reactor components

    SciTech Connect (OSTI)

    Chin, B.A.

    1993-05-15

    Experiments have shown that irradiated Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 MPa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  2. Radionuclide release from PWR fuels in a reference tuff repository groundwater subsquently changed to Radionuclide release from PWR fuels in J-13 well water

    SciTech Connect (OSTI)

    Wilson, C.N.; Oversby, V.M.

    1985-04-01

    The Nevada Nuclear Waste Storage Investigations Project (NNWSI) is studying the suitability of the welded devitrified Topopah Spring tuff at Yucca Mountain, Nye County, Nevada, for potential use as a high level nuclear waste repository. In support of the Waste Package task of NNWSI, tests have been conducted under ambient air environment to measure radionuclide release from two pressurized water reactor (PWR) spent fuels in water obtained from the J-13 well near the Yucca Mountain site. Four specimen types, representing a range of fuel physical conditions that may exist in a failed waste canister containing a limited amount of water were tested. The specimen types were: (1) fuel rod sections split open to expose bare fuel particles; (2) rod sections with water-tight end fittings with a 2.5-cm long by 150-{mu}m wide slit through the cladding; (3) rod sections with water-tight end fittings and two 200-{mu}m diameter holes through the cladding; and (4) undefected rod segments with water-tight end fittings. Radionuclide release results from the first 223-day test runs on H.B. Robinson spent fuel specimens in J-13 water are reported and compared to results from a previous test series in which similar Turkey Point reactor spent fuel specimens were tested in deionized water. Selected initial results are also given for Turkey Point fuel specimens tested in J-13 water. Results suggest that the actinides Pu, Am, Cm and Np are released congruently with U as the UO{sub 2} spent fuel matrix dissolves. Fractional release of {sup 137}Cs and {sup 99}Tc was greater than that measured for the actinides. Generally, lower radionuclide releases were measured for the H.B. Robinson fuel in J-13 water than for Turkey Point Fuel in deionized water.

  3. Criticality characteristics of mixtures of plutonium, silicon dioxide, Nevada tuff, and water

    SciTech Connect (OSTI)

    Sanchez, R.; Myers, W.; Hayes, D.

    1997-01-01

    The nuclear criticality characteristics of mixtures of plutonium, silicon dioxide, and water (Part A) or plutonium, silicon dioxide, Nevada Yucca Mountain tuff, and water (Part B) have become of interest because of the appearance of recent papers on the subject. These papers postulate that if excess weapons plutonium is vitrified into a silicate log and buried underground, a self-sustaining neutron chain reaction may develop given sufficient time and interaction with the burial medium. Moreover, given specific geologic actions resulting in postulated configurations, the referenced papers state that nuclear explosions could occur with multi-kiloton yields or yields equivalent to hundreds of tons of TNT.

  4. Pre-resistance-welding resistance check

    DOE Patents [OSTI]

    Destefan, Dennis E.; Stompro, David A.

    1991-01-01

    A preweld resistance check for resistance welding machines uses an open circuited measurement to determine the welding machine resistance, a closed circuit measurement to determine the parallel resistance of a workpiece set and the machine, and a calculation to determine the resistance of the workpiece set. Any variation in workpiece set or machine resistance is an indication that the weld may be different from a control weld.

  5. Distribution of radionuclides and water in Bandelier Tuff beneath a former Los Alamos liquid waste disposal site after 33 years

    SciTech Connect (OSTI)

    Nyhan, J.W.; Drennon, B.J.; Abeele, W.V.; Trujillo, G.; Herrera, W.J.; Wheeler, M.L.; Booth, J.W.; Purtymun, W.D.

    1984-07-01

    The distribution of radionuclides and water in Bandelier Tuff beneath a former liquid waste disposal site at Los Alamos was investigated. The waste use history of the site was described, as well as several pertinent laboratory and field studies of water and radionuclide migration in Bandelier Tuff. The distribution of plutonium, /sup 241/Am, and water was determined in a set of about 800 tuff samples collected to sampling depths of 30 m beneath two absorption beds. These data were then related to site geohydrologic data. Water and radionuclide concentrations found after 33 years were compared with the results of similar studies previously performed at this site, and the implications of these comparisons are discussed relative to nuclear waste management. 19 references, 6 figures, 4 tables.

  6. Percussive arc welding apparatus

    DOE Patents [OSTI]

    Hollar, Jr., Donald L.

    2002-01-01

    A percussive arc welding apparatus includes a generally cylindrical actuator body having front and rear end portions and defining an internal recess. The front end of the body includes an opening. A solenoid assembly is provided in the rear end portion in the internal recess of the body, and an actuator shaft assembly is provided in the front end portion in the internal recess of the actuator body. The actuator shaft assembly includes a generally cylindrical actuator block having first and second end portions, and an actuator shaft having a front end extending through the opening in the actuator body, and the rear end connected to the first end portion of the actuator block. The second end portion of the actuator block is in operational engagement with the solenoid shaft by a non-rigid connection to reduce the adverse rebound effects of the actuator shaft. A generally transversely extending pin is rigidly secured to the rear end of the shaft. One end of the pin is received in a slot in the nose housing sleeve to prevent rotation of the actuator shaft during operation of the apparatus.

  7. Study of Mechanical Properties and Characterization of Pipe Steel welded by Hybrid (Friction Stir Weld + Root Arc Weld) Approach

    SciTech Connect (OSTI)

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Wasson, Andrew J; Fairchild, Doug P; Wang, Yanli; Feng, Zhili

    2015-01-01

    Friction stir welding (FSW) has recently attracted attention as an alternative construction process for gas/oil transportation applications due to advantages compared to fusion welding techniques. A significant advantage is the ability of FSW to weld the entire or nearly the entire wall thickness in a single pass, while fusion welding requires multiple passes. However, when FSW is applied to a pipe or tube geometry, an internal back support anvil is required to resist the plunging forces exerted during FSW. Unfortunately, it may not be convenient or economical to use internal backing support due to limited access for some applications. To overcome this issue, ExxonMobil recently developed a new concept, combining root arc welding and FSW. That is, a root arc weld is made prior to FSW that supports the normal loads associated with FSW. In the present work, mechanical properties of a FSW + root arc welded pipe steel are reported including microstructure and microhardness.

  8. Stable isotopes of authigenic minerals in variably-saturated fractured tuff

    SciTech Connect (OSTI)

    Weber, D.S.; Evans, D.D.

    1988-11-01

    Identifying stable isotope variation and mineralogical changes in fractured rock may help establish the history of climatic and geomorphological processes that might affect the isolation properties of a waste repository site. This study examines the use of the stable isotope ratios of oxygen ({sup 18}O/{sup 16}O) and carbon ({sup 13}C/{sup 12}C) in authigenic minerals as hydrogeochemical tools tracing low-temperature rock-water interaction in variably-saturated fractured stuff. Isotopic compositions of fracture-filling and rock matrix minerals in the Apache Leap tuff, near Superior, Arizona were concordant with geothermal temperatures and in equilibrium with water isotopically similar to present-day meteoric water and groundwater. Oxygen and carbon isotope ratios of fracture-filling, in unsaturated fractured tuff, displayed an isotopic gradient believed to result from near-surface isotopic enrichment due to evaporation rather than the effects of rock-water interaction. Oxygen isotope ratios of rock matrix opal samples exhibited an isotopic gradient believed to result from, leaching and reprecipitation of silica at depth. Methods and results can be used to further define primary flowpaths and the movement of water in variably-saturated fractured rock. 71 refs., 23 figs., 3 tabs.

  9. Analysis of Fracture in Cores from the Tuff Confining Unit beneath Yucca Flat, Nevada Test Site

    SciTech Connect (OSTI)

    Lance Prothro

    2008-03-01

    The role fractures play in the movement of groundwater through zeolitic tuffs that form the tuff confining unit (TCU) beneath Yucca Flat, Nevada Test Site, is poorly known. This is an important uncertainty, because beneath most of Yucca Flat the TCU lies between the sources of radionuclide contaminants produced by historic underground nuclear testing and the regional carbonate aquifer. To gain a better understanding of the role fractures play in the movement of groundwater and radionuclides through the TCU beneath Yucca Flat, a fracture analysis focusing on hydraulic properties was performed on conventional cores from four vertical exploratory holes in Area 7 of Yucca Flat that fully penetrate the TCU. The results of this study indicate that the TCU is poorly fractured. Fracture density for all fractures is 0.27 fractures per vertical meter of core. For open fractures, or those observed to have some aperture, the density is only 0.06 fractures per vertical meter of core. Open fractures are characterized by apertures ranging from 0.1 to 10 millimeter, and averaging 1.1 millimeter. Aperture typically occurs as small isolated openings along the fracture, accounting for only 10 percent of the fracture volume, the rest being completely healed by secondary minerals. Zeolite is the most common secondary mineral occurring in 48 percent of the fractures observed.

  10. Optical penetration sensor for pulsed laser welding

    DOE Patents [OSTI]

    Essien, Marcelino; Keicher, David M.; Schlienger, M. Eric; Jellison, James L.

    2000-01-01

    An apparatus and method for determining the penetration of the weld pool created from pulsed laser welding and more particularly to an apparatus and method of utilizing an optical technique to monitor the weld vaporization plume velocity to determine the depth of penetration. A light source directs a beam through a vaporization plume above a weld pool, wherein the plume changes the intensity of the beam, allowing determination of the velocity of the plume. From the velocity of the plume, the depth of the weld is determined.

  11. Shimmed electron beam welding process

    DOE Patents [OSTI]

    Feng, Ganjiang; Nowak, Daniel Anthony; Murphy, John Thomas

    2002-01-01

    A modified electron beam welding process effects welding of joints between superalloy materials by inserting a weldable shim in the joint and heating the superalloy materials with an electron beam. The process insures a full penetration of joints with a consistent percentage of filler material and thereby improves fatigue life of the joint by three to four times as compared with the prior art. The process also allows variable shim thickness and joint fit-up gaps to provide increased flexibility for manufacturing when joining complex airfoil structures and the like.

  12. APPARATUS AND METHOD FOR ARC WELDING

    DOE Patents [OSTI]

    Noland, R.A.; Stone, C.C.

    1960-05-10

    An apparatus and method are given for forming a welding arc which is rotated by a magnetic field very rapidly about an annular electrode so that a weld is produced simultaneously over all points of an annular or closed path. This invention inhibits outgassing from the jacket of a fuel slug which is being welded by adjusting the pressure throughout the welding cycle to establish a balance between the gas pressure within the jacket and that of the atmosphere surrounding the jacket. Furthermore, an improved control of the magnetic field producing rotation of the welding arc is disclosed whereby this rotation is prevented from splashing about the metal being welded as the welding arc makes it molten.

  13. Long-term desorption behavior of uranium and neptunium in heterogeneous volcanic tuff materials /

    SciTech Connect (OSTI)

    Dean, Cynthia A.

    2010-05-01

    Uranium and neptunium desorption were studied in long-term laboratory experiments using four well-characterized volcanic tuff cores collected from southeast of Yucca Mountain, Nevada. The objectives of the experiments were to 1. Demonstrate a methodology aimed at characterizing distributions of sorption parameters (attributes of multiple sorption sites) that can be applied to moderately-sorbing species in heterogeneous systems to provide more realistic reactive transport parameters and a more realistic approach to modeling transport in heterogeneous systems. 2. Focus on uranium and neptunium because of their high solubility, relatively weak sorption, and high contributions to predicted dose in Yucca Mountain performance assessments. Also, uranium is a contaminant of concern at many DOE legacy sites and uranium mining sites.

  14. Performance predictions for mechanical excavators in Yucca Mountain tuffs; Yucca Mountain Site Characterization Project

    SciTech Connect (OSTI)

    Ozdemir, L.; Gertsch, L.; Neil, D.; Friant, J.

    1992-09-01

    The performances of several mechanical excavators are predicted for use in the tuffs at Yucca Mountain: Tunnel boring machines, the Mobile Miner, a roadheader, a blind shaft borer, a vertical wheel shaft boring machine, raise drills, and V-Moles. Work summarized is comprised of three parts: Initial prediction using existing rock physical property information; Measurement of additional rock physical properties; and Revision of the initial predictions using the enhanced database. The performance predictions are based on theoretical and empirical relationships between rock properties and the forces-experienced by rock cutters and bits during excavation. Machine backup systems and excavation design aspects, such as curves and grades, are considered in determining excavator utilization factors. Instanteous penetration rate, advance rate, and cutter costs are the fundamental performance indicators.

  15. Modeling of Heat and Mass Transfer in Fusion Welding (Book) ...

    Office of Scientific and Technical Information (OSTI)

    Book: Modeling of Heat and Mass Transfer in Fusion Welding Citation Details In-Document Search Title: Modeling of Heat and Mass Transfer in Fusion Welding In fusion welding, parts...

  16. Passively damped vibration welding system and method

    DOE Patents [OSTI]

    Tan, Chin-An; Kang, Bongsu; Cai, Wayne W.; Wu, Tao

    2013-04-02

    A vibration welding system includes a controller, welding horn, an anvil, and a passive damping mechanism (PDM). The controller generates an input signal having a calibrated frequency. The horn vibrates in a desirable first direction at the calibrated frequency in response to the input signal to form a weld in a work piece. The PDM is positioned with respect to the system, and substantially damps or attenuates vibration in an undesirable second direction. A method includes connecting the PDM having calibrated properties and a natural frequency to an anvil of an ultrasonic welding system. Then, an input signal is generated using a weld controller. The method includes vibrating a welding horn in a desirable direction in response to the input signal, and passively damping vibration in an undesirable direction using the PDM.

  17. Method and device for frictional welding

    DOE Patents [OSTI]

    Peacock, Harold B.

    1992-01-01

    A method for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical cannister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel's recessed bottom. Also, the channel design limits distortion of the two members during the friction welding process, further contributing to the complete seal that is obtained.

  18. Method and device for frictional welding

    DOE Patents [OSTI]

    Peacock, H.B.

    1992-10-13

    A method is described for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical canister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel's recessed bottom. Also, the channel design limits distortion of the two members during the friction welding process, further contributing to the complete seal that is obtained. 5 figs.

  19. Method and device for frictional welding

    DOE Patents [OSTI]

    Peacock, H.B.

    1991-01-01

    A method for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical cannister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel`s recessed bottom. Also, the channel design limits distortion of the two members during the friction welding, process, further contributing to the complete seal that is obtained.

  20. Role of welding parameters in determining the geometrical appearance of weld pool

    SciTech Connect (OSTI)

    Kovacevic, R.; Cao, Z.N.; Zhang, Y.M.

    1996-10-01

    A three-dimensional numerical model is developed to describe the fluid flow and heat transfer in weld pools. Both full penetration and free deformation of the top and bottom weld pool surfaces are considered. Temperature distribution and fluid flow field are obtained. In order to analyze the influence of welding parameters on the geometrical appearance of weld pools, a normalized model is developed to characterize the geometrical appearance of weld pools. It is found that welding current can significantly affect the geometrical shape. When welding current increases, the curvature of the pool boundary at the trailing end increases. The effect of the welding speed on the geometrical appearance is slight, although its influence on the pool size is great. In the interest range of arc length (from 1 mm to 4 mm), the arc length can affect both the size and the shape of the weld pool. However, compared with the welding current and speed, its influences are much weaker, GTA welding experiments are performed to verify the validity of the numerical models. The appearance of weld pools was obtained by using machine vision and a high-shutter speed camera. It is found that the calculated results have a good agreement with the experimental ones.

  1. Multi-component Cu-Strengthened Steel Welding Simulations: Atom...

    Office of Scientific and Technical Information (OSTI)

    Steel Welding Simulations: Atom Probe Tomography and Synchrotron X-ray Diffraction Analyses Citation Details In-Document Search Title: Multi-component Cu-Strengthened Steel Welding ...

  2. Assessing Steel Pipeline and Weld Susceptibility to Hydrogen...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement Webinar Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement Webinar Access the ...

  3. Status Report: Characterization of Weld Residual Stresses on...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Status Report: Characterization of Weld Residual Stresses on Full Diameter SNF Interim Storage Canister Mockup Status Report: Characterization of Weld Residual Stresses on Full ...

  4. High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    ... Evaluate the performance of best in class laser, laserhybrid and friction stir welding ... on geometric weld quality criteria, surface finish and formability Sept 2013 Progress ...

  5. Friction Stir Welding Aluminum for Lightweight Vehicles | Department...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Friction Stir Welding Aluminum for Lightweight Vehicles Friction Stir Welding Aluminum for Lightweight Vehicles Addthis Description In this video, a researcher from Pacific ...

  6. Welding apparatus and methods for using ultrasonic sensing

    DOE Patents [OSTI]

    McJunkin, Timothy R.; Johnson, John A.; Larsen, Eric D.; Smartt, Herschel B.

    2006-08-22

    A welding apparatus using ultrasonic sensing is described and which includes a movable welder having a selectively adjustable welding head for forming a partially completed weld in a weld seam defined between adjoining metal substrates; an ultrasonic assembly borne by the moveable welder and which is operable to generate an ultrasonic signal which is directed toward the partially completed weld, and is further reflected from same; and a controller electrically coupled with the ultrasonic assembly and controllably coupled with the welding head, and wherein the controller receives information regarding the ultrasonic signal and in response to the information optimally positions the welding head relative to the weld seam.

  7. Welding the AT-400A Containment Vessel

    SciTech Connect (OSTI)

    Brandon, E.

    1998-11-01

    Early in 1994, the Department of Energy assigned Sandia National Laboratories the responsibility for designing and providing the welding system for the girth weld for the AT-400A containment vessel. (The AT-400A container is employed for the shipment and long-term storage of the nuclear weapon pits being returned from the nation's nuclear arsenal.) Mason Hanger Corporation's Pantex Plant was chosen to be the production facility. The project was successfully completed by providing and implementing a turnkey welding system and qualified welding procedure at the Pantex Plant. The welding system was transferred to Pantex and a pilot lot of 20 AT-400A containers with W48 pits was welded in August 1997. This document is intended to bring together the AT-400A welding system and product (girth weld) requirements and the activities conducted to meet those requirements. This document alone is not a complete compilation of the welding development activities but is meant to be a summary to be used with the applicable references.

  8. Improving Fatigue Performance of AHSS Welds

    SciTech Connect (OSTI)

    Feng, Zhili; Yu, Xinghua; Erdman, III, Donald L.; Wang, Yanli; Kelly, Steve; Hou, Wenkao; Yan, Benda; Wang, Zhifeng; Yu, Zhenzhen; Liu, Stephen

    2015-03-01

    Reported herein is technical progress on a U.S. Department of Energy CRADA project with industry cost-share aimed at developing the technical basis and demonstrate the viability of innovative in-situ weld residual stresses mitigation technology that can substantially improve the weld fatigue performance and durability of auto-body structures. The developed technology would be costeffective and practical in high-volume vehicle production environment. Enhancing weld fatigue performance would address a critical technology gap that impedes the widespread use of advanced high-strength steels (AHSS) and other lightweight materials for auto body structure light-weighting. This means that the automotive industry can take full advantage of the AHSS in strength, durability and crashworthiness without the concern of the relatively weak weld fatigue performance. The project comprises both technological innovations in weld residual stress mitigation and due-diligence residual stress measurement and fatigue performance evaluation. Two approaches were investigated. The first one was the use of low temperature phase transformation (LTPT) weld filler wire, and the second focused on novel thermo-mechanical stress management technique. Both technical approaches have resulted in considerable improvement in fatigue lives of welded joints made of high-strength steels. Synchrotron diffraction measurement confirmed the reduction of high tensile weld residual stresses by the two weld residual stress mitigation techniques.

  9. Welding shield for coupling heaters

    DOE Patents [OSTI]

    Menotti, James Louis

    2010-03-09

    Systems for coupling end portions of two elongated heater portions and methods of using such systems to treat a subsurface formation are described herein. A system may include a holding system configured to hold end portions of the two elongated heater portions so that the end portions are abutted together or located near each other; a shield for enclosing the end portions, and one or more inert gas inlets configured to provide at least one inert gas to flush the system with inert gas during welding of the end portions. The shield may be configured to inhibit oxidation during welding that joins the end portions together. The shield may include a hinged door that, when closed, is configured to at least partially isolate the interior of the shield from the atmosphere. The hinged door, when open, is configured to allow access to the interior of the shield.

  10. FUSION WELDING METHOD AND APPARATUS

    DOE Patents [OSTI]

    Wyman, W.L.; Steinkamp, W.I.

    1961-01-17

    An apparatus for the fusion welding of metal pieces at a joint is described. The apparatus comprises a highvacuum chamber enclosing the metal pieces and a thermionic filament emitter. Sufficient power is applied to the emitter so that when the electron emission therefrom is focused on the joint it has sufficient energy to melt the metal pieces, ionize the metallic vapor abcve the molten metal, and establish an arc discharge between the joint and the emitter.

  11. Multi-mode ultrasonic welding control and optimization

    DOE Patents [OSTI]

    Tang, Jason C.H.; Cai, Wayne W

    2013-05-28

    A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

  12. Evaluating the SCC resistance of underwater welds in sodium tetrathionate

    SciTech Connect (OSTI)

    White, R.A.; Angeliu, T.M.

    1997-12-01

    The susceptibility of welds to stress corrosion cracking (SCC) is enhanced by the surface residual tensile stresses generated by the typical welding process. However, underwater plasma transferred arc (PTA) welding has been shown to produce compressive surface residual stresses, an encouraging result if repairs of cracked boiling water reactor (BWR) components are to be made without further endangering them to SCC. This program was designed to verify that underwater PTA welds are resistant to SCC and to determine if underwater PTA welding could mitigate SCC in potentially susceptible welds. This was achieved by exposing various welds on solution annealed (SA) and SA + thermally sensitized 304 stainless steel at 25 C in a solution of 1.5 gm/liter of sodium sulfide added to 0.05M sodium tetrathionate, titrated to a pH of 1.25 with H{sub 2}SO{sub 4}. The autogeneous welds were produced using gas tungsten arc (GTA) and plasma transferred arc (PTA) welding under atmospheric conditions, and PTA welding underwater. After 1 hour of sodium tetrathionate exposure, GTA and air PTA welds exhibited SCC while the underwater PTA weld heat affected zones were more resistant. Underwater PTA welds bisecting a GTA weld eliminated the cracking in the GTA weld heat affected zone under certain conditions. The lack of IG cracking in the region influenced by the underwater PTA weld is consistent with the measurement of compressive surface residual stresses inherent to the underwater welding process.

  13. Seal welded cast iron nuclear waste container

    DOE Patents [OSTI]

    Filippi, Arthur M.; Sprecace, Richard P.

    1987-01-01

    This invention identifies methods and articles designed to circumvent metallurgical problems associated with hermetically closing an all cast iron nuclear waste package by welding. It involves welding nickel-carbon alloy inserts which are bonded to the mating plug and main body components of the package. The welding inserts might be bonded in place during casting of the package components. When the waste package closure weld is made, the most severe thermal effects of the process are restricted to the nickel-carbon insert material which is far better able to accommodate them than is cast iron. Use of nickel-carbon weld inserts should eliminate any need for pre-weld and post-weld heat treatments which are a problem to apply to nuclear waste packages. Although the waste package closure weld approach described results in a dissimilar metal combination, the relative surface area of nickel-to-iron, their electrochemical relationship, and the presence of graphite in both materials will act to prevent any galvanic corrosion problem.

  14. Manual tube-to-tubesheet welding torch

    DOE Patents [OSTI]

    Kiefer, Joseph H.; Smith, Danny J.

    1982-01-01

    A welding torch made of a high temperature plastic which fits over a tube intermediate the ends thereof for welding the juncture between the tube and the back side of a tube plate and has a ballooned end in which an electrode, filler wire guide, fiber optic bundle, and blanketing gas duct are disposed.

  15. What makes an electric welding arc perform its required function

    SciTech Connect (OSTI)

    Correy, T.B.

    1982-09-01

    The physics of direct current and alternating current welding arcs, the heat transfer of direct current welding arcs, the characteristics of dc welding and ac welding power supplies and recommendations for the procurement and maintenance of precision power supplies are discussed. (LCL)

  16. Rapid estimate of solid volume in large tuff cores using a gas pycnometer

    SciTech Connect (OSTI)

    Thies, C.; Geddis, A.M.; Guzman, A.G.

    1996-09-01

    A thermally insulated, rigid-volume gas pycnometer system has been developed. The pycnometer chambers have been machined from solid PVC cylinders. Two chambers confine dry high-purity helium at different pressures. A thick-walled design ensures minimal heat exchange with the surrounding environment and a constant volume system, while expansion takes place between the chambers. The internal energy of the gas is assumed constant over the expansion. The ideal gas law is used to estimate the volume of solid material sealed in one of the chambers. Temperature is monitored continuously and incorporated into the calculation of solid volume. Temperature variation between measurements is less than 0.1{degrees}C. The data are used to compute grain density for oven-dried Apache Leap tuff core samples. The measured volume of solid and the sample bulk volume are used to estimate porosity and bulk density. Intrinsic permeability was estimated from the porosity and measured pore surface area and is compared to in-situ measurements by the air permeability method. The gas pycnometer accommodates large core samples (0.25 m length x 0.11 m diameter) and can measure solid volume greater than 2.20 cm{sup 3} with less than 1% error.

  17. Feasibility assessment of copper-base waste package container materials in a tuff repository

    SciTech Connect (OSTI)

    Acton, C.F.; McCright, R.D.

    1986-09-30

    This report discussed progress made during the second year of a two-year study on the feasibility of using copper or a copper-base alloy as a container material for a waste package in a potential repository in tuff rock at the Yucca Mountain site in Nevada. Corrosion testing in potentially corrosive irradiated environments received emphasis during the feasibility study. Results of experiments to evaluate the effect of a radiation field on the uniform corrosion rate of the copper-base materials in repository-relevant aqueous environments are given as well as results of an electrochemical study of the copper-base materials in normal and concentrated J-13 water. Results of tests on the irradiation of J-13 water and on the subsequent formation of hydrogen peroxide are given. A theoretical study was initiated to predict the long-term corrosion behavior of copper in the repository. Tests were conducted to determine whether copper would adversely affect release rates of radionuclides to the environment because of degradation of the Zircaloy cladding. A manufacturing survey to determine the feasibility of producing copper containers utilizing existing equipment and processes was completed. The cost and availability of copper was also evaluated and predicted to the year 2000. Results of this feasibility assessment are summarized.

  18. PDC IC WELD FAILURE EVALUATION AND RESOLUTION

    SciTech Connect (OSTI)

    Korinko, P.; Howard, S.; Maxwell, D.; Fiscus, J.

    2012-04-16

    During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process could be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process improvements for the actual can welding process, however, did not result in an improved weld geometry. Several possibilities for the lack of positive response exist, some of which are that (1) an insufficient number of test articles were welded under prototypic conditions, (2) the process was not optimized so that significant improvements were observable over the 'noise', and (3) the in-situ arc anneal closed the gap down too much so the can was unable to exhaust pressure ahead of the weld. Several operational and mechanical improvements were identified. The weld clamps were changed to a design consistent with those used in the legacy operations. A helium puff operation was eliminated; it is believed that this operation was the cause of the original weld defect. Also, timing of plug mast movement was found to correspond with weld irregularities. The timing of the movement was changed to occur during weld head travel between tacks. In the end a three sequential tack weld process followed by a pulse weld at the same current and travel speed as was used for the legacy processes was suggested for use during the IC qualification effort. Relative to legacy welds, the PDC IC weld demonstrates greater fluctuation in the region of the weld located between tack welds. However, canister weld response (canister to canister) is consistent and with the aid of the optical mapping system (for targeting the cut position) is considered adequate. DR measurements and METs show the PDC IC welds to have sufficient ligament length to ensure adequate canister pressure/impact capacity and to ensure adequate stub function. The PDC welding process has not been optimized as a result of this effort. Differences remain between the legacy BTC welds and the PDC IC weld, but these differences are not sufficient to prevent resumption of the current PDC IC qualification effort. During the PDC IC qualification effort, a total of 17 cans will be welded and a variety of tests/inspections will be performed. The extensive data collected during that qualification effort should be of a sufficient population to determ

  19. A strategy to seal exploratory boreholes in unsaturated tuff; Yucca Mountain Site Characterization Project

    SciTech Connect (OSTI)

    Fernandez, J.A.; Case, J.B.; Givens, C.A.; Carney, B.C.

    1994-04-01

    This report presents a strategy for sealing exploratory boreholes associated with the Yucca Mountain Site Characterization Project. Over 500 existing and proposed boreholes have been considered in the development of this strategy, ranging from shallow (penetrating into alluvium only) to deep (penetrating into the groundwater table). Among the comprehensive list of recommendations are the following: Those boreholes within the potential repository boundary and penetrating through the potential repository horizon are the most significant boreholes from a performance standpoint and should be sealed. Shallow boreholes are comparatively insignificant and require only nominal sealing. The primary areas in which to place seals are away from high-temperature zones at a distance from the potential repository horizon in the Paintbrush nonwelded tuff and the upper portion of the Topopah Spring Member and in the tuffaceous beds of the Calico Hills Unit. Seals should be placed prior to waste emplacement. Performance goals for borehole seals both above and below the potential repository are proposed. Detailed construction information on the boreholes that could be used for future design specifications is provided along with a description of the environmental setting, i.e., the geology, hydrology, and the in situ and thermal stress states. A borehole classification scheme based on the condition of the borehole wall in different tuffaceous units is also proposed. In addition, calculations are presented to assess the significance of the boreholes acting as preferential pathways for the release of radionuclides. Design calculations are presented to answer the concerns of when, where, and how to seal. As part of the strategy development, available technologies to seal exploratory boreholes (including casing removal, borehole wall reconditioning, and seal emplacement) are reviewed.

  20. Recent progress on gas tungsten arc welding of vanadium alloys

    SciTech Connect (OSTI)

    Grossbeck, M.L.; King, J.F.; Alexander, D.J.

    1997-08-01

    Emphasis has been placed on welding 6.4 mm plate, primarily by gas tungsten arc (GTA) welding. The weld properties were tested using blunt notch Charpy testing to determine the ductile to brittle transition temperature (DBTT). Erratic results were attributed to hydrogen and oxygen contamination of the welds. An improved gas clean-up system was installed on the welding glove box and the resulting high purity welds had Charpy impact properties similar to those of electron beam welds with similar grain size. A post-weld heat treatment (PWHT) of 950{degrees}C for two hours did not improve the properties of the weld in cases where low concentrations of impurities were attained. Further improvements in the gas clean-up system are needed to control hydrogen contamination.

  1. Pulsed Magnetic Welding for Advanced Core and Cladding Steel

    SciTech Connect (OSTI)

    Cao, Guoping; Yang, Yong

    2013-12-19

    To investigate a solid-state joining method, pulsed magnetic welding (PMW), for welding the advanced core and cladding steels to be used in Generation IV systems, with a specific application for fuel pin end-plug welding. As another alternative solid state welding technique, pulsed magnetic welding (PMW) has not been extensively explored on the advanced steels. The resultant weld can be free from microstructure defects (pores, non-matallic inclusions, segregation of alloying elements). More specifically, the following objectives are to be achieved, 1) To design a suitable welding apparatus fixture, and optimize welding parameters for repeatable and acceptable joining of the fuel pin end-plug. The welding will be evaluated using tensile tests for lap joint weldments and helium leak tests for the fuel pin end-plug. 2) investigate the microstructural and mechanical properties changes in PMW weldments of proposed advanced core and cladding alloys. 3) Simulate the irradiation effects on the PWM weldments using ion irradiation.

  2. Method and apparatus for real time weld monitoring

    DOE Patents [OSTI]

    Leong, Keng H. (Lemont, IL); Hunter, Boyd V. (Bolingbrook, IL)

    1997-01-01

    An improved method and apparatus are provided for real time weld monitoring. An infrared signature emitted by a hot weld surface during welding is detected and this signature is compared with an infrared signature emitted by the weld surface during steady state conditions. The result is correlated with weld penetration. The signal processing is simpler than for either UV or acoustic techniques. Changes in the weld process, such as changes in the transmitted laser beam power, quality or positioning of the laser beam, change the resulting weld surface features and temperature of the weld surface, thereby resulting in a change in the direction and amount of infrared emissions. This change in emissions is monitored by an IR sensitive detecting apparatus that is sensitive to the appropriate wavelength region for the hot weld surface.

  3. The 'world's largest' Inconel waterwall weld overlay

    SciTech Connect (OSTI)

    MacLean, K.; Fournier, E.; Gomez-Grande, J.; Scandroli, T.

    2009-11-15

    An 11,000 square foot Inconel 655 weld repaired severe wastage caused by low NOx firing with coal/petcoke at the Belledune generating station in New Brunswick, Canada. 1 ref., 1 fig., 3 photos.

  4. Vibration welding system with thin film sensor

    DOE Patents [OSTI]

    Cai, Wayne W; Abell, Jeffrey A; Li, Xiaochun; Choi, Hongseok; Zhao, Jingzhou

    2014-03-18

    A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

  5. Summary of Dissimilar Metal Joining Trials Conducted by Edison Welding Institute

    SciTech Connect (OSTI)

    MJ Lambert

    2005-11-18

    Under the direction of the NASA-Glenn Research Center, the Edison Welding Institute (EWI) in Columbus, OH performed a series of non-fusion joining experiments to determine the feasibility of joining refractory metals or refractory metal alloys to Ni-based superalloys. Results, as reported by EWI, can be found in the project report for EWI Project 48819GTH (Attachment A, at the end of this document), dated October 10, 2005. The three joining methods used in this investigation were inertia welding, magnetic pulse welding, and electro-spark deposition joining. Five materials were used in these experiments: Mo-47Re, T-111, Hastelloy X, Mar M-247 (coarse-grained, 0.5 mm to several millimeter average grain size), and Mar M-247 (fine-grained, approximately 50 {micro}m average grain size). Several iterative trials of each material combination with each joining method were performed to determine the best practice joining method. Mo-47Re was found to be joined easily to Hastelloy X via inertia welding, but inertia welding of the Mo-alloy to both Mar M-247 alloys resulted in inconsistent joint strength and large reaction layers between the two metals. T-111 was found to join well to Hastelloy X and coarse-grained Mar M-247 via inertia welding, but joining to fine-grained Mar M-247 resulted in low joint strength. Magnetic pulse welding (MPW) was only successful in joining T-111 tubing to Hastelloy X bar stock. The joint integrity and reaction layer between the metals were found to be acceptable. This single joining trial, however, caused damage to the electromagnetic concentrators used in this process. Subsequent design efforts to eliminate the problem resulted in a loss of power imparted to the accelerating work piece, and results could not be reproduced. Welding trials of Mar M-247 to T-111 resulted in catastrophic failure of the bar stock, even at lower power. Electro-spark deposition joining of Mo-47Re, in which the deposited material was Hastelloy X, did not have a noticeable reaction layer. T-111 was found to have a small reaction layer at the interface with deposited Hastelloy X. Mar M-247 had a reaction layer larger than T-111. Hastelloy X joined well with a substrate of the same alloy, and throughout the experiments was found to have a density of {approx}99%, based on metallographic observations of porosity in the deposit. Of the three joining methods tested, inertial welding of bar stock appears to be the most mature at this time. MPW may be an attractive alternative due to the potential for high bond integrity, similar to that seen in explosion bonding. However, all three joining methods used in this work will require adaptation in order to join piping and tubing. Further investigations into the change in mechanical properties of these joints with time, temperature, irradiation, and the use of interlayers between the two materials must also be performed.

  6. Welding - Friction Stir - Energy Innovation Portal

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Industrial Technologies Industrial Technologies Find More Like This Return to Search Welding - Friction Stir Idaho National Laboratory Contact INL About This Technology Technology Marketing Summary Friction welding that uses a contact rotating tool creates frictional heating of an adjacent work piece. The process employs a mixer where the two pieces touch, an area called the plastic zone, to avoid the undesirable joining (e.g. alloying) of the two work pieces.Description First, a

  7. Optimization of Weld Conditions and Alloy Composition for Welding of Single-Crystal Nickel-Based Superalloys

    SciTech Connect (OSTI)

    Vitek, John Michael; David, Stan A; Babu, Sudarsanam S

    2007-01-01

    Calculations were carried out to identify optimum welding conditions and weld alloy compositions to avoid stray grain formation during welding of single-crystal nickel-based superalloys. The calculations were performed using a combination of three models: a thermal model to describe the weld pool shape and the local thermal gradient and solidification front velocity; a geometric model to identify the local active dendrite growth variant, and a nucleation and growth model to describe the extent of stray grain formation ahead of the advancing solidification front. Optimum welding conditions (low weld power, high weld speed) were identified from the model calculations. Additional calculations were made to determine potential alloy modifications that reduce the solidification temperature range while maintaining high gamma prime content. The combination of optimum weld conditions and alloy compositions should allow for weld repair of single-crystal nickel-based superalloys without sacrificing properties or performance.

  8. Welding development for V-Cr-Ti alloys

    SciTech Connect (OSTI)

    Goodwin, G.M.; King, J.F.

    1994-09-01

    Welds have been produced and characterized using the gas-tungsten arc (GTA) and electron beam (EB) welding processes. Thin sheet (0.75 mm) welds were made with three levels of interstitial contamination, and hardness and tensile properties were found to be strongly affected by oxygen pickup. Thick-section (6 mm) welds have been produced using both processes, and no embrittlement is experienced when high purity atmosphere is maintained. Metallographic examination shows a narrow, but coarse grained, heat affected zone for the GTA welds. Transition joint welding development between vanadium alloy and stainless steel has shown encouraging results.

  9. Thermocapillary and arc phenomena in stainless steel welds

    SciTech Connect (OSTI)

    Pierce, S.W.

    1993-10-01

    Goal was to study effect of power level and distribution on thermocapiilary-induced weld shape and of arc factors on weld shape. Thermocapillarity was apparent in both conduction mode EB welds and GTA welds, particularly in the former. A non-Gaussian arc distribution is suggested for accounting for the differences between the twoss processes. At higher current levels (200--300 A), plasma shear force also contributes to weld shape development. Evidence suggests that thermocapillary flow reversal is not a factor in normal GTA welds; EDB flow reversal occurs only at high power density levels where the keyhole mode is present.

  10. Towards Real Time Diagnostics of Hybrid Welding Laser/GMAW

    SciTech Connect (OSTI)

    Timothy Mcjunkin; Dennis C. Kunerth; Corrie Nichol; Evgueni Todorov; Steve Levesque; Feng Yu; Robert Danna Couch

    2013-07-01

    Methods are currently being developed towards a more robust system real time feedback in the high throughput process combining laser welding with gas metal arc welding. A combination of ultrasonic, eddy current, electronic monitoring, and visual techniques are being applied to the welding process. Initial simulation and bench top evaluation of proposed real time techniques on weld samples are presented along with the concepts to apply the techniques concurrently to the weld process. Consideration for the eventual code acceptance of the methods and system are also being researched as a component of this project. The goal is to detect defects or precursors to defects and correct when possible during the weld process.

  11. Aluminum Tailor-Welded Blanks for High Volume Automotive Applications

    SciTech Connect (OSTI)

    Hovanski, Yuri; Upadhyay, Piyush; Pilli, Siva Prasad; Carlson, Blair; Carsley, John; Hartfield-Wunsch, Susan; Eisenmenger, Mark

    2014-02-04

    A Design of Experiment based approach is used to systematically investigate relationships between 8 different welding factors (4 related to tool geometry, 4 related to weld process control) and resulting weld properties including strength, elongation and formability in 1.2mm-2mm thick friction stir welding of AA5182-O for TWB application. The factors that result in most significant effects are elucidated. The interactions between several key factors like plunge depth, tool tilt, pin feature and pin length on the overall weld quality is discussed. Appropriate levels of factors that lead to excellent weld properties are also identified.

  12. Towards real time diagnostics of Hybrid Welding Laser/GMAW

    SciTech Connect (OSTI)

    McJunkin, T. R.; Kunerth, D. C.; Nichol, C. I. [Idaho National Laboratory, Idaho Falls, ID 83415-3570 (United States); Todorov, E.; Levesque, S. [Edison Welding Institute, Columbus, OH (United States)

    2014-02-18

    Methods are currently being developed towards a more robust system real time feedback in the high throughput process combining laser welding with gas metal arc welding. A combination of ultrasonic, eddy current, electronic monitoring, and visual techniques are being applied to the welding process. Initial simulation and bench top evaluation of proposed real time techniques on weld samples are presented along with the concepts to apply the techniques concurrently to the weld process. Consideration for the eventual code acceptance of the methods and system are also being researched as a component of this project. The goal is to detect defects or precursors to defects and correct when possible during the weld process.

  13. Friction Stir Spot Welding of Advanced High Strength Steels

    SciTech Connect (OSTI)

    Hovanski, Yuri; Grant, Glenn J.; Santella, M. L.

    2009-11-13

    Friction stir spot welding techniques were developed to successfully join several advanced high strength steels. Two distinct tool materials were evaluated to determine the effect of tool materials on the process parameters and joint properties. Welds were characterized primarily via lap shear, microhardness, and optical microscopy. Friction stir spot welds were compared to the resistance spot welds in similar strength alloys by using the AWS standard for resistance spot welding high strength steels. As further comparison, a primitive cost comparison between the two joining processes was developed, which included an evaluation of the future cost prospects of friction stir spot welding in advanced high strength steels.

  14. Welding Behavior of Free Machining Stainless Steel

    SciTech Connect (OSTI)

    BROOKS,JOHN A.; ROBINO,CHARLES V.; HEADLEY,THOMAS J.; MICHAEL,JOSEPH R.

    2000-07-24

    The weld solidification and cracking behavior of sulfur bearing free machining austenitic stainless steel was investigated for both gas-tungsten arc (GTA) and pulsed laser beam weld processes. The GTA weld solidification was consistent with those predicted with existing solidification diagrams and the cracking response was controlled primarily by solidification mode. The solidification behavior of the pulsed laser welds was complex, and often contained regions of primary ferrite and primary austenite solidification, although in all cases the welds were found to be completely austenite at room temperature. Electron backscattered diffraction (EBSD) pattern analysis indicated that the nature of the base metal at the time of solidification plays a primary role in initial solidification. The solid state transformation of austenite to ferrite at the fusion zone boundary, and ferrite to austenite on cooling may both be massive in nature. A range of alloy compositions that exhibited good resistance to solidification cracking and was compatible with both welding processes was identified. The compositional range is bounded by laser weldability at lower Cr{sub eq}/Ni{sub eq} ratios and by the GTA weldability at higher ratios. It was found with both processes that the limiting ratios were somewhat dependent upon sulfur content.

  15. Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Emery, John M.; Field, Richard V.; Foulk, James W.; Karlson, Kyle N.; Grigoriu, Mircea D.

    2015-05-26

    Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not bemore » efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.« less

  16. Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

    SciTech Connect (OSTI)

    Emery, John M.; Field, Richard V.; Foulk, James W.; Karlson, Kyle N.; Grigoriu, Mircea D.

    2015-05-26

    Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not be efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.

  17. Fusion welding of a modern borated stainless steel

    SciTech Connect (OSTI)

    Robino, C.V.; Cieslak, M.J.

    1997-01-01

    Experiments designed to assess the fabrication and service weldability of 304B4A borated stainless steel were conducted. Welding procedures and parameters for manual gas tungsten arc (GTA) welding, autogenous electron beam (EB) welding and filler-added EB welding were developed and found to be similar to those for austenitic stainless steels. Following the procedure development, four test welds were produced and evaluated by microstructural analysis and Charpy impact testing. Further samples were used for determination of the postweld heat treatment (PWHT) response of the welds. The fusion zone structure of welds in this alloy consists of primary austenite dendrites with an interdendritic eutectic-like austenite/boride constituent. Welds also show an appreciable partially molten zone that consists of the austenite/boride eutectic surrounding unmelted austenite islands. The microstructure of the EB welds was substantially finer than that of the GTA welds, and boride coarsening was not observed in the solid state heat-affected zone (HAZ) of either weld type. The impact toughness of as-welded samples was found to be relatively poor, averaging less than 10 J for both GTA and EB welds. For fusion zone notched GTA and EB samples and centerline notched EB samples, fracture generally occurred along the boundary between the partially molten and solid-state regions of the HAZ. The results of the PWHT study were very encouraging, with typical values of the impact energy for HAZ notched samples approaching 40 J, or twice the minimum code-acceptable value.

  18. A Glove Box Enclosed Gas-Tungsten Arc Welding System

    SciTech Connect (OSTI)

    Reevr, E, M; Robino, C.V.

    1999-07-01

    This report describes an inert atmosphere enclosed gas-tungsten arc welding system which has been assembled in support of the MC2730, MC2730A and MC 3500 Radioisotope Thermoelectric Generator (RTG) Enhanced Surveillance Program. One goal of this program is to fabricate welds with microstructures and impurity levels which are similar to production heat source welds previously produced at Los Alamos National Laboratory and the Mound Facility. These welds will subsequently be used for high temperature creep testing as part of the overall component lifetime assessment. In order to maximize the utility of the welding system, means for local control of the arc atmosphere have been incorporated and a wide range of welding environments can easily be evaluated. The gas-tungsten arc welding system used in the assembly is computer controlled, includes two-axis and rotary motion, and can be operated in either continuous or pulsed modes. The system can therefore be used for detailed research studies of welding impurity effects, development of prototype weld schedules, or to mimic a significant range of production-like welding conditions. Fixturing for fabrication of high temperature creep test samples have been designed and constructed, and weld schedules for grip-tab and test welds have been developed. The microstructure of these welds have been evaluated and are consistent with those used during RTG production.

  19. Apparatus for maintaining aligment of a shrinking weld joint in an electron-beam welding operation

    DOE Patents [OSTI]

    Trent, J.B.; Murphy, J.L.

    1980-01-03

    The invention is directed to an apparatus for automatically maintaining a shrinking weld joint in alignement with an electron beam during an electron-beam multipass-welding operation. The apparatus utilizes a bias means for continually urging a workpiece-supporting face plate away from a carriage mounted base that rotatably supports the face plate. The extent of displacement of the face plate away from the base in indicative of the shrinkage occuring in the weld joint area. This displacement is measured and is used to move the base on the carriage a distance equal to one-half the displacement for aligning the weld joint with the electron beam during each welding pass.

  20. Apparatus for maintaining alignment of a shrinking weld joint in an electron-beam welding operation

    DOE Patents [OSTI]

    Trent, Jett B.; Murphy, Jimmy L.

    1981-01-01

    The present invention is directed to an apparatus for automatically maintaining a shrinking weld joint in alignment with an electron beam during an electron-beam multipass-welding operation. The apparatus utilizes a biasing device for continually urging a workpiece-supporting face plate away from a carriage mounted base that rotatably supports the face plate. The extent of displacement of the face plate away from the base is indicative of the shrinkage occuring in the weld joint area. This displacement is measured and is used to move the base on the carriage a distance equal to one-half the displacement for aligning the weld joint with the electron beam during each welding pass.

  1. Feasibility of correlating V-Cr-Ti alloy weld strength with weld chemistry. CRADA final report

    SciTech Connect (OSTI)

    Grossbeck, M.L.; Odom, R.W.

    1998-06-01

    The mechanical properties of refractory metals such as vanadium are determined to a large extent by the interstitial impurities in the alloy. In the case of welding, interstitial impurities are introduced in the welding process from the atmosphere and by dissolution of existing precipitates in the alloy itself. Because of the necessity of having an ultra-pure atmosphere, a vacuum chamber or a glove box is necessary. In the V-Cr-Ti system, the titanium serves as a getter to control the concentration of oxygen and nitrogen in solid solution in the alloy. In this project the secondary ion mass spectrometry (SIMS) technique was used to detect, measure, and map the spacial distribution of impurity elements in welds in the alloy V-4Cr-4Ti. An attempt was then made to correlate the concentrations and distributions of the impurities with mechanical properties of the welds. Mechanical integrity of the welds was determined by Charpy V-notch testing. Welds were prepared by the gas-tungsten-arc (GTA) method. Charpy testing established a correlation between weld impurity concentration and the ductile to brittle transition temperature (DBTT). Higher concentrations of oxygen resulted in a higher DBTT. An exception was noted in the case of a low-oxygen weld which had a high hydrogen concentration resulting in a brittle weld. The concentrations and distributions of the impurities determined by SIMS could not be correlated with the mechanical properties of the welds. This research supports efforts to develop fusion reactor first wall and blanket structural materials.

  2. Effect of a copper filler metal on the microstructure and mechanical properties of electron beam welded titanium-stainless steel joint

    SciTech Connect (OSTI)

    Wang, Ting, E-mail: fgwangting@163.com [Key Laboratory of Special Welding in Shandong Province, Harbin Institute of Technology at Weihai, Weihai, 264209 (China)] [Key Laboratory of Special Welding in Shandong Province, Harbin Institute of Technology at Weihai, Weihai, 264209 (China); Zhang, Binggang, E-mail: zhang_bg@126.com [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001 (China)] [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001 (China); Feng, Jicai, E-mail: fengjc@hit.edu.cn [Key Laboratory of Special Welding in Shandong Province, Harbin Institute of Technology at Weihai, Weihai, 264209 (China) [Key Laboratory of Special Welding in Shandong Province, Harbin Institute of Technology at Weihai, Weihai, 264209 (China); State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001 (China); Tang, Qi, E-mail: tangqi@163.com [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001 (China)] [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001 (China)

    2012-11-15

    Cracking in an electron beam weld of titanium to stainless steel occurred during the cooling process because of internal thermal stress. Using a copper filler metal, a crack free joint was obtained, which had a tensile strength of 310 MPa. To determine the reasons for cracking in the Ti/Fe joint and the function of the copper filler metal on the improvement of the cracking resistance of the Ti/Cu/Fe joint, the microstructures of the joints were studied by optical microscopy, scanning electron microscopy and X-ray diffraction. The cracking susceptibilities of the joints were evaluated with microhardness tests on the cross-sections. In addition, microindentation tests were used to compare the brittleness of the intermetallics in the welds. The results showed that the Ti/Fe joint was characterized by continuously distributed brittle intermetallics such as TiFe and TiFe(Cr){sub 2} with high hardness ({approx} 1200 HV). For the Ti/Cu/Fe joint, most of the weld consisted of a soft solid solution of copper with dispersed TiFe intermetallics. The transition region between the weld and the titanium alloy was made up of a relatively soft Ti-Cu intermetallic layer with a lower hardness ({approx} 500 HV). The formation of soft phases reduced the cracking susceptibility of the joint. - Highlights: Black-Right-Pointing-Pointer Electron beam welded Ti/Fe joint cracked for the brittleness and residual stress. Black-Right-Pointing-Pointer Electron beam welded Ti/Cu/Fe joint with tensile strength of 310 MPa was obtained. Black-Right-Pointing-Pointer Cu diluted Ti and Fe contents in weld and separated the TiFe{sub 2} into individual blocks. Black-Right-Pointing-Pointer Interfacial hard Ti-Fe compounds were replaced by soft Ti-Cu compounds in the weld. Black-Right-Pointing-Pointer A large amount of solid solution of copper formed in the weld.

  3. Apparent Welding Textures In Altered Pumice-Rich Rocks | Open...

    Open Energy Info (EERE)

    Apparent Welding Textures In Altered Pumice-Rich Rocks Jump to: navigation, search OpenEI Reference LibraryAdd to library Journal Article: Apparent Welding Textures In Altered...

  4. Repair welding of fusion reactor components. Second year technical report

    SciTech Connect (OSTI)

    Chin, B.A.

    1993-05-15

    Experiments have shown that irradiated Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 MPa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  5. Technique to eliminate helium induced weld cracking in stainless steels

    SciTech Connect (OSTI)

    Chin-An Wang; Chin, B.A.; Grossbeck, M.L.

    1992-12-31

    Experiments have shown that Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 Mpa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  6. Friction Stir Spot Welding of Advanced High Strength Steels II...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Friction Stir Spot Welding of Advanced High Strength Steels II Friction Stir Spot Welding of Advanced High Strength Steels II 2011 DOE Hydrogen and Fuel Cells Program, and Vehicle ...

  7. Promising Inspection Technique for Vehicle Welding Offers Efficient Alternative

    Broader source: Energy.gov [DOE]

    The average car uses more than 4,000 spot welds to hold its parts together.  While manufacturers currently inspect the quality of welds by prying apart samples, Oak Ridge National Laboratory (ORNL)...

  8. Promising Inspection Technique for Vehicle Welding Offers Efficient...

    Broader source: Energy.gov (indexed) [DOE]

    non-destructive technology that could check all welds in real-time on the production line. ... In addition, checking materials real-time as they are being welded would allow ...

  9. Actively controlled vibration welding system and method (Patent) |

    Office of Scientific and Technical Information (OSTI)

    DOEPatents Actively controlled vibration welding system and method Title: Actively controlled vibration welding system and method A vibration welding system includes a controller, welding horn, an active material element, and anvil assembly. The assembly may include an anvil body connected to a back plate and support member. The element, e.g., a piezoelectric stack or shape memory alloy, is positioned with respect to the assembly. The horn vibrates in a desirable first direction to form a

  10. IR Spot Weld Inspect () | SciTech Connect

    Office of Scientific and Technical Information (OSTI)

    Software: IR Spot Weld Inspect Citation Details Software Request Title: IR Spot Weld Inspect In automotive industry, destructive inspection of spot welds is still the mandatory quality assurance method due to the lack of efficient non-destructive evaluation (NDE) tools. However, it is costly and time-consuming. Recently at ORNL, a new NDE prototype system for spot weld inspection using infrared (IR) thermography has been developed to address this problem. This software contains all the key

  11. Plutonium metal and oxide container weld development and qualification

    SciTech Connect (OSTI)

    Fernandez, R.; Horrell, D.R.; Hoth, C.W.; Pierce, S.W.; Rink, N.A.; Rivera, Y.M.; Sandoval, V.D.

    1996-01-01

    Welds were qualified for a container system to be used for long-term storage of plutonium metal and oxide. Inner and outer containers are formed of standard tubing with stamped end pieces gas-tungsten-arc (GTA) welded onto both ends. The weld qualification identified GTA parameters to produce a robust weld that meets the requirements of the Department of Energy standard DOE-STD-3013-94, ``Criteria for the Safe Storage of Plutonium Metals and Oxides.``

  12. EERE Success Story-Promising Inspection Technique for Vehicle Welding

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Offers Efficient Alternative | Department of Energy Promising Inspection Technique for Vehicle Welding Offers Efficient Alternative EERE Success Story-Promising Inspection Technique for Vehicle Welding Offers Efficient Alternative April 22, 2015 - 2:06pm Addthis ORNL researcher Jian Chen works with the prototype weld inspection system licensed by Tennessee-based APLAIR Manufacturing Systems. ORNL researcher Jian Chen works with the prototype weld inspection system licensed by Tennessee-based

  13. Effect of Post-Weld Heat Treatment on Creep Rupture Properties of Grade 91 Steel Heavy Section Welds

    SciTech Connect (OSTI)

    Li, Leijun

    2012-11-02

    This project will conduct a systematic metallurgical study on the effect of post-weld heat treatment (PWHT) on the creep rupture properties of P91 heavy section welds. The objective is to develop a technical guide for selecting PWHT parameters, and to predict expected creep-rupture life based on the selection of heat treatment parameters. The project consists of four interdependent tasks: Experimentally and numerically characterize the temperature fields of typical post-weld heat treatment procedures for various weld and joint configurations to be used in Gen IV systems. Characterize the microstructure of various regions, including the weld fusion zone, coarse-grain heat-affected zone, and fine-grain heat affected zone, in the welds that underwent the various welding and PWHT thermal histories. Conduct creep and creep-rupture testing of coupons extracted from actual and physically simulated welds. Establish the relationship among PWHT parameters, thermal histories, microstructure, creep, and creep-rupture properties.

  14. REAL TIME ULTRASONIC ALUMINUM SPOT WELD MONITORING SYSTEM

    SciTech Connect (OSTI)

    Regalado, W. Perez; Chertov, A. M.; Maev, R. Gr. [Institute for Diagnostic Imaging Research, Physics Department, University of Windsor, 292 Essex Hall, 401 Sunset Ave. N9B 3P4 Windsor, Ontario (Canada)

    2010-02-22

    Aluminum alloys pose several properties that make them one of the most popular engineering materials: they have excellent corrosion resistance, and high weight-to-strength ratio. Resistance spot welding of aluminum alloys is widely used today but oxide film and aluminum thermal and electrical properties make spot welding a difficult task. Electrode degradation due to pitting, alloying and mushrooming decreases the weld quality and adjustment of parameters like current and force is required. To realize these adjustments and ensure weld quality, a tool to measure weld quality in real time is required. In this paper, a real time ultrasonic non-destructive evaluation system for aluminum spot welds is presented. The system is able to monitor nugget growth while the spot weld is being made. This is achieved by interpreting the echoes of an ultrasound transducer located in one of the welding electrodes. The transducer receives and transmits an ultrasound signal at different times during the welding cycle. Valuable information of the weld quality is embedded in this signal. The system is able to determine the weld nugget diameter by measuring the delays of the ultrasound signals received during the complete welding cycle. The article presents the system performance on aluminum alloy AA6022.

  15. Apparatus for the concurrent inspection of partially completed welds

    DOE Patents [OSTI]

    Smartt, Herschel B.; Johnson, John A.; Larsen, Eric D.; Bitsoi, Rodney J.; Perrenoud, Ben C.; Miller, Karen S.; Pace, David P.

    2002-01-01

    An apparatus for the concurrent inspection of partially completed welds is described in which is utilized in combination with a moveable welder for forming a partially completed weld, and an ultrasonic generator mounted on a moveable welder in which is reciprocally moveable along a path of travel which is laterally disposed relative to the partially completed weld.

  16. Weld overlay coatings for erosion control

    SciTech Connect (OSTI)

    Levin, B.; DuPont, J.N.; Marder, A.R.

    1993-03-03

    A literature review was made. In spite of similarities between abrasive wear and solid particle erosion, weld overlay hardfacing alloys that exhibit high abrasion resistance may not necessarily have good erosion resistance. The performance of weld overlay hardfacing alloys in erosive environments has not been studied in detail. It is believed that primary-solidified hard phases such as carbides and intermetallic compounds have a strong influence on erosion resistance of weld overlay hardfacing alloys. However, relationships between size, shape, and volume fraction of hard phases in a hardfacing alloys and erosion resistance were not established. Almost all hardfacing alloys can be separated into two major groups based upon chemical compositions of the primary solidified hard phases: (a) carbide hardening alloys (Co-base/carbide, WC-Co and some Fe base superalloys); and (b) intermetallic hardening alloys (Ni-base alloys, austenitic steels, iron-aluminides).

  17. Actively controlled vibration welding system and method

    DOE Patents [OSTI]

    Cai, Wayne W.; Kang, Bongsu; Tan, Chin-An

    2013-04-02

    A vibration welding system includes a controller, welding horn, an active material element, and anvil assembly. The assembly may include an anvil body connected to a back plate and support member. The element, e.g., a piezoelectric stack or shape memory alloy, is positioned with respect to the assembly. The horn vibrates in a desirable first direction to form a weld on a work piece. The element controls any vibrations in a second direction by applying calibrated response to the anvil body in the second direction. A method for controlling undesirable vibrations in the system includes positioning the element with respect to the anvil assembly, connecting the anvil body to the support member through the back plate, vibrating the horn in a desirable first direction, and transmitting an input signal to the element to control vibration in an undesirable second direction.

  18. Evaluation of the intermittent GTA cold wire feed weld system

    SciTech Connect (OSTI)

    Dereskiewicz, J.P.

    1991-08-01

    An intermittent gas tungsten arc cold wire feed process was statistically evaluated to determine the feasibility of applying this process to meet the 0.030-inch weld penetration and peak temperature requirements when unfavorable joint tolerances exist on a subassembly weld. The wire feed system was determined to only slightly benefit the welding process over normal pulsed gas tungsten arc welding using traditional wire feeding capabilities. However, the complexity of this process and extensive welding operator training and qualification does not outweigh the benefits of incorporating this synchronized pulse wire feed system in production. 2 refs., 43 figs., 11 tabs.

  19. Method and apparatus for welding precipitation hardenable materials

    DOE Patents [OSTI]

    Murray, H. Jr.; Harris, I.D.; Ratka, J.O.; Spiegelberg, W.D.

    1994-06-28

    A method for welding together members consisting of precipitation age hardened materials includes the steps of selecting a weld filler material that has substantially the same composition as the materials being joined, and an age hardening characteristic temperature age threshold below that of the aging kinetic temperature range of the materials being joined, whereby after welding the members together, the resulting weld and heat affected zone (HAZ) are heat treated at a temperature below that of the kinetic temperature range of the materials joined, for obtaining substantially the same mechanical characteristics for the weld and HAZ, as for the parent material of the members joined. 5 figures.

  20. Method and apparatus for welding precipitation hardenable materials

    DOE Patents [OSTI]

    Murray, Jr., Holt; Harris, Ian D.; Ratka, John O.; Spiegelberg, William D.

    1994-01-01

    A method for welding together members consisting of precipitation age hardened materials includes the steps of selecting a weld filler material that has substantially the same composition as the materials being joined, and an age hardening characteristic temperature age threshold below that of the aging kinetic temperature range of the materials being joined, whereby after welding the members together, the resulting weld and heat affected zone (HAZ) are heat treated at a temperature below that of the kinetic temperature range of the materials joined, for obtaining substantially the same mechanical characteristics for the weld and HAZ, as for the parent material of the members joined.

  1. Method for producing titanium aluminide weld rod

    DOE Patents [OSTI]

    Hansen, Jeffrey S.; Turner, Paul C.; Argetsinger, Edward R.

    1995-01-01

    A process for producing titanium aluminide weld rod comprising: attaching one end of a metal tube to a vacuum line; placing a means between said vacuum line and a junction of the metal tube to prevent powder from entering the vacuum line; inducing a vacuum within the tube; placing a mixture of titanium and aluminum powder in the tube and employing means to impact the powder in the tube to a filled tube; heating the tube in the vacuum at a temperature sufficient to initiate a high-temperature synthesis (SHS) reaction between the titanium and aluminum; and lowering the temperature to ambient temperature to obtain a intermetallic titanium aluminide alloy weld rod.

  2. Method for the concurrent ultrasonic inspection of partially completed welds

    DOE Patents [OSTI]

    Johnson, John A. (Idaho Falls, ID); Larsen, Eric D. (Idaho Falls, ID); Miller, Karen S. (Idaho Falls, ID); Smartt, Herschel B. (Idaho Falls, ID); McJunkin, Timothy R. (Idaho Falls, ID)

    2002-01-01

    A method for the concurrent ultrasonic inspection of partially completed welds is disclosed and which includes providing a pair of transducers which are individually positioned on the opposite sides of a partially completed weld to be inspected; moving the transducers along the length of and laterally inwardly and outwardly relative to the partially completed weld; pulsing the respective transducers to produce an ultrasonic signal which passes through or is reflected from the partially completed weld; receiving from the respective transducers ultrasonic signals which pass through or are reflected from the partially completed welds; and analyzing the ultrasonic signal which has passed through or is reflected from the partially completed weld to determine the presence of any weld defects.

  3. A residual stress study in similar and dissimilar welds

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Eisazadeh, Hamid; Goldak, John A.; Aidun, Daryush K.; Coules, Harry E.; Bunn, Jeffrey R; Achuthan, A.

    2016-04-01

    Residual strain distributions in similar and dissimilar welds were measured using neutron diffraction (ND) method. Then, using three strain components, three-dimensional stress states were calculated. The results were used to determine the effect of the martensitic phase transformation and material properties on residual stress (RS) distribution. It was observed that smaller longitudinal RS was induced in the low carbon steel side of dissimilar weld when compared to its similar weld. Also, it was found that the transverse RS near and within the weld zone (WZ) in dissimilar weld exhibited a distinctive trend, with tensile mode reaching the yield strength ofmore » the base metal (BM). In order to characterize the WZ in dissimilar weld, we deployed optical microscopy, hardness, and energy dispersive X-ray spectroscopy (EDAX). This study not only provides further insight into the RS state in similar and dissimilar welds; it also delivers important consequences of phase transformation in the latter case.« less

  4. Modeling of Heat and Mass Transfer in Fusion Welding

    SciTech Connect (OSTI)

    Zhang, Wei [ORNL

    2011-01-01

    In fusion welding, parts are joined together by melting and subsequent solidification. Although this principle is simple, complex transport phenomena take place during fusion welding, and they determine the final weld quality and performance. The heat and mass transfer in the weld pool directly affect the size and shape of the pool, the solidification microstructure, the formation of weld defects such as porosity and humping, and the temperature distribution in the fusion zone and heat-affected zone (HAZ). Furthermore, the temperature evolution affects the kinetics and extent of various solid-state phase transformations, which in turn determine the final weld microstructure and mechanical properties. The formation of residual stresses and distortion originates from the thermal expansion and contraction during welding heating and cooling, respectively.

  5. Friction Stir Spot Welding of DP780 Carbon Steel

    SciTech Connect (OSTI)

    Santella, M. L.; Hovanski, Yuri; Frederick, Alan; Grant, Glenn J.; Dahl, Michael E.

    2009-09-15

    Friction stir spot welds were made in uncoated and galvannneled DP780 sheets using polycrystalline boron nitride stir tools. The tools were plunged at either a single continuous rate or in two segments consisting of a relatively high rate followed by a slower rate of shorter depth. Welding times ranged from 1-10 s. Increasing tool rotation speed from 800 to 1600 rpm increased strength values. The 2-segment welding procedures also produced higher strength joints. Average lap-shear strengths exceeding 10.3 kN were consistently obtained in 4 s on both the uncoated and the galvannealed DP780. The likelihood of diffusion and mechanical interlocking contributing to bond formation was supported by metallographic examinations. A cost analysis based on spot welding in automobile assembly showed that for friction stir spot welding to be economically competitive with resistance spot welding the cost of stir tools must approach that of resistance spot welding electrode tips.

  6. Intermetallic alloy welding wires and method for fabricating the same

    DOE Patents [OSTI]

    Santella, Michael L.; Sikka, Vinod K.

    1996-01-01

    Welding wires for welding together intermetallic alloys of nickel aluminides, nickel-iron aluminides, iron aluminides, or titanium aluminides, and preferably including additional alloying constituents are fabricated as two-component, clad structures in which one component contains the primary alloying constituent(s) except for aluminum and the other component contains the aluminum constituent. This two-component approach for fabricating the welding wire overcomes the difficulties associated with mechanically forming welding wires from intermetallic alloys which possess high strength and limited ductilities at elevated temperatures normally employed in conventional metal working processes. The composition of the clad welding wires is readily tailored so that the welding wire composition when melted will form an alloy defined by the weld deposit which substantially corresponds to the composition of the intermetallic alloy being joined.

  7. Intermetallic alloy welding wires and method for fabricating the same

    DOE Patents [OSTI]

    Santella, M.L.; Sikka, V.K.

    1996-06-11

    Welding wires for welding together intermetallic alloys of nickel aluminides, nickel-iron aluminides, iron aluminides, or titanium aluminides, and preferably including additional alloying constituents are fabricated as two-component, clad structures in which one component contains the primary alloying constituent(s) except for aluminum and the other component contains the aluminum constituent. This two-component approach for fabricating the welding wire overcomes the difficulties associated with mechanically forming welding wires from intermetallic alloys which possess high strength and limited ductilities at elevated temperatures normally employed in conventional metal working processes. The composition of the clad welding wires is readily tailored so that the welding wire composition when melted will form an alloy defined by the weld deposit which substantially corresponds to the composition of the intermetallic alloy being joined. 4 figs.

  8. Causal Factors of Weld Porosity in Gas Tungsten Arc Welding of Powder Metallurgy Produced Titanium Alloys

    SciTech Connect (OSTI)

    Muth, Thomas R; Yamamoto, Yukinori; Frederick, David Alan; Contescu, Cristian I; Chen, Wei; Lim, Yong Chae; Peter, William H; Feng, Zhili

    2013-01-01

    ORNL undertook an investigation using gas tungsten arc (GTA) welding on consolidated powder metallurgy (PM) titanium (Ti) plate, to identify the causal factors behind observed porosity in fusion welding. Tramp element compounds of sodium and magnesium, residual from the metallothermic reduction of titanium chloride used to produce the titanium, were remnant in the starting powder and were identified as gas forming species. PM-titanium made from revert scrap where sodium and magnesium were absent, showed fusion weld porosity, although to a lesser degree. We show that porosity was attributable to hydrogen from adsorbed water on the surface of the powders prior to consolidation. The removal / minimization of both adsorbed water on the surface of titanium powder and the residues from the reduction process prior to consolidation of titanium powders, are critical to achieve equivalent fusion welding success similar to that seen in wrought titanium produced via the Kroll process.

  9. Bulk and mechanical properties of the Paintbrush tuff recovered from boreholes UE25 NRG-4 and -5: Data report

    SciTech Connect (OSTI)

    Boyd, P.J.; Noel, J.S.; Martin, R.J. [New England Research, Inc., White River Junction, VT (United States); Price, R.H. [Sandia National Labs., Albuquerque, NM (United States)

    1996-09-01

    Experimental results are presented for bulk and mechanical properties measurements on specimens of the Paintbrush tuff recovered from boreholes UE25 NRG-4 and -5, at Yucca Mountain, Nevada. Measurements have been performed on three thermal/mechanical units, PTn, TSwl, and TSw2. On each specimen the following bulk properties have been reported: dry bulk density, saturated bulk density, average grain density, and porosity. Unconfined compression to failure, confined compression to failure, and indirect tensile strength tests were performed on selected specimens recovered from the boreholes. In addition, compressional and shear wave velocities were measured on specimens designated for unconfined compression and confined compression experiments. Measurements were conducted at room temperature on nominally water-saturated specimens. The nominal rate for the fracture experiments was 10{sup -5}s{sup -1}.

  10. Shielding gas selection for increased weld penetration and productivity in GTA welding

    SciTech Connect (OSTI)

    Leinonen, J.I.

    1996-12-31

    The effects of hydrogen and helium additions to the argon shielding gas on GTA weld pool profiles in the case of two austenitic stainless steel sheets 3 mm thick are investigated here in detail. One of the test steels shows good weldability, with a relatively deep, narrow weld pool profile, but the other is poorly weldable, with a shallow, wide weld pool when argon shielding gas is used. Bead-on-plate test welds were produced with arc shields of argon, argon with hydrogen additions of 2 to 18.2% and argon with helium additions of 20 to 80%. The hydrogen additions increases the depth of weld penetration in both test steels, but productivity with respect to maximum welding speed can be improved to an accepted level only with steel sheets of good weldability in terms of a relatively high depth/width (D/W) ratio. The depth of penetration in the test steel of good weldability increased somewhat with helium additions and the D/W ratio remained unchanged, while these parameters increased markedly in the poorly weldable steel when a He-20% Ar shielding gas was used and resembled those of the more weldable steel.

  11. HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS

    SciTech Connect (OSTI)

    Tang, Wei; Chen, Gaoqiang; Chen, Jian; Yu, Xinghua; Frederick, David Alan; Feng, Zhili

    2015-01-01

    Reduced-activation ferritic/martensitic (RAFM) steels are an important class of structural materials for fusion reactor internals developed in recent years because of their improved irradiation resistance. However, they can suffer from welding induced property degradations. In this paper, a solid phase joining technology friction stir welding (FSW) was adopted to join a RAFM steel Eurofer 97 and different FSW parameters/heat input were chosen to produce welds. FSW response parameters, joint microstructures and microhardness were investigated to reveal relationships among welding heat input, weld structure characterization and mechanical properties. In general, FSW heat input results in high hardness inside the stir zone mostly due to a martensitic transformation. It is possible to produce friction stir welds similar to but not with exactly the same base metal hardness when using low power input because of other hardening mechanisms. Further, post weld heat treatment (PWHT) is a very effective way to reduce FSW stir zone hardness values.

  12. CRAD, Welding, Cutting and Brazing Assessment Plan

    Broader source: Energy.gov [DOE]

    This assessment is to verify hot work requirements associated with welding, cutting, burning, brazing, grinding and other spark- or flame-producing operations have been implemented. Verify that the requirements implemented are appropriate for preventing loss of life and property from fire, and personal injury from contact with or exposure to molten metals, vapors, radiant energy, injurious rays and sparks.

  13. Defect distributions in weld-deposited cladding

    SciTech Connect (OSTI)

    Li, Y.Y.; Mabe, W.R.

    1998-11-01

    Defect distributions in stainless steel and nickel-chromium alloy weld-deposited cladding over a low alloy steel base were characterized by destructive evaluation (DE). An evaluation of the observed defects was conducted to characterize the defects by type or classification. Size distributions of cladding defect types were developed from the information obtained. This paper presents the results of the cladding evaluation.

  14. Capacitor discharge process for welding braided cable

    DOE Patents [OSTI]

    Wilson, Rick D.

    1995-01-01

    A capacitor discharge process for welding a braided cable formed from a plurality of individual cable strands to a solid metallic electrically conductive member comprises the steps of: (a) preparing the electrically conductive member for welding by bevelling one of its end portions while leaving an ignition projection extending outwardly from the apex of the bevel; (b) clamping the electrically conductive member in a cathode fixture; (c) connecting the electrically conductive member clamped in the cathode fixture to a capacitor bank capable of being charged to a preselected voltage value; (d) preparing the braided cable for welding by wrapping one of its end portions with a metallic sheet to form a retaining ring operable to maintain the individual strands of the braided cable in fixed position within the retaining ring; (e) clamping the braided cable and the retaining ring as a unit in an anode fixture so that the wrapped end portion of the braided cable faces the ignition projection of the electrically conductive member; and (f) moving the cathode fixture towards the anode fixture until the ignition projection of the electrically conductive member contacts the end portion of the braided cable thereby allowing the capacitor bank to discharge through the electrically conductive member and through the braided cable and causing the electrically conductive member to be welded to the braided cable via capacitor discharge action.

  15. Resistance Weld Qualification Analysis for Radioactive Waste Canisters

    SciTech Connect (OSTI)

    Gupta, N.K.; Gong, C.

    1995-01-10

    High level radioactive waste canisters are sealed by resistance upset welding to ensure leak tight closures. Resistance welding is fast, uniform, and can be performed remotely to minimize radiation exposure to the operators. Canisters are constructed in accordance with ASME Band PV Code, Section VIII, Division 1, however, the resistance welds are not used in Section VIII. The resistance welds are qualified by analysis using material properties obtained from the test coupons. Burst tests are performed on canister welds to meet ASME Section IX welder qualification requirements. Since burst tests are not used in Section IX for resistance weld qualification, finite element results of canister resistance welds are compared with the finite element analysis results of resistance weld tests in ASME Section IX, QW-196 to establish similarity between the two weld tests. Detailed analyses show that the primary mode of failure in both the tests is shear and, therefore, the use of burst test in place of shear test is acceptable. It is believed that the detailed analyses and results could help in establishing acceptance criteria for resistance upset welding in ASME B&PV Code, Sections VIII, and IX.

  16. Thermocapillary and arc phenomena in stainless steel welding

    SciTech Connect (OSTI)

    Pierce, S.W.; Olson, D.L.; Burgardt, P.

    1999-02-01

    This investigation characterized the effects of power level and Gaussian heat source size on thermocapillary-induced weld shape and estimated the relative influence of various possible arc phenomena in determining weld shape. Welds made with the CTAW process were compared with similar ones made with a conduction-mode EBW process and the differences were related to arc effects. Evidence of thermocapillary flow was readily apparent in both the GTA welds and the conduction-mode EB welds and was qualitatively similar in both. The similarity between the results obtained with the two processes serves to demonstrate that thermocapillary convection is the dominant factor in heat-to-heat weld shape variability. However, a similar one-to-one correspondence between welds produced with the two processes does not exist. Especially at high power, the EB welds showed stronger thermocapillary convection than the GTA welds. One important arc factor that limits thermocapillary flow in ar welds appears to be an increase in arc size with arc length and arc current. A non-Gaussian arc power distribution in GTAW seems to be most important in limiting the fluid flow. Apparently, the arc power distribution is more nearly rectangular in shape for an argon gas arc. At higher currents, above 200 A, plasma shear force may also be an important contributor to weld shape development. The conduction-mode EB welds demonstrate that thermocapillary flow reversal probably does not occur in welds made with a simple Gaussian heat source. The complex shape behavior is likely a result of an arc effect such as plasma shear.

  17. Effect of Pulsed Nd: YAG Laser Powers On 304 Stainless Steel Welding

    SciTech Connect (OSTI)

    Candan, L.; Demir, A.; Akman, E. [University of Kocaeli, Laser Technologies Research and Application Center, Kocaeli (Turkey)

    2007-04-23

    In this study, optimum welding parameters are obtained for 1mm thickness type 304 stainless steel welding using the Lumonics JK760TR pulsed Nd:YAG laser. The influences of laser welding parameters such as pulse duration, focal position, frequency, laser power, welding speed, and shielding gas (N2) pressure on penetration defining welding quality are investigated. Also comparisons of overlap ratios are presented between theory and experiment for pulse duration, frequency and welding speed.

  18. Apparatus for the concurrent ultrasonic inspection of partially completed welds

    DOE Patents [OSTI]

    Johnson, John A.

    2000-01-01

    An apparatus for the concurrent nondestructive evaluation of partially completed welds is described and which is used in combination with an automated welder and which includes an ultrasonic signal generator mounted on the welder and which generates an ultrasonic signal which is directed toward one side of the partially completed welds; an ultrasonic signal receiver mounted on the automated welder for detecting ultrasonic signals which are transmitted by the ultrasonic signal generator and which are reflected or diffracted from one side of the partially completed weld or which passes through a given region of the partially completed weld; and an analysis assembly coupled with the ultrasonic signal receiver and which processes the ultrasonic signals received by the ultrasonic signal receiver to identify welding flaws in the partially completed weld.

  19. HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON

    Office of Scientific and Technical Information (OSTI)

    INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS Wei Tang, Jian Chen, Xinghua Yu, David A. Frederick, Zhili Feng Oak Ridge National Laboratory, Oak Ridge, TN Keywords: Eurofer'97, friction stir welding, microstructure, microhardness Abstract Reduced-activation ferritic/martensitic (RAFM) steels are an important class of structural materials for fusion reactor internals developed in recent years because of their improved irradiation

  20. High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded Blanks |

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Department of Energy High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded Blanks High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded Blanks 2013 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation Meeting PDF icon lm075_hovanski_2013_o.pdf More Documents & Publications Vehicle Technologies Office Merit Review 2014: High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded Blanks Vehicle Technologies Office

  1. HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION...

    Office of Scientific and Technical Information (OSTI)

    are an important class of structural materials for fusion reactor internals developed ... among welding heat input, weld structure characterization and mechanical properties. ...

  2. Wear behavior of the surface alloyed AISI 1020 steel with Fe-Nb-B by TIG welding technique

    SciTech Connect (OSTI)

    Kilinc, B. Durmaz, M.; Abakay, E.; Sen, U.; Sen, S.

    2015-03-30

    Weld overlay coatings also known as hardfacing is a method which involves melting of the alloys and solidification for applied coatings. Recently hardfacing by welding has become a commonly used technique for improvement of material performance in extreme (high temperature, impact/abrasion, erosion, etc.) conditions.In the present study, the coatings were produced from a mixture of ferrous niobium, ferrous boron and iron powders in the ranges of -45µm particle size with different ratio. Fe{sub 12}Nb{sub 5}B{sub 3} and Fe{sub 2}NbBalloys were coated on the AISI 1020 steel surface by TIG welding. The phases formed in the coated layer are Fe{sub 2}B, NbB{sub 2}, NbFeB and Fe0,2 Nb{sub 0,8} phases. The hardness of the presence phases are changing between 1689±85 HV{sub 0.01}, and 181±7 HV{sub 0.1}. Microstructural examinations were realized by optical and scanning electron microscopy. The wear and friction behaviors of Fe{sub 12}Nb{sub 5}B{sub 3} and Fe2NbB realized on the AISI 1020 steel were investigated by the technique of TIG welding by using ball-on-disk arrangement against alumina ball.

  3. Weld monitor and failure detector for nuclear reactor system

    DOE Patents [OSTI]

    Sutton, Jr., Harry G.

    1987-01-01

    Critical but inaccessible welds in a nuclear reactor system are monitored throughout the life of the reactor by providing small aperture means projecting completely through the reactor vessel wall and also through the weld or welds to be monitored. The aperture means is normally sealed from the atmosphere within the reactor. Any incipient failure or cracking of the weld will cause the environment contained within the reactor to pass into the aperture means and thence to the outer surface of the reactor vessel where its presence is readily detected.

  4. Method and device for frictional welding (Patent) | DOEPatents

    Office of Scientific and Technical Information (OSTI)

    the friction welding, process, further contributing to the complete seal that is obtained. ... URANIUM; STORAGE; ROTATION; SEALS; CONTAINERS 050900; TRANSPORT, HANDLING, AND STORAGE

  5. SF 2001-WLD;CONTRACTOR WELDING, CUTTING AND BRAZING

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    01-WLD (11-2012) Supersedes (4-2010) Issue CONTRACTOR WELDING, CUTTING, BRAZING P ART 1: CO NT R ACT O R' S E X PO S UR E AS S E S SM ENT Identify what welding, cutting and/or brazing you are doing: (Check box or fill-in type below) Welding Thermal Cutting Brazing (No cadmium filler BAg-1 or BAg- 2; Silver not to exceed 45%) MIG Oxy-acetylene Oxy-acetylene TIG Stick Plasma arc Other Identify the base metal you are welding, cutting or brazing: (Check box or fill-in below) Carbon steel Galvanized

  6. Fluid Flow Phenomena during Welding (Book) | SciTech Connect

    Office of Scientific and Technical Information (OSTI)

    humped beads, finger penetration, and undercutting. Instabilities in the liquid film around the keyhole in electron beam and laser welds are responsible for the uneven...

  7. Santa Fe Community College offers new welding program

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Santa Fe Community College Offers Welding Program Community Connections: Your link to news and opportunities from Los Alamos National Laboratory Latest Issue: Dec. 2015-Jan. 2016...

  8. Assessing Steel Pipeline and Weld Susceptibility to Hydrogen...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Can gas impurities mitigate embrittlement effect? ... in steels in high-pressure H 2 gas - Industrially ... metal arc weld (GMAW) Fusion Zone Heat affected zone (HAZ) Base ...

  9. Method of automatically welding with a non-consumable electrode

    DOE Patents [OSTI]

    Kiefer, Joseph H.

    1982-01-01

    A method for maintaining a constant arc gap between the electrode and the weld puddle by controlling the addition of filler wire based on the arc voltage.

  10. Material flow during friction stir welding: A thermo-mechanically...

    Office of Scientific and Technical Information (OSTI)

    ORNL Tsinghua University, Beijing, China Publication Date: 2014-01-01 OSTI ... Friction Stir Welding Symposium, Beijing, China, 20140519, 20140523 Research Org: Oak ...

  11. A Submarine Welded Ignimbrite-Crystal-Rich Sandstone Facies Associatio...

    Open Energy Info (EERE)

    of rhyolitic welded ignimbrite are intercalated within a submarine, below-storm-wave-base sedimentary succession in the Cambrian Tyndall Group, Mount Read Volcanics, western...

  12. Ductile filler metal alloys for welding nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, Michael L.; McNabb, Jeffrey D.; Sikka, Vinod K.

    2003-04-08

    Nickel aluminum alloys are welded utilizing a nickel based alloy containing zirconium but substantially free of titanium and niobium which reduces the tendency to crack.

  13. Subterranean barriers including at least one weld

    DOE Patents [OSTI]

    Nickelson, Reva A.; Sloan, Paul A.; Richardson, John G.; Walsh, Stephanie; Kostelnik, Kevin M.

    2007-01-09

    A subterranean barrier and method for forming same are disclosed, the barrier including a plurality of casing strings wherein at least one casing string of the plurality of casing strings may be affixed to at least another adjacent casing string of the plurality of casing strings through at least one weld, at least one adhesive joint, or both. A method and system for nondestructively inspecting a subterranean barrier is disclosed. For instance, a radiographic signal may be emitted from within a casing string toward an adjacent casing string and the radiographic signal may be detected from within the adjacent casing string. A method of repairing a barrier including removing at least a portion of a casing string and welding a repair element within the casing string is disclosed. A method of selectively heating at least one casing string forming at least a portion of a subterranean barrier is disclosed.

  14. Weld pool development during GTA and laser beam welding of Type 304 stainless steel; Part I - theoretical analysis

    SciTech Connect (OSTI)

    Zacharia, T.; David, S.A.; Vitek, J.M. ); Debroy, T. )

    1989-12-01

    A computational and experimental study was carried out to quantitatively understand the influence of the heat flow and the fluid flow in the transient development of the weld pool during gas tungsten arc (GTA) and laser beam welding of Type 304 stainless steel. Stationary gas tungsten arc and laser beam welds were made on two heats of Type 304 austenitic stainless steels containing 90 ppm sulfur and 240 ppm sulfur. A transient heat transfer model was utilized to simulate the heat flow and fluid flow in the weld pool. In this paper, the results of the heat flow and fluid flow analysis are presented.

  15. FY 1985 status report on feasibility assessment of copper-base waste package container materials in a tuff repository

    SciTech Connect (OSTI)

    McCright, R.D.

    1985-09-30

    This report discusses progress made during the first year of a two-year study on the feasibility of using copper or a copper-base alloy as a container material for a waste package in a potential repository in tuff rock at the Yucca Mountain site in Nevada. The expected corrosion and oxidation performances of oxygen-free copper, aluminum bronze, and 70% copper-30% nickel are presented; a test plan for determining whether copper or one of the alloys can meet the containment requirements is outlined. Some preliminary corrosion test data are presented and discussed. Fabrication and joining techniques for forming waste package containers are descibed. Preliminary test data and analyses indicate that copper and copper-base alloys have several attractive features as waste package container materials, but additional work is needed before definitive conclusions can be made on the feasibility of using copper or a copper-base alloy for containers. Plans for work to be undertaken in the second year are indicated.

  16. Friction Stir Welding Aluminum for Lightweight Vehicles | Department of

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Energy Friction Stir Welding Aluminum for Lightweight Vehicles Friction Stir Welding Aluminum for Lightweight Vehicles Addthis Description In this video, a researcher from Pacific Northwest National Laboratory describes a new aluminum joining process and the industry partnership that enabled its use for mass auto production

  17. Shielded metal arc welding of AISI 4340 alloy steel. Welding procedure specification

    SciTech Connect (OSTI)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1985-08-01

    Procedure WPS-115 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for shielded metal arc welding of AISI 4340 alloy steel, in thickness range 0.187 to 2 inch; filler metal is E7018 (F-4, A-1).

  18. Joining aluminum to titanium alloy by friction stir lap welding with cutting pin

    SciTech Connect (OSTI)

    Wei, Yanni [State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072 (China) [State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072 (China); Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China); Li, Jinglong, E-mail: lijinglg@nwpu.edu.cn [Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China)] [Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China); Xiong, Jiangtao [State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072 (China) [State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072 (China); Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China); Huang, Fu; Zhang, Fusheng; Raza, Syed Hamid [Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China)] [Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi'an 710072 (China)

    2012-09-15

    Aluminum 1060 and titanium alloy Ti-6Al-4V plates were lap joined by friction stir welding. A cutting pin of rotary burr made of tungsten carbide was employed. The microstructures of the joining interface were observed by scanning electron microscopy. Joint strength was evaluated by a tensile shear test. During the welding process, the surface layer of the titanium plate was cut off by the pin, and intensively mixed with aluminum situated on the titanium plate. The microstructures analysis showed that a visible swirl-like mixed region existed at the interface. In this region, the Al metal, Ti metal and the mixed layer of them were all presented. The ultimate tensile shear strength of joint reached 100% of 1060Al that underwent thermal cycle provided by the shoulder. - Highlights: Black-Right-Pointing-Pointer FSW with cutting pin was successfully employed to form Al/Ti lap joint. Black-Right-Pointing-Pointer Swirl-like structures formed due to mechanical mixing were found at the interface. Black-Right-Pointing-Pointer High-strength joints fractured at Al suffered thermal cycle were produced.

  19. Solidification behavior and structure of Al-Cu alloy welds

    SciTech Connect (OSTI)

    Brooks, J.A.; Li, M.; Yang, N.C.Y.

    1997-09-01

    The microsegregation behavior of electron beam (EB) and gas tungsten arc (GTA) welds of Al-Cu alloys covering a range from 0.19 to 7.74 wt% Cu were characterized for dendrite core concentrations and fraction eutectic solidification. Although a single weld speed of 12.7 mm/sec was used, some differences were observed in the segregation behavior of the two weld types. The microsegregation behavior was also modeled using a finite differences technique considering dendrite tip and eutectic undercooling and solid state diffusion. Fairly good agreement was observed between measured and calculated segregation behavior although differences between the two weld types could not be completely accounted for. The concept of dendrite tip undercooling was used to explain the formation of a single through thickness centerline grain in the higher alloy content GTA welds.

  20. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect (OSTI)

    Larry Zirker; Craig Tyler

    2010-08-01

    Engineers from the Idaho National Laboratory (INL) have demonstrated an innovative method for seal or pinch welding stainless steel tubing. Sometimes a tube has fuel or contamination that must be contained, or the tube needs to be shortened or cut for handling, and the tube needs to have a guaranteed sealed weld that is both quick and easy. This technique was demonstrated in a laboratory using a resistance welding system with specially designed electrodes to ensure a tube end is seal welded or if a long tube is to be shortened, the severed ends are seal welded. The unique electrodes design is integral to achieving the sealed ends. This process could readily be adapted for robotic--remote handling or for contact handling in a glovebox or hood.

  1. Method for laser welding a fin and a tube

    DOE Patents [OSTI]

    Fuerschbach, Phillip W.; Mahoney, A. Roderick; Milewski, John O

    2001-01-01

    A method of laser welding a planar metal surface to a cylindrical metal surface is provided, first placing a planar metal surface into approximate contact with a cylindrical metal surface to form a juncture area to be welded, the planar metal surface and cylindrical metal surface thereby forming an acute angle of contact. A laser beam, produced, for example, by a Nd:YAG pulsed laser, is focused through the acute angle of contact at the juncture area to be welded, with the laser beam heating the juncture area to a welding temperature to cause welding to occur between the planar metal surface and the cylindrical metal surface. Both the planar metal surface and cylindrical metal surface are made from a reflective metal, including copper, copper alloys, stainless steel alloys, aluminum, and aluminum alloys.

  2. Process Simulation of Gas Metal Arc Welding Software

    Energy Science and Technology Software Center (OSTI)

    2005-09-06

    ARCWELDER is a Windows-based application that simulates gas metal arc welding (GMAW) of steel and aluminum. The software simulates the welding process in an accurate and efficient manner, provides menu items for process parameter selection, and includes a graphical user interface with the option to animate the process. The user enters the base and electrode material, open circuit voltage, wire diameter, wire feed speed, welding speed, and standoff distance. The program computes the size andmore » shape of a square-groove or V-groove weld in the flat position. The program also computes the current, arc voltage, arc length, electrode extension, transfer of droplets, heat input, filler metal deposition, base metal dilution, and centerline cooling rate, in English or SI units. The simulation may be used to select welding parameters that lead to desired operation conditions.« less

  3. The effect of iron dilution on strength of nickel/steel and Monel/steel welds

    SciTech Connect (OSTI)

    Fout, S.L.; Wamsley, S.D.

    1983-03-28

    The weld strength, as a function of iron content, for nickel/steel and Monel/steel welds was determined. Samples were prepared using a Gas Metal Arc (GMAW) automatic process to weld steel plate together with nickel or Monel to produce a range of iron contents typical of weld compositions. Tensile specimens of each iron content were tested to obtain strength and ductility measurements for that weld composition. Data indicate that at iron contents of less than 20% iron in a nickel/steel weld, the weld fails at the weld interface, due to a lack of fusion. Between 20% and 35% iron, the highest iron dilution that could be achieved in a nickel weld, the welds were stronger than the steel base metal. This indicates that a minimum amount of iron dilution (20%) is necessary for good fusion and optimum strength. On the other hand for Monel/steel welds, test results showed that the welds had good strength and integrity between 10% and 27% iron in the weld. Above 35% iron, the welds have less strength and are more brittle. The 35% iron content also corresponds to the iron dilution in Monel welds that has been shown to produce an increase in corrosion rate. This indicates that the iron dilution in Monel welds should be kept below 35% iron to maximize both the strength and corrosion resistance. 2 refs., 6 figs., 3 tabs.

  4. Fusion Welding of AerMet 100 Alloy

    SciTech Connect (OSTI)

    ENGLEHART, DAVID A.; MICHAEL, JOSEPH R.; NOVOTNY, PAUL M.; ROBINO, CHARLES V.

    1999-08-01

    A database of mechanical properties for weldment fusion and heat-affected zones was established for AerMet{reg_sign}100 alloy, and a study of the welding metallurgy of the alloy was conducted. The properties database was developed for a matrix of weld processes (electron beam and gas-tungsten arc) welding parameters (heat inputs) and post-weld heat treatment (PWHT) conditions. In order to insure commercial utility and acceptance, the matrix was commensurate with commercial welding technology and practice. Second, the mechanical properties were correlated with fundamental understanding of microstructure and microstructural evolution in this alloy. Finally, assessments of optimal weld process/PWHT combinations for cotildent application of the alloy in probable service conditions were made. The database of weldment mechanical properties demonstrated that a wide range of properties can be obtained in welds in this alloy. In addition, it was demonstrated that acceptable welds, some with near base metal properties, could be produced from several different initial heat treatments. This capability provides a means for defining process parameters and PWHT's to achieve appropriate properties for different applications, and provides useful flexibility in design and manufacturing. The database also indicated that an important region in welds is the softened region which develops in the heat-affected zone (HAZ) and analysis within the welding metallurgy studies indicated that the development of this region is governed by a complex interaction of precipitate overaging and austenite formation. Models and experimental data were therefore developed to describe overaging and austenite formation during thermal cycling. These models and experimental data can be applied to essentially any thermal cycle, and provide a basis for predicting the evolution of microstructure and properties during thermal processing.

  5. Influence of Aluminum Content on Grain Refinement and Strength of AZ31 Magnesium GTA Weld Metal

    SciTech Connect (OSTI)

    Babu, N. Kishore; Cross, Carl E.

    2012-06-28

    The goal is to characterize the effect of Al content on AZ31 weld metal, the grain size and strength, and examine role of Al on grain refinement. The approach is to systematically vary the aluminum content of AZ31 weld metal, Measure average grain size in weld metal, and Measure cross-weld tensile properties and hardness. Conclusions are that: (1) increased Al content in AZ31 weld metal results in grain refinement Reason: higher undercooling during solidification; (2) weld metal grain refinement resulted in increased strength & hardness Reason: grain boundary strengthening; and (3) weld metal strength can be raised to wrought base metal levels.

  6. Evaluation of Molybdenum as a Surrogate for Iridium in the GPHS Weld Development

    SciTech Connect (OSTI)

    Stine, Andrew Martin; Pierce, Stanley W.; Moniz, Paul F.

    2015-10-17

    The welding equipment used for welding iridium containers (clads) at Los Alamos National Laboratory is twenty five years old and is undergoing an upgrade. With the upgrade, there is a requirement for requalification of the welding process, and the opportunity for process improvement. Testing of the new system and requalification will require several welds on iridium test parts and clads, and any efforts to improve the process will add to the need for iridium parts. The extreme high cost of iridium imposes a severe limitation on the extent of test welding that can be done. The 2 inch diameter, 0.027 inch thick, iridium blank disc that the clad cup is formed from, is useful for initial weld trials, but it costs $5000. The development clad sets needed for final tests and requalification cost $15,000 per set. A solution to iridium cost issue would be to do the majority of the weld development on a less expensive surrogate metal with similar weld characteristics. One such metal is molybdenum. Since its melting index (melting temperature x thermal conductivity) is closest to iridium, welds on molybdenum should be similar in size for a given weld power level. Molybdenum is inexpensive; a single 2 inch molybdenum disc costs only $9. In order to evaluate molybdenum as a surrogate for iridium, GTA welds were first developed to provide full penetration on 0.030 inch thick molybdenum discs at speeds of 20, 25, and 30 inches per minute (ipm). These weld parameters were then repeated on the standard 0.027 inch thick iridium blanks. The top surface and bottom surface (root) width and grain structure of the molybdenum and iridium welds were compared, and similarities were evident between the two metals. Due to material and thickness differences, the iridium welds were approximately 35% wider than the molybdenum welds. A reduction in iridium weld current of 35% produce welds slightly smaller than the molybdenum welds yet showed that current could be scaled according to molybdenum/iridium weld width ratio to achieve similar welds. Further weld trials using various thicknesses of molybdenum determined that 0.024 inch thick molybdenum material would best match the 0.027 inch thick iridium in achieving comparable welds when using the same welding parameters. Across the range of welding speeds, the characteristic weld pool shape and solidification grain structure in the two materials was also similar. With the similarity of welding characteristics confirmed, and the appropriate thickness of molybdenum determined, it has been concluded that the use of molybdenum discs and tube sections will greatly expand the weld testing opportunities prior to iridium weld qualification

  7. Microstructure characterization of laser welded Ti-6Al-4V fusion zones

    SciTech Connect (OSTI)

    Xu, Pei-quan; Li, Leijun, E-mail: leijun.li@ualberta.ca; Zhang, Chunbo

    2014-01-15

    The as-welded microstructure of laser-welded Ti-6Al-4V is characterized as a function of CO2 key-hole mode laser welding speed. Martensitic ?? is the predominant phase, with some ? and retained ?. Phase transformation is affected by the cooling rate through laser welding speed. A higher welding speed of 1.6 to 2.0 m/min produced more martensite ?? and less retained ? in the welds. 1.4 m/min welding speed produced small amounts of ?, besides the martensite ??. A trace of ? titanium hydride phase seems to have formed in the weld fusion zone. Moiré fringes are a common feature in the TEM microstructure, due to abundance of multi-phase interfaces. Tensile twins and clusters of dislocations indicate that plastic deformation has happened in the as-welded microstructure, indicating the local stress levels to be approaching the yield stress on-cooling during laser welding.

  8. Checking Your Car's 4000 Welds is Serious Business. Scientists Just Made

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    it Easier. | Department of Energy Checking Your Car's 4000 Welds is Serious Business. Scientists Just Made it Easier. Checking Your Car's 4000 Welds is Serious Business. Scientists Just Made it Easier. March 4, 2015 - 10:45am Addthis Robotic welding is vital to auto manufacturing, but double checking the welds is done by hand. Infrared technology promises to make it a whole lot easier. | Photo by Ripley Engineering used with permission. Robotic welding is vital to auto manufacturing, but

  9. HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION

    Office of Scientific and Technical Information (OSTI)

    FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS (Conference) | SciTech Connect HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS Citation Details In-Document Search Title: HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS Reduced-activation ferritic/martensitic (RAFM) steels are an important class of structural materials for fusion reactor internals developed

  10. Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

    DOE Patents [OSTI]

    Ren, Weiju

    2014-11-11

    A method of welding including forming a filler material of a first oxide dispersoid metal, the first oxide dispersoid material having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersoid metals; positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersoid metal; and friction welding the filler material, the first metal structure and the second metal structure to provide a weld.

  11. A study of the mechanism of laser welding defects in low thermal expansion superalloy GH909

    SciTech Connect (OSTI)

    Yan, Fei; Wang, Chunming, E-mail: yanxiangfei225@163.com; Wang, Yajun; Hu, Xiyuan; Wang, Tianjiao; Li, Jianmin; Li, Guozhu

    2013-04-15

    In this paper, we describe experimental laser welding of low-thermal-expansion superalloy GH909. The main welding defects of GH909 by laser in the weld are liquation cracks and porosities, including hydrogen and carbon monoxide porosity. The forming mechanism of laser welding defects was investigated. This investigation was conducted using an optical microscope, scanning electron microscope, energy diffraction spectrum, X-ray diffractometer and other methodologies. The results demonstrated that porosities appearing in the central weld were related to incomplete removal of oxide film on the surface of the welding samples. The porosities produced by these bubbles were formed as a result of residual hydrogen or oxygenium in the weld. These elements failed to escape from the weld since laser welding has both a rapid welding speed and cooling rate. The emerging crack in the heat affected zone is a liquation crack and extends along the grain boundary as a result of composition segregation. Laves–Ni{sub 2}Ti phase with low melting point is a harmful phase, and the stress causes grain boundaries to liquefy, migrate and even crack. Removing the oxides on the surface of the samples before welding and carefully controlling technological parameters can reduce welding defects and improve formation of the GH909 alloy weld. - Highlights: ? It is a new process for the forming of GH909 alloy via laser welding. ? The forming mechanism of laser welding defects in GH909 has been studied. ? It may be a means to improve the efficiency of aircraft engine production.

  12. Friction Stir Spot Welding of DP780 Carbon Steel

    SciTech Connect (OSTI)

    Santella, Michael L [ORNL; Hovanski, Yuri [ORNL; Frederick, David Alan [ORNL; Grant, Glenn J [ORNL; Dahl, Michael E [ORNL

    2010-01-01

    Friction stir spot welds were made in uncoated and galvannealed DP780 sheets using polycrystalline boron nitride stir tools. The tools were plunged at either a single continuous rate or in two segments consisting of a relatively high rate followed by a slower rate of shorter depth. Welding times ranged from 1 to 10 s. Increasing tool rotation speed from 800 to 1600 rev min{sup -1} increased strength values. The 2-segment welding procedures also produced higher strength joints. Average lap shear strengths exceeding 10 {center_dot} 3 kN were consistently obtained in 4 s on both the uncoated and the galvannealed DP780. The likelihood of diffusion and mechanical interlocking contributing to bond formation was supported by metallographic examinations. A cost analysis based on spot welding in automobile assembly showed that for friction stir spot welding to be economically competitive with resistance spot welding the cost of stir tools must approach that of resistance spot welding electrode tips.

  13. Investigation of Iron Aluminide Weld Overlays

    SciTech Connect (OSTI)

    Banovic, S.W.; DuPont, J.B.; Levin, B.F.; Marder, A.R.

    1999-08-02

    Conventional fossil fired boilers have been retrofitted with low NO(sub)x burners in order for the power plants to comply with new clean air regulations. Due to the operating characteristics of these burners, boiler tube sulfidation corrosion typically has been enhanced resulting in premature tube failure. To protect the existing panels from accelerated attack, weld overlay coatings are typically being applied. By depositing an alloy that offers better corrosion resistance than the underlying tube material, the wastage rates can be reduced. While Ni-based and stainless steel compositions are presently providing protection, they are expensive and susceptible to failure via corrosion-fatigue due to microsegregation upon solidification. Another material system presently under consideration for use as a coating in the oxidation/sulfidation environments is iron-aluminum. These alloys are relatively inexpensive, exhibit little microsegregation, and show excellent corrosion resistance. However, their use is limited due to weldability issues and their lack of corrosion characterization in simulated low NO(sub)x gas compositions. Therefore a program was initiated in 1996 to evaluate the use of iron-aluminum weld overlay coatings for erosion/corrosion protection of boiler tubes in fossil fired boilers with low NO(sub)x burners. Investigated properties included weldability, corrosion behavior, erosion resistance, and erosion-corrosion performance.

  14. Background studies in support of a feasibility assessment on the use of copper-base materials for nuclear waste packages in a repository in tuff

    SciTech Connect (OSTI)

    Van Konynenburg, R.A.; Kundig, K.J.A.; Lyman, W.S.; Prager, M.; Meyers, J.R.; Servi, I.S.

    1990-06-01

    This report combines six work units performed in FY`85--86 by the Copper Development Association and the International Copper Research Association under contract with the University of California. The work includes literature surveys and state-of-the-art summaries on several considerations influencing the feasibility of the use of copper-base materials for fabricating high-level nuclear waste packages for the proposed repository in tuff rock at Yucca Mountain, Nevada. The general conclusion from this work was that copper-base materials are viable candidates for inclusion in the materials selection process for this application. 55 refs., 48 figs., 22 tabs.

  15. Welding Metallurgy and Processing Issues for Joining of Power Sources

    SciTech Connect (OSTI)

    Lienert, Thomas J.; Reardon, Patrick T.

    2012-08-14

    Weldability issues with the pertinent alloys have been reviewed and preliminary results of our work on Haynes 25 have been presented. Further results on the mechanical properties and metallography on the EB welds are imminent. Hot-ductility experiments will commence within a few weeks. Aging studies on the effects of heat treatment using the Gleeble are also planned. MST-6 has extensive background in the welding metallurgy of the pertinent alloys. We also have considerable experience with the various welding processes to be used.

  16. Method for laser welding ultra-thin metal foils

    DOE Patents [OSTI]

    Pernicka, John C.; Benson, David K.; Tracy, C. Edwin

    1996-01-01

    A method for simultaneously cutting and welding ultra-thin foils having a thickness of less than 0.002 inches wherein two ultra-thin films are stacked and clamped together. A pulsed laser such as of the Neodymium: YAG type is provided and the beam of the laser is directed onto the stacked films to cut a channel through the films. The laser is moved relative to the stacked foils to cut the stacked foils at successive locations and to form a plurality of connected weld beads to form a continuous weld.

  17. Welding fixture for nuclear fuel pin cladding assemblies

    DOE Patents [OSTI]

    Oakley, D.J.; Feld, S.H.

    1984-02-22

    A welding fixture is described for locating a driver sleeve about the open end of a nuclear fuel pin cladding. The welding fixture includes a holder provided with an open cavity having shoulders for properly positioning the driver sleeve, the end cap, and a soft, high temperature resistant plastic protective sleeve that surrounds a portion of the end cap stem. Ejected contaminant particles spewed forth by closure of the cladding by pulsed magnetic welding techniques are captured within a contamination trap formed in the holder for ultimate removal and disposal of contaminating particles along with the holder.

  18. Welding fixture for nuclear fuel pin cladding assemblies

    DOE Patents [OSTI]

    Oakley, David J.; Feld, Sam H.

    1986-01-01

    A welding fixture for locating a driver sleeve about the open end of a nuclear fuel pin cladding. The welding fixture includes a holder provided with an open cavity having shoulders for properly positioning the driver sleeve, the end cap, and a soft, high temperature resistant plastic protective sleeve that surrounds a portion of the end cap stem. Ejected contaminant particles spewed forth by closure of the cladding by pulsed magnetic welding techniques are captured within a contamination trap formed in the holder for ultimate removal and disposal of contaminating particles along with the holder.

  19. Method for laser welding ultra-thin metal foils

    DOE Patents [OSTI]

    Pernicka, J.C.; Benson, D.K.; Tracy, C.E.

    1996-03-26

    A method for simultaneously cutting and welding ultra-thin foils having a thickness of less than 0.002 inches wherein two ultra-thin films are stacked and clamped together. A pulsed laser such as of the Neodymium: YAG type is provided and the beam of the laser is directed onto the stacked films to cut a channel through the films. The laser is moved relative to the stacked foils to cut the stacked foils at successive locations and to form a plurality of connected weld beads to form a continuous weld. 5 figs.

  20. Friction Stir Spot Welding of Advanced High Strength Steels

    SciTech Connect (OSTI)

    Hovanski, Yuri; Santella, M. L.; Grant, Glenn J.

    2009-12-28

    Friction stir spot welding was used to join two advanced high-strength steels using polycrystalline cubic boron nitride tooling. Numerous tool designs were employed to study the influence of tool geometry on weld joints produced in both DP780 and a hot-stamp boron steel. Tool designs included conventional, concave shouldered pin tools with several pin configurations; a number of shoulderless designs; and a convex, scrolled shoulder tool. Weld quality was assessed based on lap shear strength, microstructure, microhardness, and bonded area. Mechanical properties were functionally related to bonded area and joint microstructure, demonstrating the necessity to characterize processing windows based on tool geometry.

  1. Inspection apparatus for evaluating a partially completed weld

    DOE Patents [OSTI]

    Smartt, Herschel B.; Larsen, Eric D.; Johnson, Jonn A.

    2001-01-01

    An inspection apparatus for evaluating a partially completed weld is described and which is utilized in combination with an automated movable welder which moves across a supporting surface, and wherein the inspection apparatus includes a coupling member mounted on the welder; a frame member mounted on the coupling member; an ultrasonic sensor mounted on the frame member and disposed in ultrasonic sound transmitting relation relative to the partially completed weld; and a drive assembly for adjusting the position of the ultrasonic sensor relative to the partially completed weld.

  2. Welding for testability: An approach aimed at improving the ultrasonic testing of thick-walled austenitic and dissimilar metal welds

    SciTech Connect (OSTI)

    Wagner, Sabine; Dugan, Sandra [Materials Testing Institute University of Stuttgart (MPA), Pfaffenwaldring 32, 70569 Stuttgart (Germany); Barth, Martin; Schubert, Frank; Köhler, Bernd [Fraunhofer Institute for Nondestructive Testing, Dresden Branch (IZFP-D), Maria-Reiche-Str. 2, 01109 Dresden (Germany)

    2014-02-18

    Austenitic and dissimilar welds in thick walled components show a coarse grained, dendritic microstructure. Therefore, ultrasonic testing has to deal with beam refraction, scattering and mode conversion effects. As a result, the testing techniques typically applied for isotropic materials yield dissatisfying results. Most approaches for improvement of ultrasonic testing have been based on modeling and improved knowledge of the complex wave propagation phenomena. In this paper, we discuss an alternative approach: is it possible to use a modified welding technology which eliminates the cause of the UT complications, i.e. the large-grained structure of the weld seams? Various modification parameters were tested, including: TIG current pulsing, additional DC and AC magnetic fields, and also additional external vibrations during welding. For all welds produced under different conditions, the grain structure of the weld seam was characterized by optical and GIUM microstructure visualizations on cross sections, wave field propagation measurements, and ultrasonic tests of correct detectability of flaws. The mechanical properties of the welds were also tested.

  3. Proposed GTA welding specification and acceptance criteria for the MC4163

    SciTech Connect (OSTI)

    Kwiatkowski, J.J.

    1991-04-12

    This specification documents the gas tungsten arc (GTA) welding process and production weld acceptance criteria requirements for the MC4163. This document is written specifically to apply to the welds on the MC4163 and is not to be used as a general gas tungsten arc welding specification. All sections of this specification must be complied with unless specifically exempted in writing. There are a total of five welds with three different joint designs required to fabricate the MC4163. In the order of fabrication they are (1) initiator closure disc, (2) nozzle to case girth welds, two and, (3) nozzle closure disc welds, two. This specification will only address the nozzle to case girth welds and the nozzle closure disc welds.

  4. Optical emission spectroscopy of metal vapor dominated laser-arc hybrid welding plasma

    SciTech Connect (OSTI)

    Ribic, B.; DebRoy, T.; Burgardt, P.

    2011-04-15

    During laser-arc hybrid welding, plasma properties affect the welding process and the weld quality. However, hybrid welding plasmas have not been systematically studied. Here we examine electron temperatures, species densities, and electrical conductivity for laser, arc, and laser-arc hybrid welding using optical emission spectroscopy. The effects of arc currents and heat source separation distances were examined because these parameters significantly affect weld quality. Time-average plasma electron temperatures, electron and ion densities, electrical conductivity, and arc stability decrease with increasing heat source separation distance during hybrid welding. Heat source separation distance affects these properties more significantly than the arc current within the range of currents considered. Improved arc stability and higher electrical conductivity of the hybrid welding plasma result from increased heat flux, electron temperatures, electron density, and metal vapor concentrations relative to arc or laser welding.

  5. Fatigue life improvement factors obtained by weld reinforcement and toe grinding

    SciTech Connect (OSTI)

    Mullen, C.L.; Merwin, J.E.

    1982-01-01

    The potential of weld reinforcement and toe grinding techniques for improving the fatigue life of welded joints protected from seawater corrosion is quantified based on tests performed in air on welded plate specimens. Results are presented in terms of median fatigue life improvement factors and prediction intervals obtained by linear regression analysis. The significant improvements possible with weld reinforcement are shown to be caused partly by a slight alleviation of the stress concentration imposed by sharp angles at the weld toe. Variable improvements observed for toe ground welds are shown to be associated with the variable surface modifications which different tools impose on weld toes. Load and weld geometry are shown to be particulary important when bending stresses are applied to the weld toe, since reinforcement affects the bending moment at the toe section and toe grinding affects the conditions at the highly stressed outer fibers. 14 references.

  6. High Speed Joining of Dissimilar Alloy Aluminum Tailor Welded...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Characterization of post-weld formability must be tied to the process to allow the entire ... technology gaps in all advanced materials systems must be overcome to meet the ...

  7. Residual stresses and plastic deformation in GTA-welded steel

    SciTech Connect (OSTI)

    Brand, P.C. ); Keijser, T.H. de; Ouden, G. den )

    1993-03-01

    Residual stresses and plastic deformation in single pass GTA welded low-carbon steel were studied by means of x-ray diffraction in combination with optical microscopy and hardness measurements. The residual stresses and the amount of plastic deformation (microstrain) were obtained from x-ray diffraction line positions and line broading. Since the plates were polished before welding, it was possible to observe in the optical microscope two types of Lueders bands. During heating curved Lueders bands and during cooling straight Lueders bands perpendicular to the weld are formed. The curved Lueders bands extend over a larger distance from the weld than the straight Lueders bands. The amount of plastic deformation as obtained from the x-ray diffraction analysis is in agreement with these observations. An explanation is offered for the stresses measured in combination with plastic deformations observed. It is concluded that in the present experiments plastic deformation is the main cause of the residual stresses.

  8. Weld Properties of a Free Machining Stainless Steel

    SciTech Connect (OSTI)

    J. A. Brooks; S. H. Goods; C. V. Robino

    2000-08-01

    The all weld metal tensile properties from gas tungsten arc and electron beam welds in free machining austenitic stainless steels have been determined. Ten heats with sulfur contents from 0.04 to 0.4 wt.% and a wide range in Creq/Nieq ratios were studied. Tensile properties of welds with both processes were related to alloy composition and solidification microstructure. The yield and ultimate tensile strengths increased with increasing Creq/Nieq ratios and ferrite content, whereas the ductility measured by RA at fracture decreased with sulfur content. Nevertheless, a range in alloy compositions was identified that provided a good combination of both strength and ductility. The solidification cracking response for the same large range of compositions are discussed, and compositions identified that would be expected to provide good performance in welded applications.

  9. Inverter-based GTA welding machines improve fabrication

    SciTech Connect (OSTI)

    Sammons, M.

    2000-05-01

    While known as precision process, many fabricators using the gas tungsten arc welding (GTAW) process fight several common problems that hinder quality, slow production, frustrate the operator and otherwise prevent the process from achieving its full potential. These include a limited ability to tailor the weld bead profile, poor control of the arc direction and arc wandering, poor arc starting, unstable or inconsistent arcs in the AC mode, high-frequency interference with electronics and tungsten contamination. Fortunately, new GTA welding technology--made possible by advances with inverter-based power sources and micro-processor controls--can eliminate common productivity gremlins. Further, new AC/DC inverter-based GTA power sources provide advanced arc shaping capabilities. As a result, many fabricators adopting this new technology have experienced phenomenal production increases, taken on new types of projects and reduced costs. Most importantly, the operators enjoy welding more.

  10. Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement Webinar

    Broader source: Energy.gov [DOE]

    Access the recording and download the presentation slides from the Fuel Cell Technologies Office webinar "Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement" held on January 12, 2016.

  11. Performance assessment of the direct disposal in unsaturated tuff or spent nuclear fuel and high-level waste owned by USDOE: Volume 2, Methodology and results

    SciTech Connect (OSTI)

    Rechard, R.P.

    1995-03-01

    This assessment studied the performance of high-level radioactive waste and spent nuclear fuel in a hypothetical repository in unsaturated tuff. The results of this 10-month study are intended to help guide the Office of Environment Management of the US Department of Energy (DOE) on how to prepare its wastes for eventual permanent disposal. The waste forms comprised spent fuel and high-level waste currently stored at the Idaho National Engineering Laboratory (INEL) and the Hanford reservations. About 700 metric tons heavy metal (MTHM) of the waste under study is stored at INEL, including graphite spent nuclear fuel, highly enriched uranium spent fuel, low enriched uranium spent fuel, and calcined high-level waste. About 2100 MTHM of weapons production fuel, currently stored on the Hanford reservation, was also included. The behavior of the waste was analyzed by waste form and also as a group of waste forms in the hypothetical tuff repository. When the waste forms were studied together, the repository was assumed also to contain about 9200 MTHM high-level waste in borosilicate glass from three DOE sites. The addition of the borosilicate glass, which has already been proposed as a final waste form, brought the total to about 12,000 MTHM.

  12. Measurement of Plastic Strain Distribution in Dissimilar Metal Weld by

    Office of Scientific and Technical Information (OSTI)

    Micro-hardness Mapping (Conference) | SciTech Connect Measurement of Plastic Strain Distribution in Dissimilar Metal Weld by Micro-hardness Mapping Citation Details In-Document Search Title: Measurement of Plastic Strain Distribution in Dissimilar Metal Weld by Micro-hardness Mapping Authors: Yu, Xinghua [1] ; Qiao, Dongxiao [1] ; Crooker, Paul [2] ; David, Stan A [1] ; Feng, Zhili [1] + Show Author Affiliations ORNL Electric Power Research Institute (EPRI) Publication Date: 2014-01-01 OSTI

  13. Status Report: Characterization of Weld Residual Stresses on Full Diameter

    Energy Savers [EERE]

    SNF Interim Storage Canister Mockup | Department of Energy Status Report: Characterization of Weld Residual Stresses on Full Diameter SNF Interim Storage Canister Mockup Status Report: Characterization of Weld Residual Stresses on Full Diameter SNF Interim Storage Canister Mockup The goal of work described in this document is to assess the effects of the manufacturing process on canister performance by evaluating the properties of a full-diameter cylindrical mockup of an interim storage

  14. Weld solidification cracking in 304 to 304L stainless steel

    SciTech Connect (OSTI)

    Hochanadel, Patrick W; Lienert, Thomas J; Martinez, Jesse N; Martinez, Raymond J; Johnson, Matthew Q

    2010-01-01

    A series of annulus welds were made between 304 and 304L stainless steel coaxial tubes using both pulsed laser beam welding (LBW) and pulsed gas tungsten arc welding (GTAW). In this application, a change in process from pulsed LBW to pulsed gas tungsten arc welding was proposed to limit the possibility of weld solidification cracking since weldability diagrams developed for GTAW display a greater range of compositions that are not crack susceptible relative to those developed for pulsed LBW. Contrary to the predictions of the GTAW weldability diagram, cracking was found. This result was rationalized in terms of the more rapid solidification rate of the pulsed gas tungsten arc welds. In addition, for the pulsed LBW conditions, the material compositions were predicted to be, by themselves, 'weldable' according to the pulsed LBW weldability diagram. However, the composition range along the tie line connecting the two compositions passed through the crack susceptible range. Microstructurally, the primary solidification mode (PSM) of the material processed with higher power LBW was determined to be austenite (A), while solidification mode of the materials processed with lower power LBW apparently exhibited a dual PSM of both austenite (A) and ferrite-austenite (FA) within the same weld. The materials processed by pulsed GT A W showed mostly primary austenite solidification, with some regions of either primary austenite-second phase ferrite (AF) solidification or primary ferrite-second phase austenite (FA) solidification. This work demonstrates that variations in crack susceptibility may be realized when welding different heats of 'weldable' materials together, and that slight variations in processing can also contribute to crack susceptibility.

  15. Welding studies of nickel aluminide and nickel-iron aluminides

    SciTech Connect (OSTI)

    Santella, M.L.; David, S.A.; Horton, J.A.; White, C.L.; Liu, C.T.

    1985-08-01

    Because welding is often used during the fabrication of structural components, one of the key issues in the development of nickel aluminides and nickel-iron aluminides for engineering applications is their weldability. The goals of this study were to characterize weldment microstructures and to identify some of the factors controlling weldability of ductile Ni/sub 3/Al alloys. The alloys used in this initial study were Ni/sub 3/Al containing 500 wppm boron and Ni/sub 3/Al containing 10 at. % iron and either 500 wppm or 20 wppm boron. Full-penetration autogenous welds were made in sheet shock by the electron beam (EB) and gas tungsten arc (GTA) processes. The main process variables were travel speed and preheat. The as-welded coupons were examined visually and in detail by the usual optical and electron metallographic methods. Weldments of boron-doped Ni/sub 3/Al were composed of nearly 100% ordered ..gamma..' phase. Weldments of the nickel-iron aluminides were ..gamma..' + ..beta..' phase mixtures, with martensitic ..beta..' distributed interdendritically in the fusion zone and decorating grain boundaries in the heat-affected zone. All welds made in this particular boron-doped Ni/sub 3/Al alloy contained cracks. Weldability improved with the addition of iron, and defect-free welds were made in the nickel-iron aluminides by both EB and GTA welding. Nevertheless, the iron-containing alloys were susceptible to cracking, and their weldability was affected by boron concentration, welding speed, and (for GTA) gas shielding. Defect-free welds were found to have good tensile properties relative to those of the base metal. 34 refs., 17 figs., 2 tabs.

  16. Understanding heat and fluid flow in linear GTA welds

    SciTech Connect (OSTI)

    Zacharia, T.; David, S.A.; Vitek, J.M.

    1992-12-31

    A transient heat flow and fluid flow model was used to predict the development of gas tungsten arc (GTA) weld pools in 1.5 mm thick AISI 304 SS. The welding parameters were chosen so as to correspond to an earlier experimental study which produced high-resolution surface temperature maps. The motivation of the present study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate good agreement.

  17. Understanding heat and fluid flow in linear GTA welds

    SciTech Connect (OSTI)

    Zacharia, T.; David, S.A.; Vitek, J.M.

    1992-01-01

    A transient heat flow and fluid flow model was used to predict the development of gas tungsten arc (GTA) weld pools in 1.5 mm thick AISI 304 SS. The welding parameters were chosen so as to correspond to an earlier experimental study which produced high-resolution surface temperature maps. The motivation of the present study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate good agreement.

  18. Weld solidification cracking in 304 to 204L stainless steel

    SciTech Connect (OSTI)

    Hochanadel, Patrick W [Los Alamos National Laboratory; Lienert, Thomas J [Los Alamos National Laboratory; Martinez, Jesse N [Los Alamos National Laboratory; Johnson, Matthew Q [Los Alamos National Laboratory

    2010-09-15

    A series of annulus welds were made between 304 and 304L stainless steel coaxial tubes using both pulsed laser beam welding (LBW) and pulsed gas tungsten arc welding (GTAW). In this application, a change in process from pulsed LBW to pulsed gas tungsten arc welding was proposed to limit the possibility of weld solidification cracking since weldability diagrams developed for GTAW display a greater range of compositions that are not crack susceptible relative to those developed for pulsed LBW. Contrary to the predictions of the GTAW weldability diagram, cracking was found.This result was rationalized in terms of the more rapid solidification rate of the pulsed gas tungsten arc welds. In addition, for the pulsed LBW conditions, the material compositions were predicted to be, by themselves, 'weldable' according to the pulsed LBW weldability diagram. However, the composition range along the tie line connecting the two compositions passed through the crack susceptible range. Microstructurally, the primary solidification mode (PSM) of the material processed with higher power LBW was determined to be austenite (A), while solidification mode of the materials processed with lower power LBW apparently exhibited a dual PSM of both austenite (A) and ferrite-austenite (FA) within the same weld. The materials processed by pulsed GTAW showed mostly primary austenite solidification, with some regions of either primary austenite-second phase ferrite (AF) solidification or primary ferrite-second phase austenite (FA) solidification. This work demonstrates that variations in crack susceptibility may be realized when welding different heats of 'weldable' materials together, and that slight variations in processing can also contribute to crack susceptibility.

  19. Diode laser welding of aluminum to steel

    SciTech Connect (OSTI)

    Santo, Loredana; Quadrini, Fabrizio; Trovalusci, Federica [University of Rome Tor Vergata, Department of Mechanical Engineering, Via del Politecnico 1, 00133 Rome (Italy)

    2011-05-04

    Laser welding of dissimilar materials was carried out by using a high power diode laser to join aluminum to steel in a butt-joint configuration. During testing, the laser scan rate was changed as well as the laser power: at low values of fluence (i.e. the ratio between laser power and scan rate), poor joining was observed; instead at high values of fluence, an excess in the material melting affected the joint integrity. Between these limiting values, a good aesthetics was obtained; further investigations were carried out by means of tensile tests and SEM analyses. Unfortunately, a brittle behavior was observed for all the joints and a maximum rupture stress about 40 MPa was measured. Apart from the formation of intermeltallic phases, poor mechanical performances also depended on the chosen joining configuration, particularly because of the thickness reduction of the seam in comparison with the base material.

  20. Fracture properties of a neutron-irradiated stainless steel submerged arc weld cladding overlay

    SciTech Connect (OSTI)

    Corwin, W.R.; Berggren, R.G.; Nanstad, R.K.

    1984-01-01

    The ability of stainless steel cladding to increase the resistance of an operating nuclear reactor pressure vessel to extension of surface flaws depends greatly on the properties of the irradiated cladding. Therefore, weld overlay cladding irradiated at temperatures and fluences relevant to power reactor operation was examined. The cladding was applied to a pressure vessel steel plate by the submerged arc, single-wire, oscillating-electrode method. Three layers of cladding provided a thickness adequate for fabrication of test specimens. The first layer was type 309, and the upper two layers were type 308 stainless steel. The type 309 was diluted considerably by excessive melting of the base plate. Specimens were taken from near the base plate-cladding interface and also from the upper layers. Charpy V-notch and tensile specimens were irradiated at 288/sup 0/C to a fluence of 2 x 10/sup 23/ neutrons/m/sup 2/ (>1 MeV). 10 refs., 16 figs., 4 tabs.

  1. A hot-cracking mitigation technique for welding high-strength aluminum alloy

    SciTech Connect (OSTI)

    Yang, Y.P.; Dong, P.; Zhang, J.; Tian, X.

    2000-01-01

    A hot-cracking mitigation technique for gas tungsten arc welding (GTAW) of high-strength aluminum alloy 2024 is presented. The proposed welding technique incorporates a trailing heat sink (an intense cooling source) with respect to the welding torch. The development of the mitigation technique was based on both detailed welding process simulation using advanced finite element techniques and systematic laboratory experiments. The finite element methods were used to investigate the detailed thermomechanical behavior of the weld metal that undergoes the brittle temperature range (BTR) during welding. As expected, a tensile deformation zone within the material BTR region was identified behind the weld pool under conventional GTA welding process conventional GTA welding process conditions for the aluminum alloy studied. To mitigate hot cracking, the tensile zone behind the weld pool must be eliminated or reduce to a satisfactory level if the weld metal hot ductility cannot be further improved. With detailed computational modeling, it was found that by the introduction of a trailing heat sink at some distance behind the welding arc, the tensile strain rate with respect to temperature in the zone encompassing the BTR region can be significantly reduced. A series of parametric studies were also conducted to derive optimal process parameters for the trailing heat sink. The experimental results confirmed the effectiveness of the trailing heat sink technique. With a proper implementation of the trailing heat sink method, hot cracking can be completely eliminated in welding aluminum alloy 2024 (AA 2024).

  2. Microsegregation in high-molybdenum austenitic stainless steel laser beam and gas tungsten arc welds

    SciTech Connect (OSTI)

    Kujanpaeae, V.P.; David, S.A.

    1986-01-01

    An austenitic stainless steel with 6% molybdenum (thickness 6 mm) was welded using laser beam (LB) and gas tungsten arc (GTA) processes at various welding speeds. Depending on the welding speed the primary dendrite spacing ranged from 12 to 17 ..mu..m and from 2 to 7 ..mu..m for the GTA and LB welds, respectively. Extensive segregation of molybdenum was observed in the GTA welds. The segregation ratio for molybdenum, C/sub ID//C/sub D/, was found to be 1.9 in the GTA weld, and 1.2 in the LB weld. Distribution of iron, chromium and nickel was found nearly uniform in both welds. A recovered microstructure was observed after a post-weld annealing heat treatment. Annealing had a profound effect on the molybdenum segregation ratio in the laser weld. The critical pitting temperature (CPT) determined by a standard test was 55/sup 0/C for welds made using both processes, whereas it was 75/sup 0/C for the base metal. Upon homogenization the CPT of the laser beam weld increased to the base metal value, while that of the gas tungsten arc weld remained at 60/sup 0/C.

  3. Fabrication development for high-level nuclear waste containers for the tuff repository; Phase 1 final report

    SciTech Connect (OSTI)

    Domian, H.A.; Holbrook, R.L.; LaCount, D.F. |

    1990-09-01

    This final report completes Phase 1 of an engineering study of potential manufacturing processes for the fabrication of containers for the long-term storage of nuclear waste. An extensive literature and industry review was conducted to identify and characterize various processes. A technical specification was prepared using the American Society of Mechanical Engineers Boiler & Pressure Vessel Code (ASME BPVC) to develop the requirements. A complex weighting and evaluation system was devised as a preliminary method to assess the processes. The system takes into account the likelihood and severity of each possible failure mechanism in service and the effects of various processes on the microstructural features. It is concluded that an integral, seamless lower unit of the container made by back extrusion has potential performance advantages but is also very high in cost. A welded construction offers lower cost and may be adequate for the application. Recommendations are made for the processes to be further evaluated in the next phase when mock-up trials will be conducted to address key concerns with various processes and materials before selecting a primary manufacturing process. 43 refs., 26 figs., 34 tabs.

  4. Surface-active element effects on the shape of GTA, laser, and electron-beam welds

    SciTech Connect (OSTI)

    Heiple, C.R.; Roper, J.R.; Stagner, R.T.; Aden, R.J.

    1983-03-01

    Laser and electron-beam welds were passed across selenium-doped zones in 21-6-9 stainless steel. The depth/width (d/w) ratio of a defocused laser weld with a weld pool shape similar to a GTA weld increased by over 200% in a zone where 66 ppm selenium had been added. Smaller increases were observed in selenium-doped zones for a moderately defocused electron beam weld with a higher d/w ratio in undoped base metal. When laser or electron beam weld penetration was by a keyhole mechanism, no change in d/w ratio occurred in selenium-doped zones. The results confirm the surface-tension-driven fluid-flow model for the effect of minor elements on GTA weld pool shape. Other experimental evidence bearing on the effect of minor elements on GTA weld penetration is summarized.

  5. Forming Limits of Weld Metal in Aluminum Alloys and Advanced High-Strength Steels

    SciTech Connect (OSTI)

    Stephens, Elizabeth V.; Smith, Mark T.; Grant, Glenn J.; Davies, Richard W.

    2010-10-25

    This work characterizes the mechanical properties of DP600 laser welded TWBs (1 mm-1.5 mm) near and in the weld, as well as their limits of formability. The approach uses simple uniaxial experiments to measure the variability in the forming limits of the weld region, and uses a theoretical forming limit diagram calculation to establish a probabilistic distribution of weld region imperfection using an M-K method approach

  6. Automatic hot wire GTA welding of pipe offers speed and increased deposition

    SciTech Connect (OSTI)

    Sykes, I.; Digiacomo, J.

    1995-07-01

    Heavy-wall pipe welding for the power and petrochemical industry must meet code requirements. Contractors strive to meet these requirements in the most productive way possible. The challenge put to orbital welding equipment manufacturers is to produce pipe welding equipment that cost-effectively produces code-quality welds. Orbital welding equipment using the GTA process has long produced outstanding quality results but has lacked the deposition rate to compete cost effectively with other manual and semiautomatic processes such as SMAW, FCAW and GMAW. In recent years, significant progress has been made with the use of narrow-groove weld joint designs to reduce weld joint volume and improve welding times. Astro Arc Polysoude, an orbital welding equipment manufacturer based in Sun Valley, Calif., and Nantes, France, has combined the hot wire GTAW process with orbital welding equipment using a narrow-groove weld joint design. Field test results show this process and procedure is a good alternative for many heavy-wall-pipe welding applications.

  7. Physical processes involved in strip electrode welding using the method of slatted splicing

    SciTech Connect (OSTI)

    Bushma, V. O. [Moscow State Technological University 'Stankin' (Russian Federation)

    2010-12-15

    Physical processes that take place in a strip electrode during welding using the slatted splicing technique are considered. Flowing of the welding current in the electrode is shown to be the key process which determines electrode heating and melting. Technological receipts are proposed that allow obtaining high-quality welds by the method of slatted splicing.

  8. Subsea pipeline gets welded branch without halting flow

    SciTech Connect (OSTI)

    West, A.; Hutt, G.; Starsmore, R.

    1995-12-11

    In October 1994, a 16 in. welded branch was installed without interruption to production onto Wintershall Noordzee BV`s 36-in. gas pipeline from the K13-A platform in the Dutch sector of the North Sea to Den helder, The Netherlands. The procedure is the first successfully to combine hyperbaric welding and subsea hot tapping without interruption to production. Developers of new fields can now consider exporting product without interrupting existing production and through existing infrastructure even if no convenient tie-in locations exist. Unocal evaluated export options and established that the most attractive alternative was to export gas into the Wintershall 36-in. K13-A to Den Helder pipeline. Various options for installing a branch included the following: flooding the pipeline and installing a conventional tee; stopping production and installing a welded branch followed by hot tapping; and continuing production and installing a welded branch followed by hot tapping. The chosen scheme was to retrofit a subsea side-tap assembly. This was achieved by installation of a welded branch followed by hot tapping into the 36-in. pipeline. The paper describes location determination, schedules, onshore preparation, and offshore work.

  9. Radiation chemical effects in experiments to study the reaction of glass in an environment of gamma-irradiated air, groundwater, and tuff

    SciTech Connect (OSTI)

    Van Konynenburg, R.A.

    1986-05-02

    The results of experiments performed by John K. Bates et al. on the reaction of nuclear waste glass with a gamma-irradiated 90{sup 0}C aqueous solution were analyzed using theory developed from past research in radiation chemistry. The aqueous solution they used is similar to what would be expected in a water-saturated environment in a nuclear waste repository in tuff. The purpose of our study was to develop an understanding of the radiation-chemical processes that occurred in the Bates et al. experiments so the results could be applied to the design and performance analysis of a proposed repository in unsaturated tuff in Nevada. For the Bates et al. experiments at the highest dose (269 Mrad), which originally contained about 16 ml of "equilibrated" water taken from Nevada Test Site Well J-13 and 5.4 ml of air, we predicted that water decomposition to H{sub 2} and O{sub 2} would produce a pressure increase of at least 1.0 MPa at 20{sup 0}C. We also predicted that nitrogen fixation from the air would occur, producing an increase of 1.6 x 10{sup -4} M in total fixed nitrogen concentration in solution. In addition, an equimolar production of H{sup +} would occur, which would be buffered by the HCO{sub 3}{sup -} in the water. The fixed nitrogen in solution was predicted to be present as NO{sub 2}{sup -} and NO{sub 3}{sup -} with the ratio influenced by the presence of materials catalytic to the decomposition of H{sub 2}O{sub 2}. We found reasonable agreement between our predictions and the observations of Bates et al., where comparisons were possible. We apply the results to the proposed Nevada repository to the degree possible, given the different expected conditions.

  10. Photonic layered media

    DOE Patents [OSTI]

    Fleming, James G.; Lin, Shawn-Yu

    2002-01-01

    A new class of structured dielectric media which exhibit significant photonic bandstructure has been invented. The new structures, called photonic layered media, are easy to fabricate using existing layer-by-layer growth techniques, and offer the ability to significantly extend our practical ability to tailor the properties of such optical materials.

  11. Microstructural, mechanical and weldability assessments of the dissimilar welds between ??- and ??-strengthened nickel-base superalloys

    SciTech Connect (OSTI)

    Naffakh Moosavy, Homam, E-mail: homam_naffakh@iust.ac.ir [School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Tehran 16846-13114 (Iran, Islamic Republic of); Aboutalebi, Mohammad-Reza; Seyedein, Seyed Hossein [School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Tehran 16846-13114 (Iran, Islamic Republic of); Mapelli, Carlo [Dipartimento di Meccanica, Politecnico di Milano, Via La Massa 34, Milan 20156 (Italy)

    2013-08-15

    Dissimilar welding of ??- and ??-strengthened nickel-base superalloys has been investigated to identify the relationship between the microstructure of the welds and the resultant mechanical and weldability characteristics. ??-Strengthened nickel-base Alloy 500 and ??-strengthened nickel-base Alloy 718 were used for dissimilar welding. Gas tungsten arc welding operations were utilized for performing the autogenous dissimilar welding. Alloy 500 and Alloy 718 base metals showed various types of phases, carbides, intermetallics and eutectics in their microstructure. The results for Alloy 500 weld metal showed severe segregation of titanium to the interdendritic regions. The Alloy 718 weld metal compositional analysis confirmed the substantial role of Nb in the formation of low-melting eutectic-type morphologies which can reduce the weldability. The microstructure of dissimilar weld metal with dilution level of 65% wt.% displayed semi-developed dendritic structure. The less segregation and less formation of low-melting eutectic structures caused to less susceptibility of the dissimilar weld metal to the solidification cracking. This result was confirmed by analytic modeling achievements. Dissolution of ??-Ni{sub 3}Nb precipitations took place in the Alloy 718 heat-affected zone leading to sharp decline of the microhardness in this region. Remelted and resolidified regions were observed in the partially-melted zone of Alloy 500 and Alloy 718. Nevertheless, no solidification and liquation cracking happened in the dissimilar welds. Finally, this was concluded that dissimilar welding of ??- and ??-strengthened nickel-base superalloys can successfully be performed. - Highlights: • Dissimilar welding of ??- and ??-strengthened nickel-base superalloys is studied. • Microstructural, mechanical and weldability aspects of the welds are assessed. • Microstructure of welds, bases and heat-affected zones is characterized in detail. • The type, morphology and distribution of the phases are thoroughly investigated. • Dissimilar welding is successfully performed without occurrence of any hot cracks.

  12. Gas-tungsten arc welding of aluminum alloys

    DOE Patents [OSTI]

    Frye, L.D.

    1982-03-25

    The present invention is directed to a gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to profice a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surface are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy continguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

  13. Method and device for controlling plume during laser welding

    DOE Patents [OSTI]

    Fuerschbach, Phillip W.; Jellison, James L.; Keicher, David M.; Oberkampf, William L.

    1991-01-01

    A method and apparatus for enhancing the weldment of a laser welding system is provided. The laser weld plume control device includes a cylindrical body defining an upside-down cone cavity; the upper surface of the body circumscribes the base of the cone cavity, and the vertex of the cone cavity forms an orifice concentrically located with respect to the laser beam and the plume which forms as a result of the welding operation. According to the method of the invention, gas is directed radially inward through inlets in the upper surface of the body into and through channels in the wall of the body and finally through the orifice of the body, and downward onto the surface of the weldment. The gas flow is then converted by the orifice of the device from radial flow to an axisymmetric gas jet flowing away from the weldment surface in a direction perpendicular to the surface and opposite to that of the laser.

  14. Gas-tungsten arc welding of aluminum alloys

    DOE Patents [OSTI]

    Frye, Lowell D.

    1984-01-01

    A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

  15. Development of a Fiber Laser Welding Capability for the W76, MC4702 Firing Set

    SciTech Connect (OSTI)

    Samayoa, Jose

    2010-05-12

    Development work to implement a new welding system for a Firing Set is presented. The new system is significant because it represents the first use of fiber laser welding technology at the KCP. The work used Six-Sigma tools for weld characterization and to define process performance. Determinations of workable weld parameters and comparison to existing equipment were completed. Replication of existing waveforms was done utilizing an Arbitrary Pulse Generator (APG), which was used to modulate the fiber laser’s exclusive continuous wave (CW) output. Fiber laser weld process capability for a Firing Set is demonstrated.

  16. Novel concepts in weld science: Role of gradients and composite structure. Final report

    SciTech Connect (OSTI)

    Matlock, D.K.; Olson, D.L.

    1994-03-01

    The effects of compositional and microstructural gradients on weld metal and simulated weld metal properties were evaluated in this multi-part study. The results obtained on single phase solid solution systems were used as a basis for a fundamental study of the effects of compositional gradients on crack growth, both at low temperatures, in fatigue and at high temperatures during creep. Methods to physically simulate gradients in weld metals with roll bonded laminate composites were applied to analyses of ferrite-austenite and ferrite-sigma-austenite multiphase systems. Finally, results of the physical simulation analyses were utilized to predict the effects of weld process parameters on weld metal properties.

  17. Scintillator reflective layer coextrusion

    DOE Patents [OSTI]

    Yun, Jae-Chul; Para, Adam

    2001-01-01

    A polymeric scintillator has a reflective layer adhered to the exterior surface thereof. The reflective layer comprises a reflective pigment and an adhesive binder. The adhesive binder includes polymeric material from which the scintillator is formed. A method of forming the polymeric scintillator having a reflective layer adhered to the exterior surface thereof is also provided. The method includes the steps of (a) extruding an inner core member from a first amount of polymeric scintillator material, and (b) coextruding an outer reflective layer on the exterior surface of the inner core member. The outer reflective layer comprises a reflective pigment and a second amount of the polymeric scintillator material.

  18. The role of composition and microstructure gradients on weld metal properties and behavior: Progress report for the period of June 1, 1987 to December 31, 1987. [Fe-Al-Cr-Mn-Ni weld metals

    SciTech Connect (OSTI)

    Matlock, D.K.; Olson, D.L.

    1988-01-01

    The effects of weld metal compositional and microstructural gradients on phase transformations, microstructural stability, and mechanical properties are considered from a fundamental basis in weld metal alloys which are primarily austenitic (e.g., stainless steels). Models which incorporate compositional gradients are developed to predict the resulting weld metal properties. The mechanical properties of weld metals are modeled based on composite theory in which individual weld metal zones are considered as discrete elements within a composite structure. 23 figs.

  19. FRICTION STIR SPOT WELDING OF 6016 ALUMINUM ALLOY

    SciTech Connect (OSTI)

    Mishra, Rajiv S.; Webb, S.; Freeney, T. A.; Chen, Y. L.; Gayden, X.; Grant, Glenn J.; Herling, Darrell R.

    2007-01-08

    Friction stir spot welding (FSSW) of 6016 aluminum alloy was evaluated with conventional pin tool and new off-center feature tools. The off-center feature tool provides significant control over the joint area. The tool rotation rate was varied between 1000 and 2500 rpm. Maximum failure strength was observed in the tool rotation range of 1200-1500 rpm. The results are interpreted in the context of material flow in the joint and influence of thermal input on microstructural changes. The off-center feature tool concept opens up new possibilities for plunge-type friction stir spot welding.

  20. Friction stir weld tools having fine grain structure

    DOE Patents [OSTI]

    Grant, Glenn J.; Frye, John G.; Kim, Jin Yong; Lavender, Curt A.; Weil, Kenneth Scott

    2016-03-15

    Tools for friction stir welding can be made with fewer process steps, lower cost techniques, and/or lower cost ingredients than other state-of-the-art processes by utilizing improved compositions and processes of fabrication. Furthermore, the tools resulting from the improved compositions and processes of fabrication can exhibit better distribution and homogeneity of chemical constituents, greater strength, and/or increased durability. In one example, a friction stir weld tool includes tungsten and rhenium and is characterized by carbide and oxide dispersoids, by carbide particulates, and by grains that comprise a solid solution of the tungsten and rhenium. The grains do not exceed 10 micrometers in diameter.

  1. APPARATUS AND METHOD FOR WELDING END CLOSURE TO CONTAINER

    DOE Patents [OSTI]

    Frantz, C.E.; Correy, T.B.

    1959-08-01

    A semi-automatic apparatus is described for welding a closure to the open end of a can containing a nuclear fuel slug. An arc is struck at the center of the closure and is shifted to a region near its periphery. Then the assembly of closure, can, and fuel slug is rotated so that the peripheral region of the closure is preheated. Next the arc is shifted to the periphery itself of the closure, and the assembly is rotated so that the closure is welded to the can.

  2. Fracture toughness of austenitic stainless steel weld metal at 4 K

    SciTech Connect (OSTI)

    Goodwin, G.M.

    1984-08-01

    Selection of the welding processess and weld filler metals for fabrication of a large toroidal superconducting magnet is described. Data available in the literature are collected and compared with data generated in this study for three welding processes, shielded metal arc (SMA), gas tungsten arc (GTA), and flux cored arc (FCA) welds had the highest fracture toughness as measured by K/sub Ic/ estimated from J/sub Ic/. The SMA and FCA welds had about the same toughness, below the GTA values but above the average from the literature. The fracture mode for all three processes was typified by ductile dimples. The fracture morphology of the FCA weld specimens was influenced by the solidification substructure, and small particles were found to be nucleation sites for void formation, especially for the GTA welds. All three welding processes were deemed adequate for the intended service and were used to fabricate the large magnet. A trunnion-type turning fixture eliminated the need for welding in the vertical and overhead positions. The GTA process was used for all root passes, and the horizontal welds were filled by the SMA process. Over 80% of the welds were done in the flat position with the FCA process, and its high deposition rate and ease of operation are credited with contributing greatly to the success of the effort.

  3. Influence of sulfur and welding conditions on penetration in thin strip stainless steel

    SciTech Connect (OSTI)

    Scheller, P.R. ); Brooks, R.F.; Mills, K.C. . Division of Materials Metrology)

    1995-02-01

    Welding trials and surface tension measurements have been carried out on 304 stainless steels with sulfur (S) contents between 20 and 100 ppm. Surface tension measurements, determined by the levitated drop method, indicated that the temperature coefficient of surface tension (d[gamma]/dT) changed from negative to positive values at S contents exceeding approximately 50 ppm. Strips with a thickness of approximately 1 mm were GTA welded on both single-electrode, small-scale and multi-electrode industrial-scale units. Welding speeds of 1 to 2 m min[sup [minus]1] were used on the small-scale unit and up to 5 m min[sup [minus]1] on the industrial unit. The weld penetration was found to increase, for both full and partial penetration welds, with (1) increasing sulfur contents; and (2) increasing linear energy. On the small scale-unit markedly higher penetration was observed in heats with S contents > 60 ppm. But the influence of S contents was only of minor importance for welds obtained on the industrial unit. It was found that the similar weld geometry could be obtained for both low ([<=] 60 ppm) and high (> 60 ppm) sulfur contents by careful adjustment of welding parameters. The observed changes in weld geometry are consistent with the proposition that the fluid flow in the weld pool is dominated by thermo-capillary (Marangoni) forces during the GTA welding of thin strips.

  4. Charpy toughness and tensile properties of a neutron irradiated stainless steel submerged-arc weld cladding overlay

    SciTech Connect (OSTI)

    Corwin, W.R.; Berggren, R.G.; Nanstad, R.K.

    1984-01-01

    The possibility of stainless steel cladding increasing the resistance of an operating nuclear reactor pressure vessel to extension of surface flaws is highly dependent upon the irradiated properties of the cladding. Therefore, weld overlay cladding irradiated at temperatures and fluences relevant to power reactor operation was examined. The cladding was applied to a pressure vessel steel plate by the submerged-arc, single-wire, oscillating electrode method. Three layers of cladding were applied to provide a cladding thickness adequate for fabrication of test specimens. The first layer was type 309, and the upper two layers were type 308 stainless steel. There was considerable dilution of the type 309 in the first layer of cladding as a result of excessive melting of the base plate. Specimens for the irradiation study were taken from near the base plate/cladding interface and also from the upper layers of cladding. Charpy V-notch and tensile specimens were irradiated at 288/sup 0/C to neutron fluences of 2 x 10/sup 23/ n/m/sup 2/ (E > 1 MeV). When irradiated, both types 308 and 309 cladding showed a 5 to 40% increase in yield strength accompanied by a slight increase in ductility in the temperature range from 25 to 288/sup 0/C. All cladding exhibited ductile-to-brittle transition behavior during impact testing.

  5. Numerical simulation of linear fiction welding (LFW) processes

    SciTech Connect (OSTI)

    Fratini, L.; La Spisa, D. [University of Palermo-Dept. of Industrial engineering (Italy)

    2011-05-04

    Solid state welding processes are becoming increasingly important due to a large number of advantages related to joining ''unweldable'' materials and in particular light weight alloys. Linear friction welding (LFW) has been used successfully to bond non-axisymmetric components of a range of materials including titanium alloys, steels, aluminum alloys, nickel, copper, and also dissimilar material combinations. The technique is useful in the research of quality of the joints and in reducing costs of components and parts of the aeronautic and automotive industries.LFW involves parts to be welded through the relative reciprocating motion of two components under an axial force. In such process the heat source is given by the frictional forces work decaying into heat determining a local softening of the material and proper bonding conditions due to both the temperature increase and the local pressure of the two edges to be welded. This paper is a comparative test between the numerical model in two dimensions, i.e. in plane strain conditions, and in three dimensions of a LFW process of AISI1045 steel specimens. It must be observed that the 3D model assures a faithful simulation of the actual threedimensional material flow, even if the two-dimensional simulation computational times are very short, a few hours instead of several ones as the 3D model. The obtained results were compared with experimental values found out in the scientific literature.

  6. Thermoacoustic method for relaxation of residual stresses in welded joints

    SciTech Connect (OSTI)

    Koshovyi, V.V.; Pakhn`o, M.I.; Tsykhan, O.I.

    1995-01-01

    We propose a thermoacoustic method for the relaxation of residual stresses in welded joints, present a block diagram of a generator of local thermoacoustic pulses designed for implementation of this method, and describe our experiment aimed at relaxation of residual tensile stresses.

  7. Friction Stir Welding of Lightweight Vehicle Structures: Final Report

    SciTech Connect (OSTI)

    Sanella, M L

    2008-08-31

    The purpose of this Cooperative Research and Development Agreement (CRADA) between UTBattelle, LLC and Ford Motor Company was to establish friction stir welding (FSW) and friction stir processing as viable options for use in construction of lightweight substructures for trucks and cars, including engine cradles, suspension sub frames, instrument panel supports, and intake manifolds.

  8. Dynamic Characterization of Spot Welds for AHSS | Department of Energy

    Broader source: Energy.gov (indexed) [DOE]

    11 DOE Hydrogen and Fuel Cells Program, and Vehicle Technologies Program Annual Merit Review and Peer Evaluation PDF icon lm025_feng_2011_o.pdf More Documents & Publications Dynamic Characterization of Spot Welds for AHSS Overview of Joining Activities in Lightweighting Materials FY 2009 Progress Report for Lightweighting Materials - 9. Joining

  9. Layered plasma polymer composite membranes

    DOE Patents [OSTI]

    Babcock, Walter C.

    1994-01-01

    Layered plasma polymer composite fluid separation membranes are disclosed, which comprise alternating selective and permeable layers for a total of at least 2n layers, where n is .gtoreq.2 and is the number of selective layers.

  10. Layered plasma polymer composite membranes

    DOE Patents [OSTI]

    Babcock, W.C.

    1994-10-11

    Layered plasma polymer composite fluid separation membranes are disclosed, which comprise alternating selective and permeable layers for a total of at least 2n layers, where n is [>=]2 and is the number of selective layers. 2 figs.

  11. Stainless Steel 18-10 CO2 Laser Welding And Plasma Diagnostics

    SciTech Connect (OSTI)

    Amar, Taibi [Department of Mechanical Engineering, University of M'sila (Algeria); Laboratory of Industrial Physics, Thermal centre of INSA of Lyon, CETHIL (France); Michel, Laurent [Laboratory of Industrial Physics, Thermal centre of INSA of Lyon, CETHIL (France)

    2008-09-23

    The welding of materials by CO2 laser took significant considerations in industry, for the reason of the quality of the carried out weldings, and for other many advantages, but the automation of the welding operation requires a control system in real time. The operation of welding is an operation of interaction between the radiation (laser), and the matter (welded part), which is characterized by the vaporization of the matter, formation of the keyhole in material, and appearance of plasma over the material. This study relates to the relation between the welding (molten material) and the plasma which is formed on material. The light emitted by plasma during laser welding was recorded by an OMA detector (Optical Multichannel Analyzer) over a wavelength width of 450 A ring . The analysis of this light allows to determine the composition of this plasma, its dimensions, and the state of its energy according to the laser parameters. The welded material is the stainless steel 18-10, it was found that the intensity of the light emitted by plasma depends on laser power, the welding speed, the flow rate of assist gas. The relation between the plasma and the state of the bead were analyzed for on-line monitoring welding.

  12. HANFORD SITE WELDING PROGRAM SUCCESSFULLY PROVIDING A SINGLE SITE FUNCTION FOR USE BY MULTIPLE CONTRACTORS

    SciTech Connect (OSTI)

    CANNELL GR

    2009-11-19

    The Department of Energy, Richland Operations (DOE-RL) recently restructured its Hanford work scope, awarding two new contracts over the past several months for a total of three contracts to manage the sites cleanup efforts. DOE-RL met with key contractor personnel prior to and during contract transition to ensure site welding activities had appropriate oversight and maintained code compliance. The transition also provided an opportunity to establish a single site-wide function that would provide welding and materials engineering services to the Hanford site contractors: CH2M HILL Plateau Remediation Company (CHPRC); Mission Support Alliance (MSA); Washington River Protection Solutions (WRPS); and Washington Closure Hanford (WCH). Over the years, multiple and separate welding programs (amongst the several contractors) existed at the Hanford site leading to inefficiencies resulting from duplication of administrative efforts, maintenance of welding procedures, welder performance certifications, etc. The new, single program eliminates these inefficiencies. The new program, co-managed by two of the sites' new contractors, the CHPRC ('owner' of the program and responsible for construction welding services) and the MSA (provides maintenance welding services), provides more than just the traditional construction and maintenance welding services. Also provided, are welding engineering, specialty welding development/qualification for the closure of radioactive materials containers and materials evaluation/failure analysis. The following describes the new Hanford site welding program.

  13. An investigation of the dynamic separation of spot welds under plane tensile pulses

    SciTech Connect (OSTI)

    Ma, Bohan; Fan, Chunlei; Chen, Danian Wang, Huanran; Zhou, Fenghua

    2014-08-07

    We performed ultra-high-speed tests for purely opening spot welds using plane tensile pulses. A gun system generated a parallel impact of a projectile plate onto a welded plate. Induced by the interactions of the release waves, the welded plate opened purely under the plane tensile pulses. We used the laser velocity interferometer system for any reflector to measure the velocity histories of the free surfaces of the free part and the spot weld of the welded plate. We then used a scanning electron microscope to investigate the recovered welded plates. We found that the interfacial failure mode was mainly a brittle fracture and the cracks propagated through the spot nugget, while the partial interfacial failure mode was a mixed fracture comprised ductile fracture and brittle fracture. We used the measured velocity histories to evaluate the tension stresses in the free part and the spot weld of the welded plate by applying the characteristic theory. We also discussed the different constitutive behaviors of the metals under plane shock loading and under uniaxial split Hopkinson pressure bar tests. We then compared the numerically simulated velocity histories of the free surfaces of the free part and the spot weld of the welded plate with the measured results. The numerical simulations made use of the fracture stress criteria, and then the computed fracture modes of the tests were compared with the recovered results.

  14. X-ray tomographic in-service inspection of girth welds - The European project TomoWELD

    SciTech Connect (OSTI)

    Ewert, Uwe Redmer, Bernhard Walter, David Thiessenhusen, Kai-Uwe Bellon, Carsten; Nicholson, P. Ian; Clarke, Alan L.; Finke-Härkönen, Klaus-Peter

    2015-03-31

    The new standard 'ISO 17636-2:2013: Non-destructive testing of welds - Radiographic testing - Part 2: X- and gamma-ray techniques with digital detectors', defines the practice for radiographic inspection of welded pipes for manufacturing and in-service inspection. It is applied in Europe for inspections of pipe welds in nuclear power plants as well as in chemical plants and allows a faster inspection with digital detector arrays (DDA) than with film. Nevertheless, it does not allow the evaluation of the depth and shape of volumetric and planar indications. In 2001 a planar tomography scanner, TomoCAR, was introduced for mechanized radiographic testing (RT) inspection and non-destructive measurement of cross sections. The project TomoWELD is based on a new concept of the scan geometry, an enhanced GPU based reconstruction, and the application of a new generation of photon counting DDAs based on CdTe crystal CMOS hybrids. The new detector permits the selection of energy thresholds to obtain an optimum energy range and reduction of the influence of scattered radiation. The concept and first measurements are presented. Flaw depth and shape of volumetric and planar irregularities can be determined.

  15. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc welding of nickel to nickel-copper

    SciTech Connect (OSTI)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-2301-ASME-3 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of nickel, NO2200 or NO2201 (P-41) to nickel-copper NO4400 (P-42), in thickness range 0.035 to 0.432 inch; filler metal is ERNiCu-7 (F-42); shielding gas is argon.

  16. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc welding of nickel-copper

    SciTech Connect (OSTI)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-1302-ASME-3 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of nickel-copper NO4400 (P-42), in thickness range 0.035 to 0.432 inch; filler metal is ERNiCu-7 (F-42); shielding gas is argon.

  17. Slimhole and coiled tubing standards phase 1. Weld technology (January 1996). Final report, September 1994-December 1995

    SciTech Connect (OSTI)

    Newman, K.R.; Brown, P.; Van Arnam, D.

    1996-02-01

    The reliability and understanding of coiled tubing (CT) welds is an issue of concern in the oil and gas industry. Much work has been done to understand the fatigue characteristics of the base CT material. Until recently, little work had been done to understand the fatigue life of the CT welds, which are the weakest points in the CT string. A separate project funded by a joint industry group, recently performed a large number of fatigue tests on CT welds. This separate study showed significant room for improvement in the understanding of CT welds. The GRI-supported project attempts to improve the understanding of CT weld technology and methods by analyzing failed weld samples, reviewing and recommending new CT welding procedures and reviewing alternative welding techniques which could be use for CT welding.

  18. Slimhole and coiled tubing standards phase 1. Weld technology (February 1996). Final report, September 1994-December 1995

    SciTech Connect (OSTI)

    Newman, K.R.; Brown, P.; Van Arnam, D.

    1996-02-01

    The reliability and understanding of coiled tubing (CT) welds is an issue of concern in the oil and gas industry. Much work has been done to understand the fatigue characteristics of the base CT material. Until recently, little work had been done to understand the fatigue life of the CT welds, which are the weakest points in the CT string. A separate project funded by a joint industry group, recently performed a large number of fatigue tests on CT welds. This separate study showed significant room for improvement in the understanding of CT welds. The GRI-supported project attempts to improve the understanding of CT weld technology and methods by analyzing failed weld samples, reviewing and recommending new CT welding procedures and reviewing alternative welding techniques which could be use for CT welding.

  19. Multiple density layered insulator

    DOE Patents [OSTI]

    Alger, Terry W.

    1994-01-01

    A multiple density layered insulator for use with a laser is disclosed wh provides at least two different insulation materials for a laser discharge tube, where the two insulation materials have different thermoconductivities. The multiple layer insulation materials provide for improved thermoconductivity capability for improved laser operation.

  20. Multiple density layered insulator

    DOE Patents [OSTI]

    Alger, T.W.

    1994-09-06

    A multiple density layered insulator for use with a laser is disclosed which provides at least two different insulation materials for a laser discharge tube, where the two insulation materials have different thermoconductivities. The multiple layer insulation materials provide for improved thermoconductivity capability for improved laser operation. 4 figs.

  1. Final Report: A Transport Phenomena Based Approach to Probe Evolution of Weld Macro and Microstructures and A Smart Bi-directional Model of Fusion Welding

    SciTech Connect (OSTI)

    Dr. Tarasankar DebRoy

    2009-12-11

    In recent years, applications of numerical heat transfer and fluid flow models of fusion welding have resulted in improved understanding of both the welding processes and welded materials. They have been used to accurately calculate thermal cycles and fusion zone geometry in many cases. Here we report the following three major advancements from this project. First, we show how microstructures, grain size distribution and topology of welds of several important engineering alloys can be computed starting from better understanding of the fusion welding process through numerical heat transfer and fluid flow calculations. Second, we provide a conclusive proof that the reliability of numerical heat transfer and fluid flow calculations can be significantly improved by optimizing several uncertain model parameters. Third, we demonstrate how the numerical heat transfer and fluid flow models can be combined with a suitable global optimization program such as a genetic algorithm for the tailoring of weld attributes such as attaining a specified weld geometry or a weld thermal cycle. The results of the project have been published in many papers and a listing of these are included together with a list of the graduate thesis that resulted from this project. The work supported by the DOE award has resulted in several important national and international awards. A listing of these awards and the status of the graduate students are also presented in this report.

  2. Multiple layer insulation cover

    DOE Patents [OSTI]

    Farrell, James J.; Donohoe, Anthony J.

    1981-11-03

    A multiple layer insulation cover for preventing heat loss in, for example, a greenhouse, is disclosed. The cover is comprised of spaced layers of thin foil covered fabric separated from each other by air spaces. The spacing is accomplished by the inflation of spaced air bladders which are integrally formed in the cover and to which the layers of the cover are secured. The bladders are inflated after the cover has been deployed in its intended use to separate the layers of the foil material. The sizes of the material layers are selected to compensate for sagging across the width of the cover so that the desired spacing is uniformly maintained when the cover has been deployed. The bladders are deflated as the cover is stored thereby expediting the storage process and reducing the amount of storage space required.

  3. ADVANCED INTEGRATION OF MULTI-SCALE MECHANICS AND WELDING PROCESS SIMULATION IN WELD INTEGRITY ASSESSMENT

    SciTech Connect (OSTI)

    Wilkowski, Gery M.; Rudland, David L.; Shim, Do-Jun; Brust, Frederick W.; Babu, Sundarsanam

    2008-06-30

    The potential to save trillions of BTU’s in energy usage and billions of dollars in cost on an annual basis based on use of higher strength steel in major oil and gas transmission pipeline construction is a compelling opportunity recognized by both the US Department of Energy (DOE). The use of high-strength steels (X100) is expected to result in energy savings across the spectrum, from manufacturing the pipe to transportation and fabrication, including welding of line pipe. Elementary examples of energy savings include more the 25 trillion BTUs saved annually based on lower energy costs to produce the thinner-walled high-strength steel pipe, with the potential for the US part of the Alaskan pipeline alone saving more than 7 trillion BTU in production and much more in transportation and assembling. Annual production, maintenance and installation of just US domestic transmission pipeline is likely to save 5 to 10 times this amount based on current planned and anticipated expansions of oil and gas lines in North America. Among the most important conclusions from these studies were: • While computational weld models to predict residual stress and distortions are well-established and accurate, related microstructure models need improvement. • Fracture Initiation Transition Temperature (FITT) Master Curve properly predicts surface-cracked pipe brittle-to-ductile initiation temperature. It has value in developing Codes and Standards to better correlate full-scale behavior from either CTOD or Charpy test results with the proper temperature shifts from the FITT master curve method. • For stress-based flaw evaluation criteria, the new circumferentially cracked pipe limit-load solution in the 2007 API 1104 Appendix A approach is overly conservative by a factor of 4/π, which has additional implications. . • For strain-based design of girth weld defects, the hoop stress effect is the most significant parameter impacting CTOD-driving force and can increase the crack-driving force by a factor of 2 depending on strain-hardening, pressure level as a % of SMYS, and flaw size. • From years of experience in circumferential fracture analyses and experimentation, there has not been sufficient integration of work performed for other industries into analogous problems facing the oil and gas pipeline markets. Some very basic concepts and problems solved previously in these fields could have circumvented inconsistencies seen in the stress-based and strain-based analysis efforts. For example, in nuclear utility piping work, more detailed elastic-plastic fracture analyses were always validated in their ability to predict loads and displacements (stresses and strains). The eventual implementation of these methodologies will result in acceleration of the industry adoption of higher-strength line-pipe steels.

  4. Engineering approximations in welding: Bridging the gap between the speculation and simulation

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Robino, Charles V.

    2016-01-15

    During the course of their careers, welding engineers and welding metallurgists are often confronted with questions regarding welding process and properties that on the surface appear to be simple and direct, but are in fact quite challenging. These questions generally mask an underlying complexity whose underpinnings in scientific and applied research predate even the founding of the American Welding Society, and previous Comfort A. Adams lectures provide ample and fascinating evidence of the breadth and depth of this complexity. Using these studies or their own experiences and investigations as a basis, most welding and materials engineers have developed engineering toolsmore » to provide working approaches to these day-to-day questions and problems. In this article several examples of research into developing working approaches to welding problems are presented.« less

  5. Development of an improved GTA (gas tungsten arc) weld temperature monitor fixture

    SciTech Connect (OSTI)

    Hollar, D.L.

    1990-05-01

    An initial design weld temperature control fixture was implemented into final closure of an electronic assembly in November 1986. Use of this fixture indicated several areas that could be improved. Review of these areas with the process engineer and the weld operator provided the ideas to be incorporated into the new design Phase 2 fixture. Some primary areas of change and improvement included fixture mobility to provide better accessibility to the weld joint area, automatic timed blow cooling of the weld joint, and a feature to assure proper thermocouple placement. The resulting Phase 2 fixture design provided all of the essential weld temperature monitoring features in addition to several significant improvements. Technology developed during this project will pave the way to similar process monitoring of other manual gas tungsten arc (GTA) welding applications. 9 figs.

  6. On the development of nugget growth model for resistance spot welding

    SciTech Connect (OSTI)

    Zhou, Kang, E-mail: zhoukang326@126.com, E-mail: melcai@ust.hk; Cai, Lilong, E-mail: zhoukang326@126.com, E-mail: melcai@ust.hk [Department of Mechanical and Aerospace Engineering, Hong Kong University of Science and Technology, Clear Water Bay, Kowloon (Hong Kong)

    2014-04-28

    In this paper, we developed a general mathematical model to estimate the nugget growth process based on the heat energy delivered into the welds by the resistance spot welding. According to the principles of thermodynamics and heat transfer, and the effect of electrode force during the welding process, the shape of the nugget can be estimated. Then, a mathematical model between heat energy absorbed and nugget diameter can be obtained theoretically. It is shown in this paper that the nugget diameter can be precisely described by piecewise fractal polynomial functions. Experiments were conducted with different welding operation conditions, such as welding currents, workpiece thickness, and widths, to validate the model and the theoretical analysis. All the experiments confirmed that the proposed model can predict the nugget diameters with high accuracy based on the input heat energy to the welds.

  7. Grinding assembly, grinding apparatus, weld joint defect repair system, and methods

    DOE Patents [OSTI]

    Larsen, Eric D.; Watkins, Arthur D.; Bitsoi, Rodney J.; Pace, David P.

    2005-09-27

    A grinding assembly for grinding a weld joint of a workpiece includes a grinder apparatus, a grinder apparatus includes a grinding wheel configured to grind the weld joint, a member configured to receive the grinding wheel, the member being configured to be removably attached to the grinder apparatus, and a sensor assembly configured to detect a contact between the grinding wheel and the workpiece. The grinding assembly also includes a processing circuitry in communication with the grinder apparatus and configured to control operations of the grinder apparatus, the processing circuitry configured to receive weld defect information of the weld joint from an inspection assembly to create a contour grinding profile to grind the weld joint in a predetermined shape based on the received weld defect information, and a manipulator having an end configured to carry the grinder apparatus, the manipulator further configured to operate in multiple dimensions.

  8. Boundary Layer Structure:

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Boundary Layer Structure: a comparison between methods and sites Thiago Biscaro Suzane de Sá Jae-In Song Shaoyue "Emily" Qiu Mentors: Virendra Ghate and Ewan O'Connor July 24 2015 1 st ever ARM Summer Training Outline * IntroducQon * Methodology * Results - SGP - MAO - Comparison between the 2 sites * Conclusions INTRODUCTION Focus: esQmates of PBL height Boundary Layer: "The boUom layer of the troposphere that is in contact with the surface of the earth." (AMS, Glossary of

  9. Compliant layer chucking surface

    DOE Patents [OSTI]

    Blaedel, Kenneth L.; Spence, Paul A.; Thompson, Samuel L.

    2004-12-28

    A method and apparatus are described wherein a thin layer of complaint material is deposited on the surface of a chuck to mitigate the deformation that an entrapped particle might cause in the part, such as a mask or a wafer, that is clamped to the chuck. The harder particle will embed into the softer layer as the clamping pressure is applied. The material composing the thin layer could be a metal or a polymer for vacuum or electrostatic chucks. It may be deposited in various patterns to affect an interrupted surface, such as that of a "pin" chuck, thereby reducing the probability of entrapping a particle.

  10. In-situ Thermal Strain and Temperature Measurement and Modeling during Arc Welding

    Office of Scientific and Technical Information (OSTI)

    In-situ Thermal Strain and Temperature Measurement and Modeling during Arc Welding Jian Chen, Xinghua Yu, Roger G. Miller, Zhili Feng* Oak Ridge National Laboratory, Oak Ridge TN 37831, USA *corresponding author: fengz@ornl.gov Abstract Experiments and numerical models were applied to investigate the thermal and mechanical behaviors of the materials adjacent to the weld pool during arc welding. In the experiment, a new high-temperature strain measurement technique based on digital image

  11. Sample preparation method for glass welding by ultrashort laser pulses yields higher seam strength

    SciTech Connect (OSTI)

    Cvecek, K.; Miyamoto, I.; Strauss, J.; Wolf, M.; Frick, T.; Schmidt, M.

    2011-05-01

    Glass welding by ultrashort laser pulses allows joining without the need of an absorber or a preheating and postheating process. However, cracks generated during the welding process substantially impair the joining strength of the welding seams. In this paper a sample preparation method is described that prevents the formation of cracks. The measured joining strength of samples prepared by this method is substantially higher than previously reported values.

  12. Electron beam weld development on a Filter Pack Assembly. Final report

    SciTech Connect (OSTI)

    Dereskiewicz, J.P.

    1994-06-01

    A continuous electron beam welding procedure was developed to replace the manual gas tungsten arc welding procedure on the Filter Pack Assembly. A statistical study was used to evaluate the feasibility of electron beam welding 6061-T6 aluminum covers to A356 cast weldments throughout the joint tolerance range specified on product drawings. Peak temperature exposures were not high enough to degrade the heat sensitive electrical components inside the cast weldment. Actual weldments with alodine coating on the weld joint area were successfully cleaned using a nonmetallic fiberglass brush cleaning method.

  13. Implementation of an Outer Can Welding System for Savannah River Site FB-Line

    SciTech Connect (OSTI)

    Howard, S.R.

    2003-03-27

    This paper details three phases of testing to confirm use of a Gas Tungsten Arc (GTA) system for closure welding the 3013 outer container used for stabilization/storage of plutonium metals and oxides. The outer container/lid closure joint was originally designed for laser welding, but for this application, the gas tungsten arc (GTA) welding process has been adapted. The testing progressed in three phases: (1) system checkout to evaluate system components for operational readiness, (2) troubleshooting to evaluate high weld failure rates and develop corrective techniques, and (3) pre-installation acceptance testing.

  14. Subtask 12B1: Welding development for V-Cr-Ti alloys

    SciTech Connect (OSTI)

    King, J.F.; Goodwin, G.M.; Grossbeck, M.L.; Alexander, D.J.

    1995-03-01

    Development of the metallurgical and technological basis for the welding of thick sections of V-Cr-Ti alloys. The weldability and weldment properties of the V-5Cr-5Ti alloy have been evaluated. Results for the Sigmajig test of the vanadium alloy were similar to the cracking resistance of stainless steels, and indicates hot-cracking is unlikely to be a problem. Subsize Charpy test results for GTA weld metal in the as-welded condition have shown a significant reduction in toughness compared to the base metal. The weld metal toughness properties were restored to approximately that of the base metal after exposure to a PWHT 950{degrees}C. The subsize Charpy toughness results for the EB weld metal from this same heat of vanadium alloy has shown significant improvement in properties compared to the GTA weld metal and the base metal. Further testing and analysis will be conducted to more fully characterize the properties of weld metal for each welding process and develop a basic understanding of the cause of the toughness decrease in the GTA welds. 5 figs., 1 tab.

  15. Surface preparation effects on GTA weld shape in JBK-75 stainless steel

    SciTech Connect (OSTI)

    Campbell, R.D.; Robertson, A.M. ); Heiple, C.R. ); Sturgill, P.L.; Jamsay, R.

    1993-02-01

    The results of a study are reported here on the effects of surface preparation on the shape of autogenous gas tungsten arc (GTA) welds in JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface preparation produced substantial changes in the fusion zone shape and welding behavior of this alloy. Increased and more consistent depth of fusion (higher d/w ratios) along with improved arc stability and less arc wander resulted from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any increase in depth of fusion. Abrasive treatments roughen the surface, increase the surface area, increase the surface oxide thickness, and entrap oxide. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension-driven fluid flow pattern in the weld pool. Increased depth of fusion in wire-fed U-groove weld joints also resulted when welding wire with a greater surface oxide thickness was used. Increasing the amount of wire brushing produced even deeper welds. However, a maximum in depth of fusion was observed with further wire brushing, beyond which weld fusion depth decreased.

  16. Stability of Y Ti O Precipitates in Friction Stir Welded Nanostructure...

    Office of Scientific and Technical Information (OSTI)

    This study evaluates microstructure of friction stir welded NFA using electron microscopy and atom probe tomography (APT) techniques. APT results revealed NCs are coarsened and ...

  17. Friction Stir Welding High Strength Low Alloy Steel using a Multilayer...

    Office of Scientific and Technical Information (OSTI)

    Relation: Conference: 10th International Friction Stir Welding Symposium, Beijing, China, 20140519, 20140523 Research Org: Oak Ridge National Laboratory (ORNL) Sponsoring Org:...

  18. Effect of multiple repairs in girth welds of pipelines on the mechanical properties

    SciTech Connect (OSTI)

    Vega, O.E.; Hallen, J.M.; Villagomez, A.

    2008-10-15

    This work presents the results of multiple weld repairs in the same area in seamless API X-52 microalloyed steel pipe. Four conditions of shielded metal arc welding repairs and one as-welded specimen of the girth weld were characterized to determine changes in the microstructure, grain size in the heat affected zone, and to evaluate their effect on the mechanical properties of the weld joints. The mechanical properties by means of tension tests, Charpy-V impact resistance and Vickers hardness of the welds were analyzed. The results indicate that significant changes are not generated in the microstructural constituents of the heat affected zone. Grain growth in the heat affected zone at the specimen mid-thickness with the number of repairs was observed. Tensile strength of the weld joints meets the requirement of the API 1104 standard even after the fourth weld repair. Significant reduction in Charpy-V impact resistance with the number of weld repairs was found when the notch location was in the intersection of the fusion line with the specimen mid-thickness. A significant increase in the Vickers hardness of the heat affected zone occurred after the first repair and a gradual decrease in the Vickers hardness occurred as the number of repairs increases.

  19. Robotic inspection of PWR coolant pump casing welds

    SciTech Connect (OSTI)

    Pratt, W.R.; Alford, J.W.; Davis, J.B.

    1997-12-01

    As of January 1, 1995, the Swedish Nuclear Inspectorate began requiring more thorough inspections of cast stainless-steel components in nuclear power plants, including pressurized water reactor (PWR) reactor coolant pump (RCP) casings. The examination requirements are established by fracture mechanics analyses of component weldments and demonstrated test system detection capabilities. This may include full volumetric inspection or some portion thereof. Ringhals station is a four-unit nuclear power plant, owned and operated by the Swedish State Power Board, Vattenfall. Unit 1 is a boiling water reactor. Units 2, 3, and 4 are Westinghouse-designed PWRs, ranging in size from 795 to 925 MW. The RCP casings at the PWR units are made of cast stainless steel and contain four circumferential welds that require inspection. Due to the thickness of the casings at the weld locations and configuration and surface conditions on the outside diameter of the casings, remote inspection from the inside diameter of the pump casing was mandated.

  20. Predicting mesoscale microstructural evolution in electron beam welding

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Rodgers, Theron M.; Madison, Jonathan D.; Tikare, Veena; Maguire, Michael C.

    2016-03-16

    Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstructures for electron-beam welding by comparing them with experimentally produced microstructures. When simulation input parameters are matched to experimental process parameters, qualitative and quantitative agreement for both grain size and grain morphology are achieved. The method is capable of simulating both single- and multipass welds. As a result, the simulations provide anmore » opportunity for not only accelerated design but also the integration of simulation and experiments in design such that simulations can receive parameter bounds from experiments and, in turn, provide predictions of a resultant microstructure.« less

  1. Structured luminescence conversion layer

    DOE Patents [OSTI]

    Berben, Dirk; Antoniadis, Homer; Jermann, Frank; Krummacher, Benjamin Claus; Von Malm, Norwin; Zachau, Martin

    2012-12-11

    An apparatus device such as a light source is disclosed which has an OLED device and a structured luminescence conversion layer deposited on the substrate or transparent electrode of said OLED device and on the exterior of said OLED device. The structured luminescence conversion layer contains regions such as color-changing and non-color-changing regions with particular shapes arranged in a particular pattern.

  2. Video Game Device Haptic Interface for Robotic Arc Welding

    SciTech Connect (OSTI)

    Corrie I. Nichol; Milos Manic

    2009-05-01

    Recent advances in technology for video games have made a broad array of haptic feedback devices available at low cost. This paper presents a bi-manual haptic system to enable an operator to weld remotely using the a commercially available haptic feedback video game device for the user interface. The system showed good performance in initial tests, demonstrating the utility of low cost input devices for remote haptic operations.

  3. Welding/sealing glass-enclosed space in a vacuum

    DOE Patents [OSTI]

    Tracy, C. Edwin; Benson, David K.

    1996-01-01

    A method of welding and sealing the edges of two juxtaposed glass sheets together to seal a vacuum space between the sheets comprises the steps of positioning a radiation absorbant material, such as FeO, VO.sub.2, or NiO, between the radiation transmissive glass sheets adjacent the edges and then irradiating the absorbant material, preferably with a laser beam, through at least one of the glass sheets. Heat produced by the absorbed radiation in the absorbant material melts glass in the portions of both glass sheets that are adjacent the absorbant material, and the melted glass from both sheets flows together to create the weld when the melted glass cools and hardens. The absorbant material can be dissolved and diffused into the melted glass to the extent that it no longer absorbs enough energy to keep the glass melted, thus, with appropriate proportioning of absorbant material to source energy power and welding heat needed, the process can be made self-stopping.

  4. Welding/sealing glass-enclosed space in a vacuum

    DOE Patents [OSTI]

    Tracy, C.E.; Benson, D.K.

    1996-02-06

    A method of welding and sealing the edges of two juxtaposed glass sheets together to seal a vacuum space between the sheets comprises the steps of positioning a radiation absorbent material, such as FeO, VO{sub 2}, or NiO, between the radiation transmissive glass sheets adjacent the edges and then irradiating the absorbent material, preferably with a laser beam, through at least one of the glass sheets. Heat produced by the absorbed radiation in the absorbent material melts glass in the portions of both glass sheets that are adjacent the absorbent material, and the melted glass from both sheets flows together to create the weld when the melted glass cools and hardens. The absorbent material can be dissolved and diffused into the melted glass to the extent that it no longer absorbs enough energy to keep the glass melted, thus, with appropriate proportioning of absorbent material to source energy power and welding heat needed, the process can be made self-stopping. 8 figs.

  5. Stress corrosion cracking of welded Alloy 600 penetration mockups

    SciTech Connect (OSTI)

    Sarver, J.M.; Pathania, R.S.; Stuckey, K.; Fyfitch, S.; Gelpi, A.; Foucault, M.; Hunt, E.S.

    1995-12-31

    The primary water stress corrosion cracking (PWSCC) of Alloy 600 in components other than steam generators is a problem of increasing concern for nuclear power plants. Of greatest concern at the present time is the PWSCC of Alloy 600 vessel head penetrations. The common elements of these components are threefold: (1) the Alloy 600 material has a susceptible microstructure, (2) the Alloy 600 material is either a thick-walled tube or a bar which has been machined into a thick-walled tube, and (3) the Alloy 600 material has been welded into a structure such that high residual welding stresses exist in the postwelded Alloy 600 material. The objectives of the present program were to evaluate the PWSCC behavior of various configurations of welded Alloy 600 penetrations, and possible remedial measures which would prevent or retard PWSCC in these components. Mockups were instrumented to permit instantaneous remote sensing of through-wall cracking and were autoclave tested along with control C-rings in a doped steam environment. Following the test exposures, the mockups were split and examined to characterize the cracking morphology and the material microstructure. A Weibull distribution was used to analyze the time-to-failure results, and the observed cracking locations were compared to residual stress levels predicted by an elastic-plastic finite element analysis of the mockups.

  6. Layered electrode for electrochemical cells

    DOE Patents [OSTI]

    Swathirajan, Swathy; Mikhail, Youssef M.

    2001-01-01

    There is provided an electrode structure comprising a current collector sheet and first and second layers of electrode material. Together, the layers improve catalyst utilization and water management.

  7. Layered semiconductor neutron detectors

    DOE Patents [OSTI]

    Mao, Samuel S; Perry, Dale L

    2013-12-10

    Room temperature operating solid state hand held neutron detectors integrate one or more relatively thin layers of a high neutron interaction cross-section element or materials with semiconductor detectors. The high neutron interaction cross-section element (e.g., Gd, B or Li) or materials comprising at least one high neutron interaction cross-section element can be in the form of unstructured layers or micro- or nano-structured arrays. Such architecture provides high efficiency neutron detector devices by capturing substantially more carriers produced from high energy .alpha.-particles or .gamma.-photons generated by neutron interaction.

  8. Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

    SciTech Connect (OSTI)

    Bhatt, R.B.; Kamat, H.S.; Ghosal, S.K.; De, P.K.

    1999-10-01

    The influence of nitrogen in shielding gas on the corrosion resistance of welds of a duplex stainless steel (grade U-50), obtained by gas tungsten arc (GTA) with filler wire, autogenous GTA (bead-on-plate), electron beam welding (EBW), and microplasma techniques, has been evaluated in chloride solutions at 30 C. Pitting attack has been observed in GTA, electron beam welding, and microplasma welds when welding has been carried out using pure argon as the shielding gas. Gas tungsten arc welding with 5 to 10% nitrogen and 90 to 95% argon, as the shielding gas, has been found to result in an improved pitting corrosion resistance of the weldments of this steel. However, the resistance of pitting of autogenous welds (bead-on-plate) obtained in pure argon as the shielding gas has been observed to remain unaffected. Microscopic examination, electron probe microanalysis (EPMA), and x-ray diffraction studies have revealed that the presence of nitrogen in the shielding gas in the GTA welds not only modifies the microstructure and the austenite to ferrite ratio but also results in a nearly uniform distribution of the various alloying elements, for example, chromium, nickel, and molybdenum among the constituent phases, which are responsible for improved resistance to pitting corrosion.

  9. Joint strength in high speed friction stir spot welded DP 980 steel

    SciTech Connect (OSTI)

    Saunders, Nathan; Miles, Michael; Hartman, Trent; Hovanski, Yuri; Hong, Sung Tae; Steel, Russell

    2014-05-01

    High speed friction stir spot welding was applied to 1.2 mm thick DP 980 steel sheets under different welding conditions, using PCBN tools. The range of vertical feed rates used during welding was 2.5 mm – 102 mm per minute, while the range of spindle speeds was 2500 – 6000 rpm. Extended testing was carried out for five different sets of welding conditions, until tool failure. These welding conditions resulted in vertical welding loads of 3.6 – 8.2 kN and lap shear tension failure loads of 8.9 – 11.1 kN. PCBN tools were shown, in the best case, to provide lap shear tension fracture loads at or above 9 kN for 900 spot welds, after which tool failure caused a rapid drop in joint strength. Joint strength was shown to be strongly correlated to bond area, which was measured from weld cross sections. Failure modes of the tested joints were a function of bond area and softening that occurred in the heat-affected zone.

  10. Method and device for reducing overpenetration at the start of plasma arc welds

    SciTech Connect (OSTI)

    Sanders, J.M.; Lehmann, J.M.; Ryan, P.M.

    2000-03-14

    A shim for improving plasma arc weld quality has ends tapered at about 25{degree} and notches at each end roughly centered over the corner between the tapered ends and main body of the shim. The improved shim allows lower starting plasma arc heat input and reduces the occurrence of sagging, or overpenetration, of the weld.

  11. Method and device for reducing overpenetration at the start of plasma arc welds

    DOE Patents [OSTI]

    Sanders, John M.; Lehmann, John M.; Ryan, Patrick M.

    1998-01-01

    A shim for improving plasma arc weld quality has ends tapered at about 25.degree. and notches at each end roughly centered over the corner between the tapered ends and main body of the shim. The improved shim allows lower starting plasma arc heat input and reduces the occurrence of sagging, or overpenetration, of the weld.

  12. Assessment of Weld Overlays for Mitigating Primary Water Stress Corrosion Cracking at Nickel Alloy Butt Welds in Piping Systems Approved for Leak-Before-Break

    SciTech Connect (OSTI)

    Sullivan, Edward J.; Anderson, Michael T.

    2012-08-01

    This TLR provides an assessment of weld overlays as a mitigation strategy for PWSCC, and includes an assessment of the WOL-related inspection requirements of Code Case N-770-1, as conditioned in §50.55a.

  13. Weld microstructure development and properties of precipitation-strengthened martensitic stainless steels

    SciTech Connect (OSTI)

    Brooks, J.A. ); Garrison, W.R. Jr. )

    1999-08-01

    The weld microstructural evolution, mechanical properties and solidification cracking susceptibility of three precipitation-strengthened martensitic stainless steels--PH 13-8 Mo, Custom 450 and 15-5 PH--were investigated. Liquid tin quenching of gas tungsten arc welds revealed that all three welds solidified as single-phase ferrite with a high degree of microsegregation. However, during further solidification and cooling almost complete homogenization occurred as a result of solid-state diffusion. The welds in all three alloys exhibited good resistance to solidification cracking and generally exhibited tensile and impact properties similar to those of the base metal. However, in almost all cases, the weld Charpy impact energies were somewhat less than those of the base metals. The cracking behavior and mechanical properties are discussed in terms of microstructural evolution.

  14. Effects of SO/sub 2/ shielding gas additions on GTA weld shape

    SciTech Connect (OSTI)

    Heiple, C.R.; Burgardt, P.

    1985-06-01

    Substantial increases in GTA weld depth/width ratio resulted from small additions of sulfur dioxide (SO/sub 2/) to the torch shielding gas when welding two stainless steels. The improvement was demonstrated on both Types 304 and 21-6-9 austenitic stainless steels, but would be expected for iron-base alloys generally. The weld pool shape achieved was essentially independent of variations in both SO/sub 2/ content of the torch gas and base metal composition when SO/sub 2/ in the shielding gas was in the range of 500 to 1400 ppm. With 700 ppm SO/sub 2/ in the torch gas, less than 30 ppm sulfur was added to an autogenous weld bead. For alloys where this additional sulfur can be tolerated and appropriate measures can be taken to handle the toxic SO/sub 2/, this technique offers a promising way to improve GTA weld joint penetration while suppressing variable penetration.

  15. Effect of minor chemistry elements on GTA weld fusion zone characteristics of a commercial grade titanium

    SciTech Connect (OSTI)

    Marya, S.K.

    1996-06-01

    Gas Tungsten Arc Welding (GTAW) is the most common technique employed in the fabrication of rolled thin tubes. One of the major manufacturing problems concerns the stability of weld fusion zone on materials from different casts, notwithstanding stringent monitoring of the process parameters -- current, voltage and travel speed. These parameters determine the theoretical weld heat and are expected to control the instantaneous mass of melt. According to the data compiled by Sahoo et al., oxygen is known to reduce the surface tension of most of the metals. However, investigations on the role of minor changes in concentrations of elements like sulphur, oxygen, selenium, bismuth, aluminium, and titanium in steels have very often attributed the cast to cast variations to different temperature gradients of surface tension over the weldpool. To the author`s knowledge, no reported work so far has revealed changing weld profiles in autogeneous mechanized GTA welds on titanium due to minor composition changes.

  16. Influence of Alloy and Solidification Parameters on Grain Refinement in Aluminum Weld Metal due to Inoculation

    SciTech Connect (OSTI)

    Schempp, Philipp [BAM, Germany; Tang, Z. [BIAS, Germany; Cross, Carl E. [Los Alamos National Laboratory; Seefeld, T. [BIAS, Germany; Pittner, A. [BAM, Germany; Rethmeier, M. [BAM, Germany

    2012-06-28

    The goals are: (1) Establish how much Ti/B grain refiner is need to completely refine aluminum weld metal for different alloys and different welding conditions; (2) Characterize how alloy composition and solidification parameters affect weld metal grain refinement; and (3) Apply relevant theory to understand observed behavior. Conclusions are: (1) additions of Ti/B grain refiner to weld metal in Alloys 1050, 5083, and 6082 resulted in significant grain refinement; (2) grain refinement was more effective in GTAW than LBW, resulting in finer grains at lower Ti content - reason is limited time available for equiaxed grain growth in LBW (inability to occlude columnar grain growth); (3) welding travel speed did not markedly affect grain size within GTAW and LBW clusters; and (4) application of Hunt CET analysis showed experimental G to be on the order of the critical G{sub CET}; G{sub CET} was consistently higher for GTAW than for LBW.

  17. Neutron diffraction measurements of residual stresses in friction stir welding: a review

    SciTech Connect (OSTI)

    Woo, Wan Chuck [ORNL; Feng, Zhili [ORNL; Wang, Xun-Li [ORNL; David, Stan A [ORNL

    2011-01-01

    Significant amounts of residual stresses are often generated during welding and result in critical degradation of the structural integrity and performance of components. Neutron diffraction has become a well established technique for the determination of residual stresses in welds because of the unique deep penetration, three-dimensional mapping capability, and volume averaged bulk measurements characteristic of the scattering neutron beam. Friction stir welding has gained prominence in recent years. The authors reviewed a number of neutron diffraction measurements of residual stresses in friction stir welds and highlighted examples addressing how the microstructures and residual stresses are correlated with each other. An example of in situ neutron diffraction measurement result shows the evolution of the residual stresses during welding.

  18. Three-dimensional modeling of the plasma arc in arc welding

    SciTech Connect (OSTI)

    Xu, G.; Tsai, H. L.; Hu, J.

    2008-11-15

    Most previous three-dimensional modeling on gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) focuses on the weld pool dynamics and assumes the two-dimensional axisymmetric Gaussian distributions for plasma arc pressure and heat flux. In this article, a three-dimensional plasma arc model is developed, and the distributions of velocity, pressure, temperature, current density, and magnetic field of the plasma arc are calculated by solving the conservation equations of mass, momentum, and energy, as well as part of the Maxwell's equations. This three-dimensional model can be used to study the nonaxisymmetric plasma arc caused by external perturbations such as an external magnetic field. It also provides more accurate boundary conditions when modeling the weld pool dynamics. The present work lays a foundation for true three-dimensional comprehensive modeling of GTAW and GMAW including the plasma arc, weld pool, and/or electrode.

  19. Charpy toughness and tensile properties of a neutron-irradiated stainless steel submerged arc weld cladding overlay

    SciTech Connect (OSTI)

    Corwin, W.R.; Berggren, R.G.; Nanstad, R.K.

    1984-09-01

    The cladding was applied to a pressure vessel steel plate by the submerged arc, single-wire, oscillating-electrode method. Three layers of cladding provided a thickness adequate for fabrication of test specimens. The first layer was type 309, and the upper two layers were type 308 stainless steel. The type 309 was diluted considerably by excessive melting of the base plate. Specimens were taken from near the base plate-cladding interface and also from the upper layers. Charpy V-notch and tensile specimens were irradiated at 288/sup 0/C to a fluence of 2 x 10/sup 23/ neutrons/m/sup 2/ (>1 MeV). When irradiated, both types 308 and 309 cladding increased 5 to 40% in yield strength and slightly increased in ductility in the temperature range from 25 to 288/sup 0/C. All cladding exhibited ductile-to-brittle transition behavior during impact testing. The type 308 cladding, microstructurally typical of that in reactor pressure vessels, showed very little degradation in either upper-shelf energy or transition temperature due to irradiation. Conversely, the impact properties of the specimens containing the highly diluted type 309 cladding, microstructurally similar to that produced during some off-normal welding conditions in existing reactors, experienced significant increases in transition temperature and drops of up to 50% in upper-shelf energy. The impact energies of the Charpy specimens containing the type 309 layer strongly reflected the amount of the type 309 actually in the specimen, falling into two distinct high- and low-energy populations with the low-energy population corresponding to a higher fraction of type 309 in the specimen.

  20. The Hydrothermal System of Long Valley Caldera, California |...

    Open Energy Info (EERE)

    a deep subsystem or hydrothermal reservoir in the welded tuff containing relatively hot ground water. Hydrologic, isotopic, and thermal data indicate that recharge to the...

  1. Laser-Arc Hybrid Welding of Thick Section Ni-base Alloys – Advanced Modeling and Experiments

    SciTech Connect (OSTI)

    Debroy, Tarasankar; Palmer, Todd; Zhang, Wei

    2015-05-21

    Hybrid laser-arc welding of nickel-base alloys can increase productivity and decrease costs during construction and repair of critical components in nuclear power plants. However, laser and hybrid welding of nickel-base alloys is not well understood. This project sought to understand the physical processes during hybrid welding necessary to fabricate quality joints in Alloy 690, a Ni- Cr-Fe alloy. This document presents a summary of the data and results collected over the course of the project. The supporting documents are a collection of the research that has been or will be published in peer-reviewed journals along with a report from the partner at the national lab. Understanding the solidification behavior of Alloy 690 is important for knowing the final properties of the weldment. A study was undertaken to calculate the solidification parameters, such as temperature gradient, solidification rate, and cooling rate in Alloy 690 welds. With this information and measured cell and dendrite arm spacings, an Alloy 690 map was constructed to guide process parameter development and interpret fusion zones in later hybrid welds. This research is contained in “Solidification Map of a Nickel Base Alloy.” The keyhole formed under high laser intensity gives the hybrid welding technique the greater penetration depths compared to arc welding. However, keyhole behavior can form defects in the material, so knowing transient keyhole characteristics is important. With international collaborators, a study was undertaken to validate a new process monitoring tool known as inline coherent imaging (ICI), which is able to measure the keyhole depth with spatial and temporal resolutions on the order of 10 microns and 10 microseconds. ICI was validated for five alloy systems, including Alloy 690. Additionally, the keyhole growth rates at the start of welding were measured with unprecedented accuracy. This research is contained in “Real Time Monitoring of Laser Beam Welding Keyhole Depth by Laser Interferometry.” During full penetration welding of thick sections, root defects can form, which result in unacceptable weld quality. A study was undertaken to determine the competing forces in root defect formation by independently changing the weight forces and surface tension forces. The weight force was altered by changing the plate thickness, and the surface tension force was altered by changing the surface condition at the bottom surface. Root defects do depend on these two forces. This research is contained in “Mitigation of Root Defect in Laser and Hybrid Laser-Arc Welding.” Validation of the hybrid laser-arc model is necessary to properly model heat and mass transfer and fluid flow in Alloy 690 hybrid welds. Therefore, the developed model was validated for low carbon steel. Temperatures calculated by the model were included into a microstructural model in order to calculate the phase fractions. Process maps were developed for the selection of welding parameters to avoid martensite formation. This research is contained in “Fusion Zone Microstructure in Full Penetration Laser-Arc Hybrid Welding of Low Alloy Steel.” Alloy 690 suffers from ductility dip cracking, a form of hot cracking. This type of cracking inhibits the use of multipass welding to join Alloy 690. Our partners at ORNL performed some hot ductility testing with Alloy 690 samples using digital image correlation. The results of this work is contained in the report “Summary of 690 ductility dip cracking testing using Gleeble and digital image correlation.” Macro-porosity is a limiting factor in the widespread deployment of laser and hybrid laser-arc welding for construction and repair of nuclear power plant components. Keyhole instability and fluctuation results in the formation of large bubbles, which become trapped at the advancing solid- liquid interface as pores. Laser and hybrid laser-arc welds were fabricated for a range of conditions. Porosity levels in the welds were measured in X-ray computed tomography (CT), which provides very detailed data on the size and lo

  2. Diffusion Welding of Alloys for Molten Salt Service - Status Report

    SciTech Connect (OSTI)

    Denis Clark; Ronald Mizia; Piyush Sabharwall

    2012-09-01

    The present work is concerned with heat exchanger development for molten salt service, including the proposed molten salt reactor (MSR), a homogeneous reactor in which the fuel is dissolved in a circulating fluid of molten salt. It is an outgrowth of recent work done under the Next Generation Nuclear Plant (NGNP) program; what the two reactor systems have in common is an inherently safe nuclear plant with a high outlet temperature that is useful for process heat as well as more conventional generation The NGNP program was tasked with investigating the application of a new generation of nuclear power plants to a variety of energy needs. One baseline reactor design for this program is a high temperature, gas-cooled reactor (HTGR), which provides many options for energy use. These might include the conventional Rankine cycle (steam turbine) generation of electricity, but also other methods: for example, Brayton cycle (gas turbine) electrical generation, and the direct use of the high temperatures characteristic of HTGR output for process heat in the chemical industry. Such process heat is currently generated by burning fossil fuels, and is a major contributor to the carbon footprint of the chemical and petrochemical industries. The HTGR, based on graphite fuel elements, can produce very high output temperatures; ideally, temperatures of 900 °C or even greater, which has significant energy advantages. Such temperatures are, of course, at the frontiers of materials limitations, at the upper end of the performance envelope of the metallic materials for which robust construction codes exist, and within the realm of ceramic materials, the fabrication and joining of which, on the scale of large energy systems, are at an earlier stage of development. A considerable amount of work was done in the diffusion welding of materials of interest for HTGR service with alloys such as 617 and 800H. The MSR output temperature is also materials limited, and is projected at about 700 °C. (RR E) A different set of alloys, such as Alloy N and 242, are needed to handle molten salts at this temperature. The diffusion welding development work described here builds on techniques developed during the NGNP work, as applied to these alloys. There is also the matter of dissimilar metal welding, since alloys suitable for salt service are generally not suited for service in gaseous oxidizing environments, and vice versa, and welding is required for the Class I boundaries in these systems, as identified in the relevant ASME codes.

  3. Diffusion Welding of Alloys for Molten Salt Service - Status Report

    SciTech Connect (OSTI)

    Denis Clark; Ronald Mizia

    2012-05-01

    The present work is concerned with heat exchanger development for molten salt service, including the proposed molten salt reactor (MSR), a homogeneous reactor in which the fuel is dissolved in a circulating fluid of molten salt. It is an outgrowth of recent work done under the Next Generation Nuclear Plant (NGNP) program; what the two reactor systems have in common is an inherently safe nuclear plant with a high outlet temperature that is useful for process heat as well as more conventional generation The NGNP program was tasked with investigating the application of a new generation of nuclear power plants to a variety of energy needs. One baseline reactor design for this program is a high temperature, gas-cooled reactor (HTGR), which provides many options for energy use. These might include the conventional Rankine cycle (steam turbine) generation of electricity, but also other methods: for example, Brayton cycle (gas turbine) electrical generation, and the direct use of the high temperatures characteristic of HTGR output for process heat in the chemical industry. Such process heat is currently generated by burning fossil fuels, and is a major contributor to the carbon footprint of the chemical and petrochemical industries. The HTGR, based on graphite fuel elements, can produce very high output temperatures; ideally, temperatures of 900 C or even greater, which has significant energy advantages. Such temperatures are, of course, at the frontiers of materials limitations, at the upper end of the performance envelope of the metallic materials for which robust construction codes exist, and within the realm of ceramic materials, the fabrication and joining of which, on the scale of large energy systems, are at an earlier stage of development. A considerable amount of work was done in the diffusion welding of materials of interest for HTGR service with alloys such as 617 and 800H. The MSR output temperature is also materials limited, and is projected at about 700 C. (RR E) A different set of alloys, such as Alloy N and 242, are needed to handle molten salts at this temperature. The diffusion welding development work described here builds on techniques developed during the NGNP work, as applied to these alloys. There is also the matter of dissimilar metal welding, since alloys suitable for salt service are generally not suited for service in gaseous oxidizing environments, and vice versa, and welding is required for the Class I boundaries in these systems, as identified in the relevant ASME codes.

  4. High Strength Stainless Steel Properties that Affect Resistance Welding

    SciTech Connect (OSTI)

    Kanne, W.R.

    2001-08-01

    This report discusses results of a study on selected high strength stainless steel alloy properties that affect resistance welding. The austenitic alloys A-286, JBK-75 (Modified A-286), 21-6-9, 22-13-5, 316 and 304L were investigated and compared. The former two are age hardenable, and the latter four obtain their strength through work hardening. Properties investigated include corrosion and its relationship to chemical cleaning, the effects of heat treatment on strength and surface condition, and the effect of mechanical properties on strength and weldability.

  5. Beam/seam alignment control for electron beam welding

    DOE Patents [OSTI]

    Burkhardt, Jr., James H.; Henry, J. James; Davenport, Clyde M.

    1980-01-01

    This invention relates to a dynamic beam/seam alignment control system for electron beam welds utilizing video apparatus. The system includes automatic control of workpiece illumination, near infrared illumination of the workpiece to limit the range of illumination and camera sensitivity adjustment, curve fitting of seam position data to obtain an accurate measure of beam/seam alignment, and automatic beam detection and calculation of the threshold beam level from the peak beam level of the preceding video line to locate the beam or seam edges.

  6. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, M.L.; Sikka, V.K.

    1998-03-10

    A filler metal alloy used as a filler for welding cast nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and cast in copper chill molds. 3 figs.

  7. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, Michael L.; Sikka, Vinod K.

    1998-01-01

    A filler metal alloy used as a filler for welding east nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and east in copper chill molds.

  8. Abnormal macropore formation during double-sided gas tungsten arc welding of magnesium AZ91D alloy

    SciTech Connect (OSTI)

    Shen Jun You Guoqiang; Long Siyuan; Pan Fusheng

    2008-08-15

    One of the major concerns during gas tungsten arc (GTA) welding of cast magnesium alloys is the presence of large macroporosity in weldments, normally thought to occur from the presence of gas in the castings. In this study, a double-sided GTA welding process was adopted to join wrought magnesium AZ91D alloy plates. Micropores were formed in the weld zone of the first side that was welded, due to precipitation of H{sub 2} as the mushy zone freezes. When the reverse side was welded, the heat generated caused the mushy zone in the initial weld to reform. The micropores in the initial weld then coalesced and expanded to form macropores by means of gas expansion through small holes that are present at the grain boundaries in the partially melted zone. Macropores in the partially melted zone increase with increased heat input, so that when a filler metal is used the macropores are smaller in number and in size.

  9. The role of composition and microstructure gradients on weld metal properties and behavior: Progress report, 1 January 1988--31 December 1988

    SciTech Connect (OSTI)

    Matlock, D.K.; Olson, D.L.

    1989-01-01

    The effects of weld metal compositional and microstructural gradients on phase transformation, microstructural stability, and mechanical properties are considered from a fundamental basis in weld metal alloys which are primarily austenitic (e.g., stainless steels). Models which incorporate compositional gradients are developed to predict the resulting weld metal properties and behavior. The mechanical properties of weld metal are modeled based on composite theory in which individual weld metal zones are considered as discrete elements within a composite structure. 17 refs., 28 figs.

  10. Layered seal for turbomachinery

    DOE Patents [OSTI]

    Sarawate, Neelesh Nandkumar; Morgan, Victor John; Weber, David Wayne

    2015-11-20

    The present application provides seal assemblies for reducing leakages between adjacent components of turbomachinery. The seal assemblies may include outer shims, and at least a portion of the outer shims may be substantially impervious. At least one of the outer shims may be configured for sealing engagement with seal slots of the adjacent components. The seal assemblies may also include at least one of an inner shim and a filler layer positioned between the outer shims. The at least one inner shim may be substantially solid and the at least one filler layer may be relatively porous. The seal assemblies may be sufficiently flexible to account for misalignment between the adjacent components, sufficiently stiff to meet assembly requirements, and sufficiently robust to operating meet requirements associated with turbomachinery.

  11. Resistance spot welding of ultra-fine grained steel sheets produced by constrained groove pressing: Optimization and characterization

    SciTech Connect (OSTI)

    Khodabakhshi, F.; Kazeminezhad, M., E-mail: mkazemi@sharif.edu; Kokabi, A.H.

    2012-07-15

    Constrained groove pressing as a severe plastic deformation method is utilized to produce ultra-fine grained low carbon steel sheets. The ultra-fine grained sheets are joined via resistance spot welding process and the characteristics of spot welds are investigated. Resistance spot welding process is optimized for welding of the sheets with different severe deformations and their results are compared with those of as-received samples. The effects of failure mode and expulsion on the performance of ultra-fine grained sheet spot welds have been investigated in the present paper and the welding current and time of resistance spot welding process according to these subjects are optimized. Failure mode and failure load obtained in tensile-shear test, microhardness, X-ray diffraction, transmission electron microscope and scanning electron microscope images have been used to describe the performance of spot welds. The region between interfacial to pullout mode transition and expulsion limit is defined as the optimum welding condition. The results show that optimum welding parameters (welding current and welding time) for ultra-fine grained sheets are shifted to lower values with respect to those for as-received specimens. In ultra-fine grained sheets, one new region is formed named recrystallized zone in addition to fusion zone, heat affected zone and base metal. It is shown that microstructures of different zones in ultra-fine grained sheets are finer than those of as-received sheets. - Highlights: Black-Right-Pointing-Pointer Resistance spot welding process is optimized for joining of UFG steel sheets. Black-Right-Pointing-Pointer Optimum welding current and time are decreased with increasing the CGP pass number. Black-Right-Pointing-Pointer Microhardness at BM, HAZ, FZ and recrystallized zone is enhanced due to CGP.

  12. Development of weld closure stations for plutonium long-term storage containers

    SciTech Connect (OSTI)

    Fernandez, R.; Martinez, D.A.; Martinez, H.E.; Nelson, T.O.; Ortega, R.E.; Rofer, C.K.; Romero, W.; Stewart, J.; Trujillo, V.L.

    1998-12-31

    Weld closure stations for plutonium long-term storage containers have been designed, fabricated, and tested for the Advanced Recovery and Integrated Extraction System (ARIES) at the TA-55 Plutonium Facility of the Los Alamos National Laboratory. ARIES is a processing system used for the dismantlement of the plutonium pits from nuclear weapons. ARIES prepares the extracted-plutonium in a form which is compatible with long-term storage and disposition options and meets international inspection requirements. The processed plutonium is delivered to the canning module of the ARIES line, where it is packaged in a stainless steel container. This container is then packaged in a secondary container for long-term storage. Each of the containers is hermetically sealed with a full penetration weld closure that meets the requirements of the ASME Section IX Boiler and Pressure Vessel Code. Welding is performed with a gas tungsten arc process in an inert atmosphere of helium. The encapsulated helium in the nested containers allows for leak testing the weld closure and container. The storage package was designed to meet packaging requirements of DOE Standard 3013-96 for long-term storage of plutonium metal and oxides. Development of the process parameters, weld fixture, weld qualification, and the welding chambers is discussed in this paper.

  13. Weld microstructure development and properties of precipitation-strengthened martensitic stainless steels

    SciTech Connect (OSTI)

    Brooks, J.

    1994-12-31

    Precipitation-strengthened martensitic stainless steels provide excellent strength (170--220 ksi Y.S.) with high corrosion resistance. However, upon aging, a large reduction in toughness may also occur. The gas tungsten arc (GTA) cold wire feed process was used to weld half inch thick plates of PH 13-8 Mo and Custom 450 from which both tensile and Charpy specimens were machined. A fundamental understanding of the details of weld microstructural evolution was developed by liquid tin quenching GTA welds in which the solidification behavior, primary phase of solidification, microsegregation, and solid-state transformations could be followed. For both alloys studied, the as-welded yield strengths were similar to those of the unaged base material, 130 ksi. Weld properties were very similar to those of the base materials for both alloy systems. Weld strength increases significantly upon aging and achieves a maximum at intermediate aging temperatures. The increase in strength is accompanied by a large decrease in Charpy impact energy; however, the minimum in toughness occurs at aging temperatures slightly less than those resulting in peak strengths. The evolution of the weld microstructure was found to support predictions of microstructural modeling. Although a high degree of alloying partitioning occurs during solidification, a large degree of homogenization occurs upon further solidification and cooling as a result of solid-state diffusion.

  14. Friction Stir Spot Welding (FSSW) of Advanced High Strength Steel (AHSS)

    SciTech Connect (OSTI)

    Santella, M. L.; Hovanski, Yuri; Pan, Tsung-Yu

    2012-04-16

    Friction stir spot welding (FSSW) is applied to join advanced high strength steels (AHSS): galvannealed dual phase 780 MPa steel (DP780GA), transformation induced plasticity 780 MPa steel (TRIP780), and hot-stamped boron steel (HSBS). A low-cost Si3N4 ceramic tool was developed and used for making welds in this study instead of polycrystalline cubic boron nitride (PCBN) material used in earlier studies. FSSW has the advantages of solid-state, low-temperature process, and the ability of joining dissimilar grade of steels and thicknesses. Two different tool shoulder geometries, concave with smooth surface and convex with spiral pattern, were used in the study. Welds were made by a 2-step displacement control process with weld time of 4, 6, and 10 seconds. Static tensile lap-shear strength achieved 16.4 kN for DP780GA-HSBS and 13.2kN for TRIP780-HSBS, above the spot weld strength requirements by AWS. Nugget pull-out was the failure mode of the joint. The joining mechanism was illustrated from the cross-section micrographs. Microhardness measurement showed hardening in the upper sheet steel (DP780GA or TRIP780) in the weld, but softening of HSBS in the heat-affect zone (HAZ). The study demonstrated the feasibility of making high-strength AHSS spot welds with low-cost tools.

  15. Welding metallurgy of nickel alloys in gas turbine components

    SciTech Connect (OSTI)

    Lingenfelter, A. C., LLNL

    1997-05-21

    Materials for gas turbine engines are required to meet a wide range of temperature and stress application requirements. These alloys exhibit a combination of creep resistance, creep rupture strength, yield and tensile strength over a wide temperature range, resistance to environmental attack (including oxidation, nitridation, sulphidation and carburization), fatigue and thermal fatigue resistance, metallurgical stability and useful thermal expansion characteristics. These properties are exhibited by a series of solid-solution-strengthened and precipitation-hardened nickel, iron and cobalt alloys. The properties needed to meet the turbine engine requirements have been achieved by specific alloy additions, by heat treatment and by thermal mechanical processing. A thorough understanding of the metallurgy and metallurgical processing of these materials is imperative in order to successfully fusion weld them. This same basic understanding is required for repair of a component with the added dimension of the potential effects of thermal cycling and environmental exposure the component will have endured in service. This article will explore the potential problems in joining and repair welding these materials.

  16. Evaluation of Internal Brushing on Pinch Weld Quality

    SciTech Connect (OSTI)

    Korinko, P

    2005-12-01

    Post machining operations such as borescope inspection can cause linear indications down the length of the bore of fill stems. Often these indications are removed or obscured using rotary wire brushing. This study evaluated the effect this mechanical operation may have on pinch weld quality when relatively cold welds were made. A total of four stems with two levels of brushing of both Type 304L and 21-6-9 stainless steels were tested. In addition, two each of the Type 304L stems were Nitradd cleaned and the other two were aqueously cleaned; all four 21-6-9 stems were aqueously cleaned. All of the brushed stem areas exhibited more surface anomalies based on borescope evaluation. On average, the bond rating was a higher value (worse) for the brushed areas than the unadulterated areas for both Type 304L and 21-6-9 stems. The test method used may have biased the results towards a lesser quality bond for the brushed areas so additional testing is recommended.

  17. Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel

    SciTech Connect (OSTI)

    Jafarzadegan, M.; State Key Laboratory of Advanced Welding Production Technology, School of Materials Science and Eng., Harbin Institute of Technology, P.O. Box: 150001, Harbin ; Feng, A.H.; Abdollah-zadeh, A.; Saeid, T.; Shen, J.; Assadi, H.

    2012-12-15

    In the present study, 3 mm-thick plates of 304 stainless steel and st37 steel were welded together by friction stir welding at a welding speed of 50 mm/min and tool rotational speed of 400 and 800 rpm. X-ray diffraction test was carried out to study the phases which might be formed in the welds. Metallographic examinations, and tensile and microhardness tests were used to analyze the microstructure and mechanical properties of the joint. Four different zones were found in the weld area except the base metals. In the stir zone of the 304 stainless steel, a refined grain structure with some features of dynamic recrystallization was evidenced. A thermomechanically-affected zone was characterized on the 304 steel side with features of dynamic recovery. In the other side of the stir zone, the hot deformation of the st37 steel in the austenite region produced small austenite grains and these grains transformed to fine ferrite and pearlite and some products of displacive transformations such as Widmanstatten ferrite and martensite by cooling the material after friction stir welding. The heat-affected zone in the st37 steel side showed partially and fully refined microstructures like fusion welding processes. The recrystallization in the 304 steel and the transformations in the st37 steel enhanced the hardness of the weld area and therefore, improved the tensile properties of the joint. - Highlights: Black-Right-Pointing-Pointer FSW produced sound welds between st37 low carbon steel and 304 stainless steel. Black-Right-Pointing-Pointer The SZ of the st37 steel contained some products of allotropic transformation. Black-Right-Pointing-Pointer The material in the SZ of the 304 steel showed features of dynamic recrystallization. Black-Right-Pointing-Pointer The finer microstructure in the SZ increased the hardness and tensile strength.

  18. Quasi-Rayleigh waves in butt-welded thick steel plate

    SciTech Connect (OSTI)

    Kamas, Tuncay E-mail: victorg@sc.edu Giurgiutiu, Victor E-mail: victorg@sc.edu Lin, Bin E-mail: victorg@sc.edu

    2015-03-31

    This paper discusses theoretical and experimental analyses of weld guided surface acoustic waves (SAW) through the guided wave propagation (GWP) analyses. The GWP analyses have been carried out by utilizing piezoelectric wafer active sensors (PWAS) for in situ structural inspection of a thick steel plate with butt weld as the weld bead is ground flush. Ultrasonic techniques are commonly used for validation of welded structures in many in-situ monitoring applications, e.g. in off-shore structures, in nuclear and pressure vessel industries and in a range of naval applications. PWAS is recently employed in such ultrasonic applications as a resonator as well as a transducer. Quasi-Rayleigh waves a.k.a. SAW can be generated in relatively thick isotropic elastic plate having the same phase velocity as Rayleigh waves whereas Rayleigh waves are a high frequency approximation of the first symmetric (S0) and anti-symmetric (A0) Lamb wave modes. As the frequency becomes very high the S0 and the A0 wave speeds coalesce, and both have the same value. This value is exactly the Rayleigh wave speed and becomes constant along the frequency i.e. Rayleigh waves are non-dispersive guided surface acoustic waves. The study is followed with weld-GWP tests through the pitch-catch method along the butt weld line. The tuning curves of quasi-Rayleigh wave are determined to show the tuning and trapping effect of the weld bead that has higher thickness than the adjacent plates on producing a dominant quasi-Rayleigh wave mode. The significant usage of the weld tuned and guided quasi-Rayleigh wave mode is essentially discussed for the applications in the in-situ inspection of relatively thick structures with butt weld such as naval offshore structures. The paper ends with summary, conclusions and suggestions for future work.

  19. Effect of water on mechanical properties and stress corrosion behavior of alloy 600, alloy 690, EN82H welds, and EN52 welds

    SciTech Connect (OSTI)

    Brown, C.M.; Mills, W.J.

    1999-02-01

    The fracture toughness and tensile properties of alloy 600 (UNS N06600), alloy 690 (UNS N06690), and their welds (EN82H [UNS N06082] and EN52 [UNS N06052]) were characterized in 54 C and 338 C water with an elevated hydrogen content. Results were compared with air data to evaluate the effect of low- and high-temperature water on the mechanical properties. In addition, the stress corrosion cracking (SCC) behavior of EN82H and EN52 welds was evaluated in 360 C water. Elastic-plastic (J{sub IC}) fracture toughness testing revealed that the fracture resistance of all test materials was exceptionally high in 54 C and 338 C air and 338 C water, demonstrating that fracture properties essentially were unaffected by the high-temperature water environment. In 54 C water, however, J{sub IC} values for EN82H and EN52 welds were reduced by an order of magnitude, and alloy 690 showed a fivefold decrease in J{sub IC}. Scanning electron fractography revealed that the degraded fracture properties were associated with a fracture mechanism transition from ductile dimple rupture to intergranular cracking. The latter was associated with hydrogen-induced cracking mechanism. The fracture toughness for alloy 600 remained high in 54 C water, and microvoid coalescence was the operative mechanism in low-temperature air and water. Tensile properties for all test materials essentially were unaffected by the water environment, except for the total elongation for EN82H welds, which was reduced significantly in 54 C water. Constant-load testing of precracked weld specimens in 360 C water resulted in extensive intergranular SCC in EN82H welds, whereas no SCC occurred in EN52 welds under comparable test conditions.

  20. The effect of chromium on the weldability and microstructure of Fe-Cr-Al weld cladding

    SciTech Connect (OSTI)

    Regina, J.R.; Dupont, J.N.; Marder, A.R.

    2007-06-15

    Iron-aluminum-based weld cladding is currently being considered as corrosion-resistant coatings for boiler tubes in coal-fired power plants. Although these alloys could potentially be good coating candidates due to their excellent high-temperature corrosion resistance, Fe-Al weld cladding is susceptible to cracking due to hydrogen embrittlement at elevated aluminum concentrations. Additions of chromium to these iron-aluminum alloys have been shown to improve the corrosion resistance of the alloys and could potentially increase the lifetimes of the coatings. The current study investigated the effect of chromium on the hydrogen cracking susceptibility of Fe-Al weld cladding.

  1. Porosity in millimeter-scale welds of stainless steel : three-dimensional characterization.

    SciTech Connect (OSTI)

    Aagesen, Larry K.; Madison, Jonathan D.

    2012-05-01

    A variety of edge joints utilizing a continuous wave Nd:YAG laser have been produced and examined in a 304-L stainless steel to advance fundamental understanding of the linkage between processing and resultant microstructure in high-rate solidification events. Acquisition of three-dimensional reconstructions via micro-computed tomography combined with traditional metallography has allowed for qualitative and quantitative characterization of weld joints in a material system of wide use and broad applicability. The presence, variability and distribution of porosity, has been examined for average values, spatial distributions and morphology and then related back to fundamental processing parameters such as weld speed, weld power and laser focal length.

  2. Investigation of fracture mechanical behavior of nodular cast iron and welded joints with parent-material-like weld metal

    SciTech Connect (OSTI)

    Baer, W.; Pusch, G.

    1995-12-31

    The focus of the investigations was the determination of fracture mechanical characteristics and crack resistance curves of the J-Integral and CTOD concept by application of the partial unloading compliance technique and D.C. potential drop technique (four point bend) under static load. The results show a close correlation between crack initiation values as well as crack resistance curves and graphite morphology parameters determined by means of quantitative microstructural analysis where the influence of the matrix (distance of graphite particles) dominates the crack resistance and fracture performance of ferritic nodular cast iron under consideration of the notch effect of graphite particles. SEM in-situ tensile tests showed that due to a beneficial shielding effect of the strength overmatching parent-material-like weld metal (mis-match ratio M = 1.21), cracks positioned directly in the plane of the fusion line did not deviate into the weld metal in spite of its lower toughness compared to that of the parent material. They also showed an unsymmetrical formation of damage in front of the crack tip.

  3. Microstructure evolution of Al/Mg butt joints welded by gas tungsten arc with Zn filler metal

    SciTech Connect (OSTI)

    Liu Fei; Zhang Zhaodong; Liu Liming, E-mail: liulm@dlut.edu.cn

    2012-07-15

    Based on the idea of alloying welding seam, Gas tungsten arc welding method with pure Zn filler metal was chosen to join Mg alloy and Al alloy. The microstructures, phases, element distribution and fracture morphology of welding seams were examined. The results indicate that there was a transitional zone in the width of 80-100 {mu}m between the Mg alloy substrate and fusion zone. The fusion zone was mainly composed of MgZn{sub 2}, Zn-based solid solution and Al-based solid solution. The welding seam presented distinct morphology in different location owning to the quite high cooling rate of the molten pool. The addition of Zn metal could prevent the formation of Mg-Al intermetallics and form the alloyed welding seam during welding. Therefore, the tensile strengths of joints have been significantly improved compared with those of gas tungsten arc welded joints without Zn metal added. Highlights: Black-Right-Pointing-Pointer Mg alloy AZ31B and Al alloy 6061 are welded successfully. Black-Right-Pointing-Pointer Zinc wire is employed as a filler metal to form the alloyed welding seam. Black-Right-Pointing-Pointer An alloyed welding seam is benefit for improving of the joint tensile strength.

  4. Vehicle Technologies Office Merit Review 2014: On-Line Weld NDE with IR Thermography

    Broader source: Energy.gov [DOE]

    Presentation given by Oak Ridge National Laboratory at 2014 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Office Annual Merit Review and Peer Evaluation Meeting about on-line weld...

  5. Surface temperature distribution of GTA weld pools on thin-plate 304 stainless steel

    SciTech Connect (OSTI)

    Zacharia, T.; David, S.A.; Vitek, J.M.; Kraus, H.G.

    1995-11-01

    A transient multidimensional computational model was utilized to study gas tungsten arc (GTA) welding of thin-plate 304 stainless steel (SS). The model eliminates several of the earlier restrictive assumptions including temperature-independent thermal-physical properties. Consequently, all important thermal-physical properties were considered as temperature dependent throughout the range of temperatures experienced by the weld metal. The computational model was used to predict surface temperature distribution of the GTA weld pools in 1.5-mm-thick AISI 304 SS. The welding parameters were chosen so as to correspond with an earlier experimental study that produced high-resolution surface temperature maps. One of the motivations of the present study was to verify the predictive capability of the computational model. Comparison of the numerical predictions and experimental observations indicate excellent agreement, thereby verifying the model.

  6. Cracked lifting lug welds on ten-ton UF{sub 6} cylinders

    SciTech Connect (OSTI)

    Dorning, R.E.

    1991-12-31

    Ten-ton, Type 48X, UF{sub 6} cylinders are used at the Portsmouth Gaseous Diffusion Plant to withdraw enriched uranium hexafluoride from the cascade, transfer enriched uranium hexafluoride to customer cylinders, and feed enriched product to the cascade. To accomplish these activities, the cylinders are lifted by cranes and straddle carriers which engage the cylinder lifting lugs. In August of 1988, weld cracks on two lifting lugs were discovered during preparation to lift a cylinder. The cylinder was rejected and tagged out, and an investigating committee formed to determine the cause of cracking and recommend remedial actions. Further investigation revealed the problem may be general to this class of cylinder in this use cycle. This paper discusses the actions taken at the Portsmouth site to deal with the cracked lifting lug weld problem. The actions include inspection activities, interim corrective actions, metallurgical evaluation of cracked welds, weld repairs, and current monitoring/inspection program.

  7. Investigation on the Interface Morphologies of Explosive Welding of Inconel 625 to Steel A516 Plates

    SciTech Connect (OSTI)

    Mousavi, S. A. A. Akbari; Zareie, H. R. [School of Metallurgy and Materials Engineering, University College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of)

    2011-01-17

    The purpose of this study is to produce composite plates by explosive cladding process. This is a process in which the controlled energy of explosives is used to create a metallic bond between two similar or dissimilar materials. The welding conditions were tailored through parallel geometry route with different operational parameters. In this investigation, a two-pronged study was adopted to establish the conditions required for producing successful solid state welding: (a) Analytical calculations to determine the weldability domain or welding window; (b) Metallurgical investigations of explosive welding experiments carried out under different explosive ratios to produce both wavy and straight interfaces. The analytical calculations confirm the experimental results. Optical microscopy studies show that a transition from a smooth to wavy interface occurs with an increase in explosive ratio. SEM studies show that the interface was outlined by characteristic sharp transition between two materials.

  8. Significance of locally intensified strain aging to the fracture toughness of welded steel structures

    SciTech Connect (OSTI)

    Dawes, M.G.

    1995-12-31

    A review of past studies shows that tests on specimens notched after welding can give overestimates of the fracture toughness that occurs at the tips of flaws present during welding. This situation results from locally intensified straining and aging embrittlement (LISAE), which has been shown to trigger low stress brittle fractures in both notched and welded wide plate tension tests, and welded structures in service. Although the relative susceptibilities of steels to strain aging embrittlement are sometimes assessed by testing bulk strained and aged samples, the results of such tests may be optimistic. A summary is given of work to develop a fracture toughness test method for LISAE. The new test will give increased confidence and accuracy in fracture assessments, be of use in selecting tough materials, and aid the development of materials that are resistant to LISAE.

  9. Simultaneous laser cutting and welding of metal foil to edge of a plate

    DOE Patents [OSTI]

    Pernicka, J.C.; Benson, D.K.; Tracy, C.E.

    1996-03-19

    A method is described for welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads. 7 figs.

  10. Simultaneous laser cutting and welding of metal foil to edge of a plate

    DOE Patents [OSTI]

    Pernicka, John C.; Benson, David K.; Tracy, C. Edwin

    1996-01-01

    A method of welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads.

  11. Vehicle Technologies Office Merit Review 2015: Collision Welding of Dissimilar Materials by Vaporizing Foil Actuator

    Broader source: Energy.gov [DOE]

    Presentation given by Ohio State University at 2015 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Office Annual Merit Review and Peer Evaluation Meeting about collision welding of...

  12. Vehicle Technologies Office Merit Review 2014: Collision Welding of Dissimilar Materials by Vaporizing Foil Actuator

    Broader source: Energy.gov [DOE]

    Presentation given by The Ohio State University at 2014 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Office Annual Merit Review and Peer Evaluation Meeting about collision welding...

  13. Metal deposition using seed layers

    DOE Patents [OSTI]

    Feng, Hsein-Ping; Chen, Gang; Bo, Yu; Ren, Zhifeng; Chen, Shuo; Poudel, Bed

    2013-11-12

    Methods of forming a conductive metal layers on substrates are disclosed which employ a seed layer to enhance bonding, especially to smooth, low-roughness or hydrophobic substrates. In one aspect of the invention, the seed layer can be formed by applying nanoparticles onto a surface of the substrate; and the metallization is achieved by electroplating an electrically conducting metal onto the seed layer, whereby the nanoparticles serve as nucleation sites for metal deposition. In another approach, the seed layer can be formed by a self-assembling linker material, such as a sulfur-containing silane material.

  14. Buried oxide layer in silicon

    DOE Patents [OSTI]

    Sadana, Devendra Kumar; Holland, Orin Wayne

    2001-01-01

    A process for forming Silicon-On-Insulator is described incorporating the steps of ion implantation of oxygen into a silicon substrate at elevated temperature, ion implanting oxygen at a temperature below 200.degree. C. at a lower dose to form an amorphous silicon layer, and annealing steps to form a mixture of defective single crystal silicon and polycrystalline silicon or polycrystalline silicon alone and then silicon oxide from the amorphous silicon layer to form a continuous silicon oxide layer below the surface of the silicon substrate to provide an isolated superficial layer of silicon. The invention overcomes the problem of buried isolated islands of silicon oxide forming a discontinuous buried oxide layer.

  15. Eutectic structures in friction spot welding joint of aluminum alloy to copper

    SciTech Connect (OSTI)

    Shen, Junjun Suhuddin, Uceu F. H.; Cardillo, Maria E. B.; Santos, Jorge F. dos

    2014-05-12

    A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl{sub 2} eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

  16. IR-based Spot Weld NDT in Automotive Applications (Conference) | SciTech

    Office of Scientific and Technical Information (OSTI)

    Connect IR-based Spot Weld NDT in Automotive Applications Citation Details In-Document Search Title: IR-based Spot Weld NDT in Automotive Applications Authors: Chen, Jian [1] ; Feng, Zhili [1] + Show Author Affiliations ORNL Publication Date: 2015-01-01 OSTI Identifier: 1185972 DOE Contract Number: DE-AC05-00OR22725 Resource Type: Conference Resource Relation: Conference: Thermosense XXXVII - 2015, Baltimore, MD, USA, 20150420, 20150424 Research Org: Oak Ridge National Laboratory (ORNL)

  17. The Effect of Weld Residual Stress on Life of Used Nuclear Fuel Dry Storage Canisters

    SciTech Connect (OSTI)

    Ronald G. Ballinger; Sara E. Ferry; Bradley P. Black; Sebastien P. Teysseyre

    2013-08-01

    With the elimination of Yucca Mountain as the long-term storage facility for spent nuclear fuel in the United States, a number of other storage options are being explored. Currently, used fuel is stored in dry-storage cask systems constructed of steel and concrete. It is likely that used fuel will continue to be stored at existing open-air storage sites for up to 100 years. This raises the possibility that the storage casks will be exposed to a salt-containing environment for the duration of their time in interim storage. Austenitic stainless steels, which are used to construct the canisters, are susceptible to stress corrosion cracking (SCC) in chloride-containing environments if a continuous aqueous film can be maintained on the surface and the material is under stress. Because steel sensitization in the canister welds is typically avoided by avoiding post-weld heat treatments, high residual stresses are present in the welds. While the environment history will play a key role in establishing the chemical conditions for cracking, weld residual stresses will have a strong influence on both crack initiation and propagation. It is often assumed for modeling purposes that weld residual stresses are tensile, high and constant through the weld. However, due to the strong dependence of crack growth rate on stress, this assumption may be overly conservative. In particular, the residual stresses become negative (compressive) at certain points in the weld. The ultimate goal of this research project is to develop a probabilistic model with quantified uncertainties for SCC failure in the dry storage casks. In this paper, the results of a study of the residual stresses, and their postulated effects on SCC behavior, in actual canister welds are presented. Progress on the development of the model is reported.

  18. Stability of Y Ti O Precipitates in Friction Stir Welded Nanostructured

    Office of Scientific and Technical Information (OSTI)

    Ferritic Alloys (Journal Article) | SciTech Connect Stability of Y Ti O Precipitates in Friction Stir Welded Nanostructured Ferritic Alloys Citation Details In-Document Search Title: Stability of Y Ti O Precipitates in Friction Stir Welded Nanostructured Ferritic Alloys Nanostructured ferritic alloys (NFAs), which have complex microstructures consisting of ultrafine ferritic grains with a dispersion of stable oxide particles and nanoclusters (NC), are promising materials for fuel cladding

  19. Friction welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon

    DOE Patents [OSTI]

    Byrne, Stephen C. (Monroeville, PA); Ray, Siba P. (Pittsburgh, PA); Rapp, Robert A. (Columbus, OH)

    1984-01-01

    A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a metal conductor and a ceramic electrode body connected by a friction weld between a portion of the body having a level of free metal or metal alloy sufficient to effect such a friction weld and a portion of the metal conductor.

  20. Solid cartridge for a pulse weld forming electrode and method of joining tubular members

    DOE Patents [OSTI]

    Bonnen, John Joseph Francis; Golovashchenko, Sergey Fedorovich; Mamutov, Alexander; Maison, Lloyd Douglas; Dawson, Scott Alwyn; deVries, James

    2016-02-23

    A cartridge assembly is disclosed for a pulse welding a first tube supported on a mandrel to a second tube. An outer tool is assembled over the second tube and a stored charge is discharged in the cartridge assembly. The cartridge comprises an annular conductor and a solid casing enveloping the conductor. The stored charge is electrically connected to the conductor and discharged through the conductor to compress the second tube and pulse weld the second tube to the first tube.

  1. Progress Report for Diffusion Welding of the NGNP Process Application Heat Exchangers

    SciTech Connect (OSTI)

    R.E. Mizia; D.E. Clark; M.V. Glazoff; T.E. Lister; T.L. Trowbridge

    2011-04-01

    The NGNP Project is currently investigating the use of metallic, diffusion welded, compact heat exchangers to transfer heat from the primary (reactor side) heat transport system to the secondary heat transport system. The intermediate heat exchanger will transfer this heat to downstream applications such as hydrogen production, process heat, and electricity generation. The channeled plates that make up the heat transfer surfaces of the intermediate heat exchanger will have to be assembled into an array by diffusion welding.

  2. Webinar January 12: Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement

    Broader source: Energy.gov [DOE]

    The Energy Department will present a live webinar titled "Assessing Steel Pipeline and Weld Susceptibility to Hydrogen Embrittlement” on Tuesday, January 12, from 12 to 1 p.m. EST. This webinar will discuss the breadth of testing performed at Sandia National Laboratories focused on the effects of hydrogen gas on steel pipelines and welds, and demonstrate how measured fatigue crack growth laws can be applied to calculate minimum wall thickness needed for steel hydrogen pipelines.

  3. Friction Stir Spot Welding of Advanced High Strength Steels | Department of

    Broader source: Energy.gov (indexed) [DOE]

    Energy 09 DOE Hydrogen Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation Meeting, May 18-22, 2009 -- Washington D.C. PDF icon lm_14_grant.pdf More Documents & Publications Friction Stir Spot Welding of Advanced High Strength Steels II FY 2009 Progress Report for Lightweighting Materials - 9. Joining Pulse Pressure Forming of Lightweight Materials, Development of High Strength Superplastic Al Sheet, Friction Stir Spot Welding of Advanced High Strength Steels

  4. Precision welding cuts downtime at Grand Coulee Dam

    SciTech Connect (OSTI)

    Light, S.; White, E.

    1997-03-01

    The three large 700-MW generators at Grand Coulee Dam--originally built and installed by Canadian General Electric in the late 1970s--are being upgraded using precision welding techniques and leading edge installation technology. These generators suffered from numerous water leaks at and around the bar water connections, resulting in a significant number of forced repair outages that were increasing in frequency. The US Bureau of Reclamation, in conjunction with the Bonneville Power Administration, decided to overhaul these machines. The design from Siemens Power Corp. provided state-of-the-art materials and included a rating increase from 700 to 805 MW, which would make these three machines the highest output single-unit hydrogenerators in the world. The upgrade was to be accomplished with only the replacement of the stator components; there would be no changes to the rotating element. The cost for all three machines is approximately $27.5 million. This project is described in this paper.

  5. GTA Welding Research and Development for Plutonium Containment

    SciTech Connect (OSTI)

    Sessions, C.E.

    2002-02-21

    This paper discusses the development of two welding systems that are used to contain actinide metals and oxides for long term storage. The systems are termed the bagless transfer system (BTS) and the outer container welder (OCW) system. The BTS is so named because it permits the containment of actinides without a polymeric package (i.e., bag). The development of these two systems was directed by Department of Energy Standard 3013, hereafter referred to as DOE 3013. This document defines the product and container requirements. In addition, it references national codes and standards for leak rates, ANSI N14.5, and design, American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section VIII (BandPVC).

  6. Templated, layered manganese phosphate

    DOE Patents [OSTI]

    Thoma, Steven G.; Bonhomme, Francois R.

    2004-08-17

    A new crystalline maganese phosphate composition having an empirical formula: O). The compound was determined to crystallize in the trigonal space group P-3c1 with a=8.8706(4) .ANG., c=26.1580(2) .ANG., and V (volume)=1783 .ANG..sup.3. The structure consists of sheets of corner sharing Mn(II)O.sub.4 and PO.sub.4 tetrahedra with layers of (H.sub.3 NCH.sub.2 CH.sub.2).sub.3 N and water molecules in-between. The pronated (H.sub.3 NCH.sub.2 CH.sub.2).sub.3 N molecules provide charge balancing for the inorganic sheets. A network of hydrogen bonds between water molecules and the inorganic sheets holds the structure together.

  7. Robotic weld overlay coatings for erosion control. Final technical progress report, July 1992--July 1995

    SciTech Connect (OSTI)

    Levin, B.F.; DuPont, J.N.; Marder, A.R.

    1995-10-15

    The erosion behavior of weld overlay coatings has been studied. Eleven weld overlay alloys were deposited on 1018 steel substrates using the plasma arc welding process and erosion tested at 400{degrees}C at 90{degrees} and 30{degrees} particle impact angles. The microstructure of each coating was characterized before erosion testing. A relative ranking of the coatings erosion resistance was developed by determining the steady state erosion rates. Ultimet, Inconel-625, and 316L SS coatings showed the best erosion resistance at both impact angles. It was found that weld overlays that exhibit good abrasion resistance did not show good erosion resistance. Erosion tests were also performed for selected wrought materials with chemical composition similar to weld overlays. Eroded surfaces of the wrought and weld alloys were examined by Scanning Electron Microscopy (SEM). Microhardness tests were performed on the eroded samples below the erosion surface to determine size of the plastically deformed region. It was found that one group of coatings experienced significant plastic deformation as a result of erosion while the other did not. It was also established that, in the steady state erosion regime, the size of the plastically deformed region is constant.

  8. Welding Induced Alignment Distortion in Dual-in-Line LD Packages

    SciTech Connect (OSTI)

    Liu, Wenning N.; Sun, Xin; Khaleel, Mohammad A.; Shi, Frank G.

    2007-11-11

    The tolerance for the movement of a single mode fiber relative to the laser is extremely tight, a submicron movement can often lead to a significant misalignment and thus the reduction in the power coupled into the fiber. Among various fiber pigtailing assembly technologies, pulsed laser welding is the method with submicron accuracy and is most conducive to automation. However, the melting-solidification process during laser welding can often distort the pre-achieved fiber-optic alignment. This Welding-Induced-Alignment-Distortion (WIAD) is a serious concern and significantly affects the yield for single mode fiber pigtailing to a semiconductor laser. In this paper, effect of laser welding sequence on WIAD in a dual-in-line packager is numerically investigated by means of Finite Element Method (FEM). Optimal welding sequence may minimize WIAD in dual-in-line package. Additionally, unsymmetrical space between fiber and U-channel induced by laser welding of U-channel–to-plate in DIP LD packages is found to have obvious effect on WIAD.

  9. A Comparative Study of Welded ODS Cladding materials for AFCI/GNEP Applications

    SciTech Connect (OSTI)

    Indrajit Charit; Megan Frary; Darryl Butt; K.L. Murty; Larry Zirker; James Cole; Mitchell Meyer; Rajiv S. Mishra; Mark Woltz

    2011-03-31

    This research project involved working on the pressure resistance welding of oxide dispersion strengthened (ODS) alloys which will have a large role to play in advanced nuclear reactors. The project also demonstrated the research collaboration between four universities and one nation laboratory (Idaho National Laboratory) with participation from an industry for developing for ODS alloys. These alloys contain a high number density of very fine oxide particles that can impart high temperature strength and radiation damage resistance suitable for in-core applications in advanced reactors. The conventional fusion welding techniques tend to produce porosity-laden microstructure in the weld region and lead to the agglomeration and non-uniform distribution of the neededoxide particles. That is why two solid state welding methods - pressure resistance welding (PRW) and friction stir welding (FSW) - were chosen to be evaluated in this project. The proposal is expected to support the development of Advanced Burner Reactors (ABR) under the GNEP program (now incorporated in Fuel Cycle R&D program). The outcomes of the concluded research include training of graduate and undergraduate students and get them interested in nuclear related research.

  10. Method of beam welding metallic parts together and apparatus for doing same

    DOE Patents [OSTI]

    Lewandowski, Edward F.; Cassidy, Dale A.; Sommer, Robert G.

    1987-01-01

    The disclosed method provides for temporarily clamping a metallic piece to one side of a metallic plate while leaving the opposite side of the plate exposed, and providing a heat conductive heat sink body configured to engage the adjacent portions of such one side of the plate and the piece at all regions proximate to but not at the interface between these components. Such exposed side of such plate is then subjected to an electron welding beam, in exact registry with but opposite to the piece. The electron welding beam is supplied with adequate energy for penetrating through the plate, across the interface, and into the piece, whereby the electron welding beam produces molten material from both the plate and the piece in the region of the interface. The molten material flows into any interstices that may exist in the interface, and upon cooling solidifies to provide a welded joint between the plate and piece, where the interface was, virtually without any interstices. The heat sink material prevents the molten material from extruding beyond what was the interface, to provide a clean welded joint. The heat sink body also mechanically holds the plate and piece together prior to the actual welding.

  11. Method of beam welding metallic parts together and apparatus for doing same

    DOE Patents [OSTI]

    Lewandowski, E.F.; Cassidy, D.A.; Sommer, R.G.

    1985-11-29

    This method provides for temporarily clamping a metallic piece to one side of a metallic plate while leaving the opposite side of the plate exposed, and providing a heat conductive heat sink body configured to engage the adjacent portions of such one side of the plate and the piece at all regions proximate to but not at the interface between these components. The exposed side of such plate is then subjected to an electron welding beam, in exact registry with but opposite to the piece. The electron welding beam is supplied with adequate energy for penetrating through the plate, across the interface, and into the piece, whereby the electron welding beam produces molten material from both the plate and the piece in the region of the interface. The molten material flows into any interstices that may exist in the interface, and upon cooling solidifies to provide a welded joint between the plate and piece, where the interface was, virtually without any interstices. The heat sink material prevents the molten material from extrucing beyond what was the interface, to provide a clean welded joint. The heat sink body also mechanically holds the plate and piece together prior to the actual welding.

  12. Corrosion of nickel and Monel welds of steel in chlorine trifluoride

    SciTech Connect (OSTI)

    Fout, S.L.

    1988-07-25

    Failures in the weld areas of nickel-plated steel pipe carrying chlorine trifluoride, ClF/sub 3/, prompted this investigation to determine the effect of weld composition on corrosion by ClF/sub 3/. Monel/steel and nickel/steel alloys of composition to simulate weld overlays were tested to determine their corrosion rates in ClF/sub 3/ at 200/degree/F and 300/degree/F. For both nickel/steel and Monel/steel, the corrosion rate was higher at the higher temperature. For nickel/steel alloys at compositions up to 50% iron, which would cover a range considered normal for welding, the corrosion rate would be within acceptable limits. For Monel/steel alloys, compositions up to 35% iron have an acceptable corrosion rate. Above this, the corrosion would be greater than a tolerable amount. It should pose no problem to keep the heat input to the weld low enough to produce a Monel weld with an iron content below 35%. 2 refs., 5 figs., 2 tabs.

  13. Novel concepts in weld metal science: Role of gradients and composite structure

    SciTech Connect (OSTI)

    Matlock, D.K.; Olson, D.L.

    1991-12-01

    The effects of compositional and microstructural gradients on weld metal properties are being investigated. Crack propagation is solidified alloy structures is being characterized as to solidification orientation and the profile of the compositional variations. The effects of compositional gradients, are considered based on a thermodynamic analysis, referred to as the Cahn-Hillard analysis, which describes the degree to which a local surface energy is modified by the presence of a compositional gradient. The analysis predicts that both ductile and brittle fracture mechanisms are enhanced by the presence of a composition gradient. Special techniques to produce laboratory samples with microstructures which simulate the composition and microstructure gradients in solidified weld metal are used, along with appropriate mathematical models, to evaluate the properties of the composite weld metals. The composite modeling techniques are being applied to describe the effects of compositional and microstructural gradients on weld metal properties in Ni-Cu alloys. The development of metal matrix composition weld deposits on austenitic stainless steels has been studied. The particulate metal matrix composites were produced with ceramic or refractory metal powder filled cored wire, which was gas tungsten arc and gas metal arc welded.

  14. Processes for multi-layer devices utilizing layer transfer

    DOE Patents [OSTI]

    Nielson, Gregory N; Sanchez, Carlos Anthony; Tauke-Pedretti, Anna; Kim, Bongsang; Cederberg, Jeffrey; Okandan, Murat; Cruz-Campa, Jose Luis; Resnick, Paul J

    2015-02-03

    A method includes forming a release layer over a donor substrate. A plurality of devices made of a first semiconductor material are formed over the release layer. A first dielectric layer is formed over the plurality of devices such that all exposed surfaces of the plurality of devices are covered by the first dielectric layer. The plurality of devices are chemically attached to a receiving device made of a second semiconductor material different than the first semiconductor material, the receiving device having a receiving substrate attached to a surface of the receiving device opposite the plurality of devices. The release layer is etched to release the donor substrate from the plurality of devices. A second dielectric layer is applied over the plurality of devices and the receiving device to mechanically attach the plurality of devices to the receiving device.

  15. The effects of confining pressure on the strength and elastic properties of the Paintbrush tuff recovered from boreholes USW NRG-6 and USW NRG-7/7A: Data report

    SciTech Connect (OSTI)

    Martin, R.J.; Noel, J.S.; Boyd, P.J.

    1997-09-01

    Experimental results are presented for bulk and mechanical properties measurements on specimens of the Paintbrush tuff recovered from the USW NRG-6 and USW NRG-7/7A borehole at Yucca Mountain, Nevada. Measurements have been performed on five thermal/mechanical units: TCw, PTn, TSw2, and TSw3. The following bulk properties are reported for each specimen: dry bulk density, saturated bulk density, average grain density and porosity. Confined compression to failure tests were performed on selected specimens recovered from the boreholes at confining pressures of 5 and 10 MPa. In addition, compressional and shear wave velocities were measured on the specimens prior to testing. Measurements were conducted under drained conditions at room temperature on nominally water saturated specimens. The nominal strain rate for the experiments was 10{sup -5} s{sup -1}.

  16. Progress report on the results of testing advanced conceptual design metal barrier materials under relevant environmental conditions for a tuff repository

    SciTech Connect (OSTI)

    McCright, R.D.; Halsey, W.G.; Van Konynenburg, R.A.

    1987-12-01

    This report discusses the performance of candidate metallic materials envisioned for fabricating waste package containers for long-term disposal at a possible geological repository at Yucca Mountain, Nevada. Candidate materials include austenitic iron-base to nickel-base alloy (AISI 304L, AISI 316L, and Alloy 825), high-purity copper (CDA 102), and copper-base alloys (CDA 613 and CDA 715). Possible degradation modes affecting these container materials are identified in the context of anticipated environmental conditions at the repository site. Low-temperature oxidation is the dominant degradation mode over most of the time period of concern (minimum of 300 yr to a maximum of 1000 yr after repository closure), but various forms of aqueous corrosion will occur when water infiltrates into the near-package environment. The results of three years of experimental work in different repository-relevant environments are presented. Much of the work was performed in water taken from Well J-13, located near the repository, and some of the experiments included gamma irradiation of the water or vapor environment. The influence of metallurgical effects on the corrosion and oxidation resistance of the material is reviewed; these effects result from container fabrication, welding, and long-term aging at moderately elevated temperatures in the repository. The report indicates the need for mechanisms to understand the physical/chemical reactions that determine the nature and rate of the different degradation modes, and the subsequent need for models based on these mechanisms for projecting the long-term performance of the container from comparatively short-term laboratory data. 91 refs., 17 figs., 16 tabs.

  17. Oxygen-reducing catalyst layer

    DOE Patents [OSTI]

    O'Brien, Dennis P.; Schmoeckel, Alison K.; Vernstrom, George D.; Atanasoski, Radoslav; Wood, Thomas E.; Yang, Ruizhi; Easton, E. Bradley; Dahn, Jeffrey R.; O'Neill, David G.

    2011-03-22

    An oxygen-reducing catalyst layer, and a method of making the oxygen-reducing catalyst layer, where the oxygen-reducing catalyst layer includes a catalytic material film disposed on a substrate with the use of physical vapor deposition and thermal treatment. The catalytic material film includes a transition metal that is substantially free of platinum. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

  18. Deep Insights from Thin Layers

    Broader source: Energy.gov [DOE]

    A new technique developed by researchers at a trio of National Labs reveals secrets to proteins -- one layer at a time.

  19. Layer-by-Layer Assembly of Enzymes on Carbon Nanotubes

    SciTech Connect (OSTI)

    Wang, Jun; Liu, Guodong; Lin, Yuehe

    2008-06-01

    The use of Layer-by-layer techniques for immobilizing several types of enzymes, e.g. glucose oxidase (GOx), horse radish oxidases(HRP), and choline oxidase(CHO) on carbon nanotubes and their applications for biosenseing are presented. The enzyme is immobilized on the negatively charged CNT surface by alternatively assembling a cationic polydiallyldimethyl-ammonium chloride (PDDA) layer and a enzyme layer. The sandwich-like layer structure (PDDA/enzyme/PDDA/CNT) formed by electrostatic assembling provides a favorable microenvironment to keep the bioactivity of enzyme and to prevent enzyme molecule leakage. The morphologies and electrocatalytic acitivity of the resulted enzyme film were characterized using TEM and electrochemical techniques, respectively. It was found that these enzyme-based biosensors are very sensitive, selective for detection of biomolecules, e.g. glucose, choline.

  20. Leakage pathway layer for solar cell

    SciTech Connect (OSTI)

    Luan, Andy; Smith, David; Cousins, Peter; Sun, Sheng

    2015-12-01

    Leakage pathway layers for solar cells and methods of forming leakage pathway layers for solar cells are described.

  1. Development of a pseudo phased array technique using EMATs for DM weld testing

    SciTech Connect (OSTI)

    Cobb, Adam C. Fisher, Jay L.; Shiokawa, Nobuyuki; Hamano, Toshiaki; Horikoshi, Ryoichi; Ido, Nobukazu

    2015-03-31

    Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS material in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.

  2. Progress Report for Diffusion Welding of the NGNP Process Application Heat Exchangers

    SciTech Connect (OSTI)

    R.E. Mizia; D.E. Clark; M.V. Glazoff; T.E. Lister; T.L. Trowbridge

    2011-12-01

    The U.S. Department of Energy selected the high temperature gas-cooled reactor as the basis for the Next Generation Nuclear Plant (NGNP). The NGNP will demonstrate the use of nuclear power for electricity, hydrogen production, and process heat applications. The NGNP Project is currently investigating the use of metallic, diffusion welded, compact heat exchangers to transfer heat from the primary (reactor side) heat transport system to the secondary heat transport system. An intermediate heat exchanger will transfer this heat to downstream applications such as hydrogen production, process heat, and electricity generation. The channeled plates that make up the heat transfer surfaces of the intermediate heat exchanger will have to be assembled into an array by diffusion welding. This report describes the preliminary results of a scoping study that evaluated the diffusion welding process parameters and the resultant mechanical properties of diffusion welded joints using Alloy 800H. The long-term goal of the program is to progress towards demonstration of small heat exchanger unit cells fabricated with diffusion welds. Demonstration through mechanical testing of the unit cells will support American Society of Mechanical Engineers rules and standards development, reduce technical risk, and provide proof of concept for heat exchanger fabrication methods needed to deploy heat exchangers in several potential NGNP configurations.1 Researchers also evaluated the usefulness of modern thermodynamic and diffusion computational tools (Thermo-Calc and Dictra) in optimizing the parameters for diffusion welding of Alloy 800H. The modeling efforts suggested a temperature of 1150 C for 1 hour with an applied pressure of 5 MPa using 15 {micro}m nickel foil as joint filler to reduce chromium oxidation on the welded surfaces. Good agreement between modeled and experimentally determined concentration gradients was achieved

  3. MODELING OF HIGH SPEED FRICTION STIR SPOT WELDING USING A LAGRANGIAN FINITE ELEMENT APPROACH

    SciTech Connect (OSTI)

    Miles, Michael; Karki, U.; Woodward, C.; Hovanski, Yuri

    2013-09-03

    Friction stir spot welding (FSSW) has been shown to be capable of joining steels of very high strength, while also being very flexible in terms of controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding (RSW) if tool life is sufficiently high, and if machine spindle loads are sufficiently low so that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11-14 kN. Therefore, in the current work tool speeds of 3000 rpm and higher were employed, in order to generate heat more quickly and to reduce welding loads to acceptable levels. The FSSW process was modeled using a finite element approach with the Forge® software package. An updated Lagrangian scheme with explicit time integration was employed to model the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate [3]. The modeling approach can be described as two-dimensional, axisymmetric, but with an aspect of three dimensions in terms of thermal boundary conditions. Material flow was calculated from a velocity field which was two dimensional, but heat generated by friction was computed using a virtual rotational velocity component from the tool surface. An isotropic, viscoplastic Norton-Hoff law was used to model the evolution of material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures and the movement of the joint interface with reasonable accuracy for the welding of a dual phase 980 steel.

  4. FUNDAMENTAL STUDY OF MICRO-DEFECTS IN ELECTROPOLISHED EB-WELDED AND HYDROFORMED SRF ACCELERATING STRUCTURES

    SciTech Connect (OSTI)

    Sumption, Mike

    2014-08-29

    In the area of niobium elecroploshing fundamentals, we focused on undersanding the influence of the surface topology, and geometry (with effects from gravity included. The formation of a viscous film is essential for the electropolishing process to take place. The exact nature and composition of the film formed on niobium is still unknown because of its solubility in the electrolyte. Extensive pitting may take place at surface where a stable film cannot form. This has to be taken into consideration while determining the speed with which the SRF cavities are rotated while EP. Hydrodynamic aspects must be taken into consideration while optimizing the polishing parameters. There is improvement in surface finish with polishing time. There is a huge change in surface quality when the EP time is increased from 2 hours to 4 hours but not much change takes place when the time is further increased to 6 hours. So keeping the economic points in view, about 100 um defect layer removal may be sufficient to get the desired performance. In the area of Electropolishing of untreated and treated niobium with Weld Joints we studied untreated and treated Nb, especially for the heat affected areas next to welded bumps, electropolished for different durations. The electropolishing of the untreated Nb caused the formation of pits on the surface at about 15 min but they disappeared when the electropolishing duration was more than 15 min. Electropolishing for 120 min smoothened the surface of untreated Nb by levelling the surface, but the severe formation of pits on the whole surface was found after 240 min. The treatment of Nb significantly changed the Nb surface morphology which was covered by grains of different size that looked light or dark in the optical microscope. The treated Nb was susceptible to pitting during the entire electropolishing starting from 15 min and the dark grains had more susceptibility to pitting than the light grains. In addition, electropolishing for 240 min again resulted in severe pit formation. In the area of Bulge test and microstructure studies, we worked to create a useful constitutive relationship for the complex stress state that accompanies SRF cavity formation. To do so, bulge tests were performed on Cu and Nb tube samples that exhibited the greatest degrees of uniaxial elongation after HT. The data from the bulge tests and an accompanying set of tensile tests provided input to a finite-element model that recreated the bulge tests numerically. As expected the model based on the bulge test results fit the experimental data well at least at low stress levels safely below the bursting pressure. Not so for that based on the tensile results. The results of the study emphasize the importance of for bulge testing rather than tensile testing when deriving the constitutional relationships eventually needed for modelling the hydroforming of Nb SRF cavities.

  5. Effects of Fusion Zone Size and Failure Mode on Peak Load and Energy Absorption of Advanced High Strength Steel Spot Welds under Lap Shear Loading Conditions

    SciTech Connect (OSTI)

    Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2008-06-01

    This paper examines the effects of fusion zone size on failure modes, static strength and energy absorption of resistance spot welds (RSW) of advanced high strength steels (AHSS) under lap shear loading condition. DP800 and TRIP800 spot welds are considered. The main failure modes for spot welds are nugget pullout and interfacial fracture. Partial interfacial fracture is also observed. Static weld strength tests using lap shear samples were performed on the joint populations with various fusion zone sizes. The resulted peak load and energy absorption levels associated with each failure mode were studied for all the weld populations using statistical data analysis tools. The results in this study show that AHSS spot welds with conventionally required fusion zone size of can not produce nugget pullout mode for both the DP800 and TRIP800 welds under lap shear loading. Moreover, failure mode has strong influence on weld peak load and energy absorption for all the DP800 welds and the TRIP800 small welds: welds failed in pullout mode have statistically higher strength and energy absorption than those failed in interfacial fracture mode. For TRIP800 welds above the critical fusion zone level, the influence of weld failure modes on peak load and energy absorption diminishes. Scatter plots of peak load and energy absorption versus weld fusion zone size were then constructed, and the results indicate that fusion zone size is the most critical factor in weld quality in terms of peak load and energy absorption for both DP800 and TRIP800 spot welds.

  6. Development of automated welding process for field fabrication of thick walled pressure vessels. Technical progress report, second quarter, FY 1980, ending March 28, 1980

    SciTech Connect (OSTI)

    Schneider, U.A.

    1980-01-01

    Progress on a metallurgical contract is reported: (1) specifications of 2 1/4 chromium-1 molybdenum low alloy steel plate for a coal gasification project; (2) methods of welding and analyses of helium-argon mixtures for welding; and (3) tensile properties of welded joints. (LTN)

  7. Effects of current on droplet generation and arc plasma in gas metal arc welding

    SciTech Connect (OSTI)

    Hu, J.; Tsai, H. L.

    2006-09-01

    In gas metal arc welding (GMAW), a technology using pulsed currents has been employed to achieve the one-droplet-per-pulse (ODPP) metal transfer mode with the advantages of low average currents, a stable and controllable droplet generation, and reduced spatter. In this paper, a comprehensive model was developed to study the effects of different current profiles on the droplet formation, plasma generation, metal transfer, and weld pool dynamics in GMAW. Five types of welding currents were studied, including two constant currents and three wave form currents. In each type, the transient temperature and velocity distributions of the arc plasma and the molten metal, and the shapes of the droplet and the weld pool were calculated. The results showed that a higher current generates smaller droplets, higher droplet frequency, and higher electromagnetic force that becomes the dominant factor detaching the droplet from the electrode tip. The model has demonstrated that a stable ODPP metal transfer mode can be achieved by choosing a current with proper wave form for given welding conditions.

  8. Precipitation of sigma and chi phases in ?-ferrite of Type 316FR weld metals

    SciTech Connect (OSTI)

    Chun, Eun Joon; Baba, Hayato; Nishimoto, Kazutoshi; Saida, Kazuyoshi

    2013-12-15

    The decomposition behavior and kinetics of ?-ferrite are examined using aging treatments between 873 and 1073 K for Type 316FR stainless steel weld metals with different solidification modes (316FR AF, 316FR FA). The dominant precipitates are sigma, chi, and secondary austenite nucleated at ?-ferrite/austenite interfaces or in the interior of the ferrite grains. These precipitates consume all the ferrite during isothermal aging in both 316FR AF and FA weld metals. Differences in the precipitation behavior (precipitation initiation time and precipitation speed) between weld metals can be explained by i) the degree of Cr and Mo microsegregation within ?-ferrite or austenite near ferrite and ii) the nucleation sites induced due to the solidification mode (AF or FA), such as the ferrite amount. For both weld materials, a Johnson–Mehl-type equation can express the precipitation behavior of the sigma + chi phases and quantitatively predict the behavior at the service-exposure temperatures of a fast breed reactor. - Highlights: • Precipitation of ? and ? phase in Type 316FR welds (two solidification modes) • Different precipitation behaviors: precipitation initiation time and growth speed • Johnson-Mehl–type equation is the most applicable to the precipitation behaviors • Precipitation behaviors are predicted under service conditions of FBRs.

  9. Friction Stir Spot Welding of DP780 and Hot-Stamp Boron Steels

    SciTech Connect (OSTI)

    Santella, Michael L.; Frederick, Alan; Hovanski, Yuri; Grant, Glenn J.

    2008-05-16

    Friction stir spot welds were made in two high-strength steels: DP780, and a hot-stamp-boron steel with tensile strength of 1500 MPa. The spot welds were made at either 800 or 1600 rpm using either of two polycrystalline boron nitride tools. One stir tool, BN77, had the relatively common pin-tool shape. The second tool, BN46, had a convex rather than a concave shoulder profile and a much wider and shorter pin. The tools were plunged to preprogrammed depths either at a continuous rate (1-step schedule) or in two segments consisting of a relatively high rate followed by a slower rate. In all cases, the welds were completed in 4s. The range of lap-shear values were compared to values required for resistance spot welds on the same steels. The minimum value of 10.3 kN was exceeded for friction stir spot welding of DP780 using a 2-step schedule and either the BN77- or the BN46-type stir tool. The respective minimum value of 12 kN was also exceeded for the HSB steel using the 2-step process and the BN46 stir tool.

  10. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect (OSTI)

    N. Jerred; L. Zirker; I. Charit; J. Cole; M. Frary; D. Butt; M. Meyer; K. L. Murty

    2010-10-01

    Pressure Resistance Welding (PRW) is a solid state joining process used for various high temperature metallic materials (Oxide dispersion strengthened alloys of MA957, MA754; martensitic alloy HT-9, tungsten etc.) for advanced nuclear reactor applications. A new PRW machine has been installed at the Center for Advanced Energy Studies (CAES) in Idaho Falls for conducting joining research for nuclear applications. The key emphasis has been on understanding processing-microstructure-property relationships. Initial studies have shown that sound joints can be made between dissimilar materials such as MA957 alloy cladding tubes and HT-9 end plugs, and MA754 and HT-9 coupons. Limited burst testing of MA957/HT-9 joints carried out at various pressures up to 400oC has shown encouraging results in that the joint regions do not develop any cracking. Similar joint strength observations have also been made by performing simple bend tests. Detailed microstructural studies using SEM/EBSD tools and fatigue crack growth studies of MA754/HT-9 joints are ongoing.

  11. Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Rabby, Reza; Tang, Wei; Reynolds, A. P.

    2015-07-01

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtainedmore » when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.« less

  12. Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds

    SciTech Connect (OSTI)

    Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2006-04-28

    This paper examines the effects of fusion zone size on failure modes, static strength and energy absorption of resistance spot welds (RSW) of advanced high strength steels (AHSS). DP800 and TRIP800 spot welds are considered. The main failure modes for spot welds are nugget pullout and interfacial fracture. Partial interfacial fracture is also observed. The critical fusion zone sizes to ensure nugget pull-out failure mode are developed for both DP800 and TRIP800 using the limit load based analytical model and the micro-hardness measurements of the weld cross sections. Static weld strength tests using cross tension samples were performed on the joint populations with controlled fusion zone sizes. The resulted peak load and energy absorption levels associated with each failure mode were studied using statistical data analysis tools. The results in this study show that the conventional weld size of 4 t can not produce nugget pullout mode for both the DP800 and TRIP800 materials. The results also suggest that performance based spot weld acceptance criteria should be developed for different AHSS spot welds.

  13. STRESS CORROSION CRACK GROWTH RESPONSE FOR ALLOY 152/52 DISSIMILAR METAL WELDS IN PWR PRIMARY WATER

    SciTech Connect (OSTI)

    Toloczko, Mychailo B.; Olszta, Matthew J.; Overman, Nicole R.; Bruemmer, Stephen M.

    2015-08-15

    As part of ongoing research into primary water stress corrosion cracking (PWSCC) susceptibility of alloy 690 and its welds, SCC tests have been conducted on alloy 152/52 dissimilar metal (DM) welds with cracks positioned with the goal to assess weld dilution and fusion line effects on SCC susceptibility. No increased crack growth rate was found when evaluating a 20% Cr dilution zone in alloy 152M joined to carbon steel (CS) that had not undergone a post-weld heat treatment (PWHT). However, high SCC crack growth rates were observed when the crack reached the fusion line of that material where it propagated both on the fusion line and in the heat affected zone (HAZ) of the carbon steel. Crack surface and crack profile examinations of the specimen revealed that cracking in the weld region was transgranular (TG) with weld grain boundaries not aligned with the geometric crack growth plane of the specimen. The application of a typical pressure vessel PWHT on a second set of alloy 152/52 – carbon steel DM weld specimens was found to eliminate the high SCC susceptibility in the fusion line and carbon steel HAZ regions. PWSCC tests were also performed on alloy 152-304SS DM weld specimens. Constant K crack growth rates did not exceed 5x10-9 mm/s in this material with post-test examinations revealing cracking primarily on the fusion line and slightly into the 304SS HAZ.

  14. Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

    SciTech Connect (OSTI)

    Rabby, Reza; Tang, Wei; Reynolds, A. P.

    2015-07-01

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtained when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.

  15. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    SciTech Connect (OSTI)

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; Payzant, E. Andrew; Kolbus, Lindsay M.

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stir zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.

  16. Weld overlay coatings for erosion control. Task A: Literature review, progress report

    SciTech Connect (OSTI)

    Levin, B.; DuPont, J.N.; Marder, A.R.

    1993-03-03

    A literature review was made. In spite of similarities between abrasive wear and solid particle erosion, weld overlay hardfacing alloys that exhibit high abrasion resistance may not necessarily have good erosion resistance. The performance of weld overlay hardfacing alloys in erosive environments has not been studied in detail. It is believed that primary-solidified hard phases such as carbides and intermetallic compounds have a strong influence on erosion resistance of weld overlay hardfacing alloys. However, relationships between size, shape, and volume fraction of hard phases in a hardfacing alloys and erosion resistance were not established. Almost all hardfacing alloys can be separated into two major groups based upon chemical compositions of the primary solidified hard phases: (a) carbide hardening alloys (Co-base/carbide, WC-Co and some Fe base superalloys); and (b) intermetallic hardening alloys (Ni-base alloys, austenitic steels, iron-aluminides).

  17. Using Phased Array Ultrasonic Testing in Lieu of Radiography for Acceptance of Carbon Steel Piping Welds

    SciTech Connect (OSTI)

    Moran, Traci L.; Anderson, Michael T.; Cinson, Anthony D.; Crawford, Susan L.; Nove, Carol A.

    2014-08-01

    The Pacific Northwest National Laboratory (PNNL) is conducting studies for the U.S. Nuclear Regulatory Commission (NRC) to assess the capability, effectiveness, and reliability of ultrasonic testing (UT) as a replacement method for radiographic testing (RT) for volumetric examination of nuclear power plant (NPP) components. This particular study focused on evaluating the use of UT on carbon steel plate welds. Welding fabrication flaws included a combination of planar and volumetric types, e.g., incomplete fusion, lack of penetration, cracks, porosity, and slag inclusions. The examinations were conducted using phased-array (PA) UT techniques applied primarily for detection and flaw type characterization. This paper will discuss the results of using UT in lieu of RT for detection and classification of fabrication flaws in carbon steel plate welds.

  18. Effects of shielding gas compositions on arc plasma and metal transfer in gas metal arc welding

    SciTech Connect (OSTI)

    Rao, Z. H.; Liao, S. M.; Tsai, H. L.

    2010-02-15

    This article presents the effects of shielding gas compositions on the transient transport phenomena, including the distributions of temperature, flow velocity, current density, and electromagnetic force in the arc and the metal, and arc pressure in gas metal arc welding of mild steel at a constant current input. The shielding gas considered includes pure argon, 75% Ar, 50% Ar, and 25% Ar with the balance of helium. It is found that the shielding gas composition has significant influences on the arc characteristics; droplet formation, detachment, transfer, and impingement onto the workpiece; and weld pool dynamics and weld bead profile. As helium increases in the shielding gas, the droplet size increases but the droplet detachment frequency decreases. For helium-rich gases, the current converges at the workpiece with a 'ring' shape which produces non-Gaussian-like distributions of arc pressure and temperature along the workpiece surface. Detailed explanations to the physics of the very complex but interesting transport phenomena are given.

  19. High power x-ray welding of metal-matrix composites

    DOE Patents [OSTI]

    Rosenberg, Richard A.; Goeppner, George A.; Noonan, John R.; Farrell, William J.; Ma, Qing

    1999-01-01

    A method for joining metal-matrix composites (MMCs) by using high power x-rays as a volumetric heat source is provided. The method involves directing an x-ray to the weld line between two adjacent MMCs materials to create an irradiated region or melt zone. The x-rays have a power density greater than about 10.sup.4 watts/cm.sup.2 and provide the volumetric heat required to join the MMC materials. Importantly, the reinforcing material of the metal-matrix composites remains uniformly distributed in the melt zone, and the strength of the MMCs are not diminished. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys.

  20. Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

    SciTech Connect (OSTI)

    Upadhyay, Piyush; Reynolds, Anthony

    2015-05-25

    Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient at the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.

  1. Dynamic strain gages analysis of critical welds used in power plant circuit breakers

    SciTech Connect (OSTI)

    MacDougall, E.A. ); Wilhelm, W.G. )

    1990-01-01

    A history of failures in power plant circuit breakers associated with critical welds in the internal pole shafts has been investigated. This paper describes the test, equipment, and instrumentation and summarized the preliminary results of testing performed on these breakers at Brookhaven National Laboratory. It includes the description of the instrumentation including the use of a full bridge strain gage sensor and instrumentation amplifier connected to an oscilloscope. The combination provided a sensitive instrument capable of revealing subtle changes in circuit breaker performance. The strain gages were attached to pole shafts and monitored dynamically. The observed changes in wave signature were recorded as a function of accumulated operating cycles. Complex changes in wave shape recorded on an oscillograph indicate patterns related to impending weld failure. The life expectancy measured in the number of circuit breaker open and closing cycles is compared with the weld and other component failures. 8 refs., 4 figs.

  2. Integrity assessment of the ferritic / austenitic dissimilar weld joint between intermediate heat exchanger and steam generator in fast reactor

    SciTech Connect (OSTI)

    Jayakumar, T.; Laha, K.; Chandravathi, K. S.; Parameswaran, P.; Goyal, S.; Kumar, J. G.; Mathew, M. D.

    2012-07-01

    Integrity of the modified 9Cr-1Mo / alloy 800 dissimilar joint welded with Inconel 182 electrodes has been assessed under creep condition based on the detailed analysis of microstructure and stress distribution across the joint by finite element analysis. A hardness peak at the ferritic / austenitic weld interface and a hardness trough at the inter-critical heat affected zone (HAZ) in ferritic base metal developed. Un-tempered martensite was found at the ferritic / austenitic weld interface to impart high hardness in it; whereas annealing of martensitic structure of modified 9Cr-1Mo steel by inter-critical heating during welding thermal cycle resulted in hardness tough in the inter-critical HAZ. Creep tests were carried out on the joint and ferritic steel base metal at 823 K over a stress range of 160-320 MPa. The joint possessed lower creep rupture strength than its ferritic steel base metal. Failure of the joint at relatively lower stresses occurred at the ferritic / austenitic weld interface; whereas it occurred at inter-critical region of HAZ at moderate stresses. Cavity nucleation associated with the weld interface particles led to premature failure of the joint. Finite element analysis of stress distribution across the weld joint considering the micro-mechanical strength inhomogeneity across it revealed higher von-Mises and principal stresses at the weld interface. These stresses induced preferential creep cavitation at the weld interface. Role of precipitate in enhancing creep cavitation at the weld interface has been elucidated based on the FE analysis of stress distribution across it. (authors)

  3. Mechanisms of hydrogen-assisted fracture in austenitic stainless steel welds.

    SciTech Connect (OSTI)

    Balch, Dorian K.; Sofronis, Petros; Somerday, Brian P.; Novak, Paul

    2005-03-01

    The objective of this study was to quantify the hydrogen-assisted fracture susceptibility of gas-tungsten arc (GTA) welds in the nitrogen-strengthened, austenitic stainless steels 21Cr-6Ni-9Mn (21-6-9) and 22Cr-13Ni-5Mn (22-13-5). In addition, mechanisms of hydrogen-assisted fracture in the welds were identified using electron microscopy and finite-element modeling. Elastic-plastic fracture mechanics experiments were conducted on hydrogen-charged GTA welds at 25 C. Results showed that hydrogen dramatically lowered the fracture toughness from 412 kJ/m{sup 2} to 57 kJ/m{sup 2} in 21-6-9 welds and from 91 kJ/m{sup 2} to 26 kJ/m{sup 2} in 22-13-5 welds. Microscopy results suggested that hydrogen served two roles in the fracture of welds: it promoted the nucleation of microcracks along the dendritic structure and accelerated the link-up of microcracks by facilitating localized deformation. A continuum finite-element model was formulated to test the notion that hydrogen could facilitate localized deformation in the ligament between microcracks. On the assumption that hydrogen decreased local flow stress in accordance with the hydrogen-enhanced dislocation mobility argument, the finite-element results showed that deformation was localized in a narrow band between two parallel, overlapping microcracks. In contrast, in the absence of hydrogen, the finite-element results showed that deformation between microcracks was more uniformly distributed.

  4. Stress Corrosion Cracking and Non-Destructive Examination of Dissimilar Metal Welds and Alloy 600

    SciTech Connect (OSTI)

    Jackson, Deborah A.

    2002-07-01

    The United States Nuclear Regulatory Commission (USNRC) has conducted research since 1977 in the areas of environmentally assisted cracking and assessment and reliability of non-destructive examination (NDE). Recent occurrences of cracking in Alloy 82/182 welds and Alloy 600 base metal at several domestic and overseas plants have raised several issues relating to both of these areas of NRC research. The occurrences of cracking were identified by the discovery of boric acid deposits resulting from through-wall cracking in the primary system pressure boundary. Analyses indicate that the cracking has occurred due to primary water stress corrosion cracking (PWSCC) in Alloy 82/182 welds. This cracking has occurred in two different locations: in hot leg nozzle-to-safe end welds and in control rod drive mechanism (CRDM) nozzle welds. The cracking associated with safe-end welds is important due to the potential for a large loss of reactor coolant inventory, and the cracking of CRDM nozzle base metal and welds, particularly circumferential cracking of CRDM nozzle base metal, is important due to the potential for a control rod to eject resulting in a loss of coolant accident. The industry response in the U.S. to this cracking is being coordinated through the Electric Power Research Institute's Materials Reliability Project (EPRI-MRP) in a comprehensive, multifaceted effort. Although the industry program is addressing many of the issues raised by these cracking occurrences, confirmatory research is necessary for the staff to evaluate the work conducted by industry groups. Several issues requiring additional consideration regarding the generic implications of these isolated events have been identified. This paper will discuss the recent events of significant cracking in domestic and foreign plants, discuss the limitations of NDE in detecting SCC, identify deficiencies in information available in this area, discuss the USNRC approach to address these issues, and discuss the development of an international cooperative effort. (authors)

  5. Influence of composition gradients on weld metal creep behavior: An analysis based on laminate composites

    SciTech Connect (OSTI)

    Choi, I.

    1989-01-01

    The effects of weld metal microsegregation, as altered by post-weld heat treatments, on both low and high temperatures tensile properties were investigated on Monel alloy 400. Flat, all weld metal, tensile specimens were machined from single pass GTA welds and were heat treated in vacuum in the range of 600 C to 1000 C to produce samples with different composition gradients. Short-time tensile tests were run at room temperature and elevated temperature. Long-time constant load creep tests were performed at 500 C. The room temperature mechanical properties of the as-welded specimen and heat treated specimens were similar and thus unaffected by variations in composition gradients. In contrast, at high temperatures the steady state creep rates decreased, rupture strains increased, and rupture lives decreases with increases in heat treatment temperature, that is, with decreases in the amplitudes of composition gradients. The deformation behavior of solidified dendritic structure was modeled based on results obtained on laminate composites of nickel and copper. The laminates, prepared by roll bonding, were annealed to produce controlled composition gradients with dimensions equivalent to those observed in the weld metal. The steady state creep rates of laminate composites decreased with increases in heat treatment time, that is, with decreases in the amplitudes of composition gradients. To rationalize the creep properties of each component in laminate composites, nickel-copper solid solutions having systematic compositional variations were prepared and tested under the same conditions as the laminate composites. The creep rates of nickel-copper solid solutions showed a minimum with nickel composition.

  6. Boundary Layer Cloud Turbulence Characteristics

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Boundary Layer Cloud Turbulence Characteristics Virendra Ghate Bruce Albrecht Parameter Observational Readiness (/10) Modeling Need (/10) Cloud Boundaries 9 9 Cloud Fraction Variance Skewness Up/Downdraft coverage Dominant Freq. signal Dissipation rate ??? Observation-Modeling Interface

  7. Intermetallic Layers in Soldered Joints

    Energy Science and Technology Software Center (OSTI)

    1998-12-10

    ILAG solves the one-dimensional partial differential equations describing the multiphase, multicomponent, solid-state diffusion-controlled growth of intermetallic layers in soldered joints. This software provides an analysis capability for materials researchers to examine intermetallic growth mechanisms in a wide variety of defense and commercial applications involving both traditional and advanced materials. ILAG calculates the interface positions of the layers, as well as the spatial distribution of constituent mass fractions, and outputs the results at user-prescribed simulation times.

  8. Yucca Mountain Waste Package Closure System Robotic Welding and Inspection System

    SciTech Connect (OSTI)

    C. I. Nichol; D. P. Pace; E. D. Larsen; T. R. McJunkin; D. E. Clark; M. L. Clark; K. L. Skinner; A. D. Watkins; H. B. Smartt

    2011-10-01

    The Waste Package Closure System (WPCS), for the closure of radioactive waste in canisters for permanent storage of spent nuclear fuel (SNF) and high-level waste in the Yucca Mountain Repository was designed, fabricated, and successfully demonstrated at the Idaho National Laboratory (INL). This article focuses on the robotic hardware and tools necessary to remotely weld and inspect the closure lid welds. The system was operated remotely and designed for use in a radiation field, due to the SNF contained in the waste packages being closed.

  9. Remote reactor repair: GTA (gas tungsten Arc) weld cracking caused by entrapped helium

    SciTech Connect (OSTI)

    Kanne, W.R. Jr.

    1988-01-01

    A repair patch was welded to the wall of a nuclear reactor tank using remotely controlled thirty-foot long robot arms. Further repair was halted when gas tungsten arc (GTA) welds joining type 304L stainless steel patches to the 304 stainless steel wall developed toe cracks in the heat-affected zone (HAZ). The role of helium in cracking was investigated using material with entrapped helium from tritium decay. As a result of this investigation, and of an extensive array of diagnostic tests performed on reactor tank wall material, helium embrittlement was shown to be the cause of the toe cracks.

  10. The influence of composition gradients on tensile properties of weld metal

    SciTech Connect (OSTI)

    Choi, I.D.; Matlock, D.K.; Olson, D.L.

    1988-09-01

    In this study, the effects of weld metal microsegregation, as altered by post-weld heat treatments, on both low and high temperature tensile properties were investigated on an alloy system which exhibits significant segregation of the major alloying elements without complex transformations or precipitation. Monel alloy 400, which consists primarily of nickel and copper, was chosen as a model system. This system is a single phase FCC solid solution at all temperatures, and has a low distribution coefficient, k. On solidification, significant microsegregation occurs with copper segregating to the interdendritic boundaries.

  11. Hybrid window layer for photovoltaic cells

    DOE Patents [OSTI]

    Deng, Xunming

    2010-02-23

    A novel photovoltaic solar cell and method of making the same are disclosed. The solar cell includes: at least one absorber layer which could either be a lightly doped layer or an undoped layer, and at least a doped window-layers which comprise at least two sub-window-layers. The first sub-window-layer, which is next to the absorber-layer, is deposited to form desirable junction with the absorber-layer. The second sub-window-layer, which is next to the first sub-window-layer, but not in direct contact with the absorber-layer, is deposited in order to have transmission higher than the first-sub-window-layer.

  12. Hybrid window layer for photovoltaic cells

    DOE Patents [OSTI]

    Deng, Xunming; Liao, Xianbo; Du, Wenhui

    2011-10-04

    A novel photovoltaic solar cell and method of making the same are disclosed. The solar cell includes: at least one absorber layer which could either be a lightly doped layer or an undoped layer, and at least a doped window-layers which comprise at least two sub-window-layers. The first sub-window-layer, which is next to the absorber-layer, is deposited to form desirable junction with the absorber-layer. The second sub-window-layer, which is next to the first sub-window-layer, but not in direct contact with the absorber-layer, is deposited in order to have transmission higher than the first-sub-window-layer.

  13. Hybrid window layer for photovoltaic cells

    DOE Patents [OSTI]

    Deng, Xunming; Liao, Xianbo; Du, Wenhui

    2011-02-01

    A novel photovoltaic solar cell and method of making the same are disclosed. The solar cell includes: at least one absorber layer which could either be a lightly doped layer or an undoped layer, and at least a doped window-layers which comprise at least two sub-window-layers. The first sub-window-layer, which is next to the absorber-layer, is deposited to form desirable junction with the absorber-layer. The second sub-window-layer, which is next to the first sub-window-layer, but not in direct contact with the absorber-layer, is deposited in order to have transmission higher than the first-sub-window-layer.

  14. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc welding of chromium-nickel steel to nickel-copper

    SciTech Connect (OSTI)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-2602-ASME-3 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of 300 series Cr-Ni steels (P-8-1) to nickel-copper N04400 (P-42), in thickness range 0.035 to 0.432 inch; filler metal is ERNiCu-7 (F-42); shielding gas is argon.

  15. Welding procedure specification: gas tungsten arc welding of nickel-copper to nickel-chromium-iron. Supplement 1. Records of procedure qualification tests

    SciTech Connect (OSTI)

    Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

    1986-06-01

    Procedure WPS-2303-ASME-3 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of nickel-copper N04400 (P-42) to nickel-chromium-iron N06600 (P-43), in thickness range of 0.035 to 0.432 inch; filler metal is ERNiCu-7 (F-42); shielding gas is argon.

  16. Mechanical properties and microstructures of a magnesium alloy gas tungsten arc welded with a cadmium chloride flux

    SciTech Connect (OSTI)

    Zhang, Z.D.; Liu, L.M. Shen, Y.; Wang, L.

    2008-01-15

    Gas tungsten arc (GTA) welds were prepared on 5-mm thick plates of wrought magnesium AZ31B alloy, using an activated flux. The microstructural characteristics of the weld joint were investigated using optical and scanning microscopy, and the fusion zone microstructure was compared with that of the base metal. The elemental distribution was also investigated by electron probe microanalysis (EPMA). Mechanical properties were determined by standard tensile tests on small-scale specimens. The as-welded fusion zone prepared using a CdCl{sub 2} flux exhibited a larger grain size than that prepared without flux; the microstructure consisted of matrix {alpha}-Mg, eutectic {alpha}-Mg and {beta}-Al{sub 12}Mg{sub 17}. The HAZ was observed to be slightly wider for the weld prepared with a CdCl{sub 2} flux compared to that prepared without flux; thus the tensile strength was lower for the flux-prepared weld. The fact that neither Cd nor Cl was detected in the weld seam by EPMA indicates that the CdCl{sub 2} flux has a small effect on convection in the weld pool.

  17. Evaluation of pitting corrosion resistance of high-alloyed stainless steels welds for FGD plants in Korea

    SciTech Connect (OSTI)

    Baek, K.K.; Sung, H.J.; Im, C.S.; Hong, I.P.; Kim, D.K.

    1998-12-31

    For successful application of high-alloyed stainless steels for Flue Gas Desulfurization (FGD) plants, pitting corrosion resistance of arc welds of N-added 6%Mo austenitic stainless steels (UNS N 08367) and super duplex stainless steels (UNS S 32550) made with various filler metals were evaluated using the Green Death solution. For Gas Tungsten Arc (GTA) and Gas Metal Arc (GMA) welds of N 08367, Critical Pitting Temperature (CPT) of base metal was 65--70 C, whereas weld made by ERNiCrMo-3 filler metal yielded CPT of 50 C. Welds made by ERNiCrMo-10 or ERNiCrMo-4 filler metals showed CPT of 60--65 C and 65--70C, respectively. For GTA and GMA welds of S 32550, CPT of welds made by ERNiCrMo-3 was 45--50 C, indicating that the filler metal can provide pitting corrosion resistance matching the S 32550 alloy. Thus, a proper pitting corrosion resistance of weldments of high-alloy stainless steels can be achieved by selecting filler metals having at least +10 higher Pitting Resistance Equivalent Number (PRE{sub N}) value than the base metal regardless of the type of arc welding process. The over-alloyed filler metals would compensate preferential segregation of Cr, MO along the dendrite boundary, which made the dendrite core more susceptible to pitting. Nitrogen addition to the GTA welds of N 08367 made with ERNiCrMo-3 failed to improve pitting corrosion resistance, which was attributed to the precipitation of nitrogen in the weld metal in the form of Nb-nitride.

  18. Microstructure evolution in the fusion welding of heat-treatable Al-Cu-Li alloys. Ph.D. Thesis

    SciTech Connect (OSTI)

    Hou, K.

    1994-01-01

    Aluminum alloys 2090 and 2195 and Al-2.5Cu were welded autogenously using the gas tungsten-arc (GTA) and CO2 laser beam (LB) welding processes. Relationships between microstructure and mechanical properties in the fusion zone (FZ) and the heat-affected zone (HAZ) in both the as-welded and the postweld heat-treated conditions were studied. Solute segregation due to non-equilibrium solidification in the FZ and its effect on precipitation after postweld aging was quantitatively investigated. After aging treatment, precipitates were found surrounding eutectic regions where higher solute content was measured. Fast cooling LB weld exhibited narrower solute enriched regions and narrower precipitate segregation zones (PSZ`s) adjacent to the eutectic. A partial recovery of strength and hardness in the FZ`s was achieved by postweld aging at 160 C and 190 C for 16 hours. A higher Li/Cu ratio in 2090 promoted the formation of uniformly distributed delta(prime) precipitates in the as-welded HAZ. An evident reduction in the FZ ductility occurred in the 2195 LB welds due to the existence of porosity and shrinkage cavities, and the constraint effect from narrower FZ`s. GTA welds in both 2090 and 2195 alloys exhibited a hardness recovery in the near HAZ, which was not obvious in the LB welds. Postweld aging enhanced this hardness variation. Overaging, dissolution and reprecipitation of various strengthening precipitates occurred in the different regions of the HAZ, and consequently induced the hardness variation. Higher heat inputs increased the HAZ width and enhanced the hardness increase in the near HAZ. Aged HAZ microstructure was affected by the precipitation in the as-welded condition. The formation of Li-containing precipitates in the GTA HAZ, especially alpha(prime) in Li-lean 2195, consumed Li from the matrix. Consequently, the precipitation of T1 was affected.

  19. GTA weld penetration and the effects of deviations in machine variables

    SciTech Connect (OSTI)

    Giedt, W.H.

    1987-07-01

    Analytical models for predicting the temperature distribution during GTA welding are reviewed with the purpose of developing a procedure for investigating the effects of deviations in machine parameters. The objective was to determine the accuracy required in machine settings to obtain reproducible results. This review revealed a wide range of published values (21 to 90%) for the arc heating efficiency. Low values (21 to 65%) were associated with evaluation of efficiency using constant property conduction models. Values from 75 to 90% were determined from calorimetric type measurements and are applicable for more accurate numerical solution procedures. Although numerical solutions can yield better overall weld zone predictions, calculations are lengthy and complex. In view of this and the indication that acceptable agreement with experimental measurements can be achieved with the moving-point-source solution, it was utilized to investigate the effects of deviations or errors in voltage, current, and travel speed on GTA weld penetration. Variations resulting from welding within current goals for voltage (+-0.1 V), current (+-3.0 A), and travel speed (+-2.0%) were found to be +-2 to 4%, with voltage and current being more influential than travel speed.

  20. Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Yu, Xinghua; Qiao, Dongxiao; Wang, Yanli; Zhang, Wei; Feng, Zhili

    2014-01-01

    A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductilemore » fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.« less

  1. Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

    SciTech Connect (OSTI)

    Lim, Yong Chae [ORNL; Sanderson, Samuel [MegaStir Technologies LLC; Mahoney, Murray [Consultant; Yu, Xinghua [ORNL; Qiao, Dongxiao [ORNL; Wang, Yanli [ORNL; Zhang, Wei [ORNL; Feng, Zhili [ORNL

    2014-01-01

    A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductile fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.

  2. Laser-ultrasonic inspection of hybrid laser-arc welded HSLA-65 steel

    SciTech Connect (OSTI)

    Lévesque, D.; Rousseau, G.; Monchalin, J.-P. [National Research Council Canada, Boucherville, QC (Canada); Wanjara, P.; Cao, X. [National Research Council Canada, Montreal, QC (Canada)

    2014-02-18

    The hybrid laser-arc welding (HLAW) process is a relatively low heat input joining technology that combines the synergistic qualities of both the high energy density laser beam for deep penetration and the arc for wide fit-up gap tolerance. This process is especially suitable for the shipbuilding industry where thick-gauge section, long steel plates have been widely used in a butt joint configuration. In this study, preliminary exploration was carried out to detect and visualize the welding defects using laser ultrasonics combined with the synthetic aperture focusing technique (SAFT). Results obtained on 9.3 mm thick butt-welded HSLA-65 steel plates indicated that the laser-ultrasonic SAFT inspection technique can successfully detect and visualize the presence of porosity, lack of fusion and internal crack defects. This was further confirmed by X-ray digital radiography and metallography. The results obtained clearly show the potential of using the laser-ultrasonic technology for the automated inspection of hybrid laser-arc welds.

  3. Paraxial ray-tracing approach for the simulation of ultrasonic inspection of welds

    SciTech Connect (OSTI)

    Gardahaut, Audrey; Jezzine, Karim [CEA, LIST, Digiteo Labs, Bât 565, PC 120, F-91191, Gif-sur-Yvette (France); Cassereau, Didier [CNRS, UMR 7623, LIP, 15 rue de l'école de médecine, 75006 Paris, France and ESPCI ParisTech, 10 rue Vauquelin, 75005 Paris (France)

    2014-02-18

    On-site inspection of bimetallic or austenitic welds can be very difficult to interpret owing to their internal structures. Skewing and splitting of the ultrasonic beam may occur due to the anisotropic and inhomogeneous properties of the welding material. In this paper, we present a ray-based method to simulate the propagation of ultrasonic waves in such structures. The formalism is based on dynamic ray tracing system in Cartesian coordinates along a reference ray. Standard ray tracing consists in the solution of a system of linear ordinary differential equations of the first order and is used to determine the trajectory of the ray. Likewise, dynamic ray tracing (DRT) also called paraxial ray tracing consists in the solution of an additional system of linear ordinary differential equations along the ray allowing paraxial quantities to be computed. It is used to evaluate the geometrical spreading and amplitude along the ray and in its vicinity. DRT is applied on a smooth representation of the elastic properties of the weld obtained thanks to an image processing technique applied on a macrograph of the weld. Simulation results are presented and compared to finite elements and experimental results.

  4. Diffusion welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon

    DOE Patents [OSTI]

    Byrne, Stephen C.; Vasudevan, Asuri K.

    1984-01-01

    A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a metal conductor diffusion welded to a portion of a ceramic electrode body having a level of free metal or metal alloy sufficient to effect a metal bond.

  5. Finite element simulation of magnetic detection of creep damage at seam welds

    SciTech Connect (OSTI)

    Sablik, M.J.; Rubin, S.W.; Jiles, D.C.; Kaminski, D.; Bi, Y.

    1996-09-01

    Using appropriately modified magnetization curves for each element of creep-damaged material, a finite element calculation has been carried out to simulate magnetic detection of non-uniform creep damage around a seam weld in a 2.25 Cr 1 Mo steam pipe. The magnetization curves for the creep-damaged elements were obtained from an earlier model for the magnetic effect of a uniformly creep-damaged material as given by Chen, et al. In the finite element calculation, a magnetic C-core with primary and secondary coils was placed with its pole pieces flush against the specimen in the vicinity of the weld. The secondary emf was shown to be reduced when creep damage was present inside the pipe wall at the cusp of weld and in the vicinity of the cusp. The C-core detected the creep damage best if it completely spanned the weld seam width. Also, the current in the primary needed to be such that the C-core was not magnetically saturated.

  6. Estimate of the allowable dimensions of diagnosed defects in category III and IV welded pipeline joints{sup 1}

    SciTech Connect (OSTI)

    Grin', E. A.; Bochkarev, V. I.

    2013-01-15

    An approach for estimating the permissible dimensions of technological defects in butt welded joints in category III and IV pipelines is described. The allowable size of a welding defect is determined from the condition of compliance with the specifications on strength for a reference cross section (damaged joint) of the pipeline taking into account its weakening by a given defect.With regard to the fairly widespread discovery of technological defects in butt welded joints during diagnostics of auxiliary pipelines for thermal electric power plants, the proposed approach can be used in practice by repair and consulting organizations.

  7. Stress corrosion cracking resistance of alloys 600 and 690 and compatible weld metals in BWRs: Final report

    SciTech Connect (OSTI)

    Page, R. A.; McMinn, A.

    1988-07-01

    The relative susceptibilities of alloy 600 and 690 base metals and I-82, I-182, R-127 and R-135 weld metals to intergranular stress corrosion cracking (IGSCC) in either pure water or a simulated resin intrusion environment at 288/degree/C were evaluated. Alloy 600, I-182, and I-82 weld metals were susceptible to various degrees of IGSCC in oxygen containing pure water when creviced, and immune to IGSCC when uncreviced. Alloy 690 was immune to IGSCC under all pure water conditions. Alloy 500, alloy 690, I-182, and I-82 were all susceptible to cracking in the simulated resin intrusion environment, although alloy 690 exhibited the greatest resistance to SCC. The high chromium experimental weld alloy were immune to cracking under all conditions examined. The IGSCC susceptibility of seven different weld metals used to weld alloy 600 and A508 were also evaluated in the resin intrusion environment at 288/degree/C. Weldments made with I-625, I-182, and I-82 (GTAW) were the most susceptible, whereas welds made with I-132 were the least susceptible. Most of the weldments failed at the fusion line between the weld metal and the A508 steel, and the SCC susceptibility increased with increasing hardness measured at the fusion line. There was no effect of crevice condition or heat treatment on SCC susceptibility. The SCC susceptibility of Type 316 NG stainless steel welded with R-127, R-135, I-72 and Type 308L weld metals was evaluated in pure water and resin intrusion environments at 288/degree/C. All of the materials were immune to SCC in the pure water environment. In the resin intrusion environment, both the I-72 and R-135 weld metals were immune to SACC, but the R-127 and Type 308L weld metals exhibited SCC. The Type 316 NG stainless steel was susceptible to transgranular SCC in the resin intrusion environment, except when welded with I-72, in which case it was immune. 36 refs., 4 tabs.

  8. Method and design for externally applied laser welding of internal connections in a high power electrochemical cell

    DOE Patents [OSTI]

    Martin, Charles E; Fontaine, Lucien; Gardner, William H

    2014-01-21

    An electrochemical cell includes components that are welded from an external source after the components are assembled in a cell canister. The cell canister houses electrode tabs and a core insert. An end cap insert is disposed opposite the core insert. An external weld source, such as a laser beam, is applied to the end cap insert, such that the end cap insert, the electrode tabs, and the core insert are electrically coupled by a weld which extends from the end cap insert to the core insert.

  9. Ultrasonic Flaw Detection of Cracks and Machined Flaws as Observed Through Austenitic Stainless Steel Piping Welds

    SciTech Connect (OSTI)

    Anderson, Michael T.; Cinson, Anthony D.; Crawford, Susan L.; Cumblidge, Stephen E.; Diaz, Aaron A.

    2009-07-01

    Piping welds in the pressure boundary of light water reactors (LWRs) are subject to a volumetric examination based on Section XI of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. Due to access limitations and high background radiation levels, the technique used is primarily ultrasonic rather than radiographic. Many of the austenitic welds in safety-related piping systems provide limited access to both sides of the weld, so a far-side examination is necessary. Historically, far-side inspections have performed poorly because of the coarse and elongated grains that make up the microstructures of austenitic weldments. The large grains cause the ultrasound to be scattered, attenuated, and redirected. Additionally, grain boundaries or weld geometry may reflect coherent ultrasonic echoes, making flaw detection and discrimination a more challenging endeavor. Previous studies conducted at the Pacific Northwest National Laboratory (PNNL) on ultrasonic far-side examinations in austenitic piping welds involved the application of conventional transducers, use of low-frequency Synthetic Aperture Focusing Techniques (SAFT), and ultrasonic phased-array (PA) methods on specimens containing implanted thermal fatigue cracks and machined reflectors [1-2]. From these studies, PA inspection provided the best results, detecting nearly all of the flaws from the far side. These results were presented at the Fifth International Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurised Components in 2006. This led to an invitation to examine field-removed specimens containing service-induced intergranular stress corrosion cracks (IGSCC) at the Electric Power Research Institute’s (EPRI) Nondestructive Evaluation (NDE) Center, in Charlotte, North Carolina. Results from this activity are presented.

  10. Digital control and data acquisition for high-value GTA welding

    SciTech Connect (OSTI)

    George, T.G.; Franco-Ferreira, E.A.

    1993-10-01

    Electric power for the Cassini space probe wig be provided by radioisotope thermoelectric generators (RTGs) thermally driven by General-Purpose Heat Source (GPHS) modules. Each GPHS module contains four, 150-g, pellets of {sup 238}PuO{sub 2}, and each of the four pellets is encapsulated within a thin-wall iridium-alloy shell. GTA girth welding of these capsules is performed at Los Alamos National Laboratory (LANL) on an automated, digitally-controlled welding system. This paper discusses baseline design considerations for system automation and strategies employed to maximize process yield, improve process consistency, and generate required quality assurance information. Design of the automated girth welding system was driven by a number of factors which militated for precise parametric control and data acquisition. Foremost among these factors was the extraordinary value of the capsule components. In addition, DOE order 5700.6B, which took effect on 23 September 1986, required that all operations adhere to strict levels of process quality assurance. A detailed technical specification for the GPHS welding system was developed on the basis of a joint Lanl/Westinghouse Savannah River Company (WSRC) design effort. After a competitive bidding process, Jetline Engineering, Inc., of Irvine, California, was selected as the system manufacturer. During the period over which four identical welding systems were fabricated, very close liason was maintained between the LANL/WSRC technical representatives and the vendor. The level of rapport was outstanding, and the end result was the 1990 delivery of four systems that met or exceeded all specification requirements.

  11. In mold laser welding for high precision polymer based optical components

    SciTech Connect (OSTI)

    Oliveira, N., E-mail: id2694@alunos.uminho.pt, E-mail: pontes@dep.uminho.pt; Pontes, A. J., E-mail: id2694@alunos.uminho.pt, E-mail: pontes@dep.uminho.pt [IPC - Institute for Polymers and Composites, Department of Polymer Engineering, University of Minho, 4800-058 Guimarăes (Portugal)

    2014-05-15

    To assemble a complete subsystem as a rear lamp, is necessary to have different machines and to perform several tasks. This necessity obliges the companies to have large structures to support all the assembling process. These huge structures are very costly and have as a consequence the reduction of the competitiveness of the companies. The process presented in this document has the intention of reducing the number of tasks needed to produce the final subsystem/product. To achieve this goal were combined several technologies, as in-mould assembling, laser welding and LEDs (light-emitting diode). One of the advantages of this process was the utilization of only one injection molding machine with three injection units to do all the assembling process. To achieve the main objective, firstly, the rear lamp was designed according to with the legislation of UNECE Vehicle Regulations - 1958 Agreements; Regulation No. 50 -Rev.2 - Position lamps, stop lamps, direction indicators for motorcycles. Posterior several polymeric materials were studied at different levels. Initial were studied several concentrations of carbon nanotubes mixed with PC (polycarbonate). This had the objective of determine, if these materials are suitable to conduct the necessary electric current to turn on the different LEDs. One of the main advantages of this process is the use of the laser transmission welded process. Since, with this welding technology is possible reduce the complexity of the final part. To understand the potentialities of this technology a combination of two materials was studied. The studied showed that all materials presented a high transparency to the laser beam. In terms of weld process, the study showed that the best welding conditions are the lowest velocity, diameter and power. With these studies was possible conclude that this new process is suitable to be implemented at the industrial level.

  12. Microstructure, crystallographic texture and mechanical properties of friction stir welded AA2017A

    SciTech Connect (OSTI)

    Ahmed, M.M.Z.; Wynne, B.P.; Rainforth, W.M.; Threadgill, P.L.

    2012-02-15

    In this study a thick section (20 mm) friction stir welded AA2017A-T451 has been characterized in terms of microstructure, crystallographic texture and mechanical properties. For microstructural analysis both optical and scanning electron microscopes have been used. A detailed crystallographic texture analysis has been carried out using the electron back scattering diffraction technique. Crystallographic texture has been examined in both shoulder and probe affected regions of the weld NG. An entirely weak texture is observed at the shoulder affected region which is mainly explained by the effect of the sequential multi pass deformation experienced by both tool probe and tool shoulder. The texture in the probe dominated region at the AS side of the weld is relatively weak but still assembles the simple shear texture of FCC metals with B/B{sup Macron} and C components existing across the whole map. However, the texture is stronger at the RS than at the AS of the weld, mainly dominated byB/B{sup Macron} components and with C component almost absent across the map. An alternating bands between (B) components and (B{sup Macron }) component are observed only at the AS side of the weld. - Highlights: Black-Right-Pointing-Pointer Detailed investigation of microstructure and crystallographic texture. Black-Right-Pointing-Pointer The grain size is varied from the top to the bottom of the NG. Black-Right-Pointing-Pointer An entirely weak texture is observed at the shoulder affected region. Black-Right-Pointing-Pointer The texture in the probe affected region is dominated by simple shear texture.

  13. Experimental Investigations on Pulsed Nd:YAG Laser Welding of C17300 Copper-Beryllium and 49Ni-Fe Soft Magnetic Alloys

    SciTech Connect (OSTI)

    Mousavi, S. A. A. Akbari [School of Metallurgy and Materials Engineering, School of Engineering University of Tehran, Tehran (Iran, Islamic Republic of); School of Metallurgy and Materials Engineering, School of Engineering University of Tehran, Tehran (Iran, Islamic Republic of); Ebrahimzadeh, H. [School of Metallurgy and Materials Engineering, School of Engineering University of Tehran, Tehran (Iran, Islamic Republic of)

    2011-01-17

    Copper-beryllium and soft magnetic alloys must be joined in electrical and electro-mechanical applications. There is a high difference in melting temperatures of these alloys which cause to make the joining process very difficult. In addition, copper-beryllium alloys are of age hardenable alloys and precipitations can brittle the weld. 49Ni-Fe alloy is very hot crack sensitive. Moreover, these alloys have different heat transfer coefficients and reflection of laser beam in laser welding process. Therefore, the control of welding parameters on the formation of adequate weld puddle composition is very difficult. Laser welding is an advanced technique for joining of dissimilar materials since it can precisely control and adjust the welding parameters. In this study, a 100W Nd:YAG pulsed laser machine was used for joining 49Ni-Fe soft magnetic to C17300 copper-beryllium alloys. Welding of samples was carried out autogenously by changing the pulse duration, diameter of beam, welding speed, voltage and frequency. The spacing between samples was set to almost zero. The ample were butt welded. It was required to apply high voltage in this study due to high reflection coefficient of copper alloys. Metallography, SEM analysis, XRD and microhardness measurement was used for survey of results. The results show that the weld strength depends upon the chemical composition of the joints. To change the wells composition and heat input of the welds, it was attempted to deviate the laser focus away from the weld centerline. The best strength was achieved by deviation of the laser beam away about 0.1mm from the weld centerline. The result shows no intermetallic compounds if the laser beam is deviated away from the joint.

  14. Doped LZO buffer layers for laminated conductors

    DOE Patents [OSTI]

    Paranthaman, Mariappan Parans [Knoxville, TN; Schoop, Urs [Westborough, MA; Goyal, Amit [Knoxville, TN; Thieme, Cornelis Leo Hans [Westborough, MA; Verebelyi, Darren T. [Oxford, MA; Rupich, Martin W. [Framingham, MA

    2010-03-23

    A laminated conductor includes a metallic substrate having a surface, a biaxially textured buffer layer supported by the surface of the substrate, the biaxially textured buffer layer comprising LZO and a dopant for mitigating metal diffusion through the LZO, and a biaxially textured conductor layer supported by the biaxially textured buffer layer.

  15. Lubricant-infused nanoparticulate coatings assembled by layer...

    Office of Scientific and Technical Information (OSTI)

    Lubricant-infused nanoparticulate coatings assembled by layer-by-layer deposition Title: Lubricant-infused nanoparticulate coatings assembled by layer-by-layer deposition ...

  16. Organic photovoltaic cells utilizing ultrathin sensitizing layer

    DOE Patents [OSTI]

    Rand, Barry P.; Forrest, Stephen R.

    2011-05-24

    A photosensitive device includes a series of organic photoactive layers disposed between two electrodes. Each layer in the series is in direct contact with a next layer in the series. The series is arranged to form at least one donor-acceptor heterojunction, and includes a first organic photoactive layer comprising a first host material serving as a donor, a thin second organic photoactive layer comprising a second host material disposed between the first and a third organic photoactive layer, and the third organic photoactive layer comprising a third host material serving as an acceptor. The first, second, and third host materials are different. The thin second layer serves as an acceptor relative to the first layer or as a donor relative to the third layer.

  17. Chemical solution seed layer for rabits tapes

    SciTech Connect (OSTI)

    Goyal, Amit; Paranthaman, Mariappan; Wee, Sung-Hun

    2014-06-10

    A method for making a superconducting article includes the steps of providing a biaxially textured substrate. A seed layer is then deposited. The seed layer includes a double perovskite of the formula A.sub.2B'B''O.sub.6, where A is rare earth or alkaline earth metal and B' and B'' are different rare earth or transition metal cations. A superconductor layer is grown epitaxially such that the superconductor layer is supported by the seed layer.

  18. Buffer layer for thin film structures

    DOE Patents [OSTI]

    Foltyn, Stephen R.; Jia, Quanxi; Arendt, Paul N.; Wang, Haiyan

    2010-06-15

    A composite structure including a base substrate and a layer of a mixture of strontium titanate and strontium ruthenate is provided. A superconducting article can include a composite structure including an outermost layer of magnesium oxide, a buffer layer of strontium titanate or a mixture of strontium titanate and strontium ruthenate and a top-layer of a superconducting material such as YBCO upon the buffer layer.

  19. Buffer layer for thin film structures

    DOE Patents [OSTI]

    Foltyn, Stephen R.; Jia, Quanxi; Arendt, Paul N.; Wang, Haiyan

    2006-10-31

    A composite structure including a base substrate and a layer of a mixture of strontium titanate and strontium ruthenate is provided. A superconducting article can include a composite structure including an outermost layer of magnesium oxide, a buffer layer of strontium titanate or a mixture of strontium titanate and strontium ruthenate and a top-layer of a superconducting material such as YBCO upon the buffer layer.

  20. Material property evaluations of bimetallic welds, stainless steel saw fusion lines, and materials affected by dynamic strain aging

    SciTech Connect (OSTI)

    Rudland, D.; Scott, P.; Marschall, C.; Wilkowski, G.

    1997-04-01

    Pipe fracture analyses can often reasonably predict the behavior of flawed piping. However, there are material applications with uncertainties in fracture behavior. This paper summarizes work on three such cases. First, the fracture behavior of bimetallic welds are discussed. The purpose of the study was to determine if current fracture analyses can predict the response of pipe with flaws in bimetallic welds. The weld joined sections of A516 Grade 70 carbon steel to F316 stainless steel. The crack was along the carbon steel base metal to Inconel 182 weld metal fusion line. Material properties from tensile and C(T) specimens were used to predict large pipe response. The major conclusion from the work is that fracture behavior of the weld could be evaluated with reasonable accuracy using properties of the carbon steel pipe and conventional J-estimation analyses. However, results may not be generally true for all bimetallic welds. Second, the toughness of austenitic steel submerged-arc weld (SAW) fusion lines is discussed. During large-scale pipe tests with flaws in the center of the SAW, the crack tended to grow into the fusion line. The fracture toughness of the base metal, the SAW, and the fusion line were determined and compared. The major conclusion reached is that although the fusion line had a higher initiation toughness than the weld metal, the fusion-line J-R curve reached a steady-state value while the SAW J-R curve increased. Last, carbon steel fracture experiments containing circumferential flaws with periods of unstable crack jumps during steady ductile tearing are discussed. These instabilities are believed to be due to dynamic strain aging (DSA). The paper discusses DSA, a screening criteria developed to predict DSA, and the ability of the current J-based methodologies to assess the effect of these crack instabilities. The effect of loading rate on the strength and toughness of several different carbon steel pipes at LWR temperatures is also discussed.

  1. Fracture toughness, tensile and stress corrosion cracking properties of Alloy 600, Alloy 690 and their welds in water

    SciTech Connect (OSTI)

    Brown, C.M.; Mills, W.J.

    1996-10-01

    The fracture toughness and tensile properties of Alloy 600, Alloy 690 and their welds, EN82H and EN52, were characterized in 54 and 338 C water with an elevated hydrogen content. Results were compared with air data to evaluate the effect of low and high temperature water on mechanical properties. In addition, the stress corrosion cracking (SCC) behavior of EN82H and EN52 welds was evaluated in 360 C water with high hydrogen. Elastic-plastic J{sub c} fracture toughness testing revealed that the fracture resistance of all test materials was exceptionally high in 54 and 338 C air and 338 C water, demonstrating that fracture properties were essentially unaffected by the high temperature water environment. In 54 C water, however, J{sub c} values for EN82H and EN52 welds were reduced by an order of magnitude, and Alloy 690 showed a five-fold decrease in J{sub c}. Tensile properties for all test materials were essentially unaffected by the water environment, except for the total elongation for EN82H welds which was significantly reduced in 54 C water. At a strain rate of 5 x 10{sup 6} sec{sup {minus}1} in low temperature water, there appears to be sufficient time for environmental interactions to restrict ductility in EN82H welds. Constant-load testing of precracked weld specimens in 360 C water resulted in extensive intergranular SCC in EN82H welds loaded to K{sub I} levels between 35 and 55 MPa {radical}m, whereas no SCC occurred in EN52 welds under comparable test conditions.

  2. Deformation Behavior of Laser Welds in High Temperature Oxidation Resistant Fe-Cr-Al Alloys for Fuel Cladding Applications

    SciTech Connect (OSTI)

    Field, Kevin G; Gussev, Maxim N; Yamamoto, Yukinori; Snead, Lance Lewis

    2014-11-01

    Ferritic-structured Fe-Cr-Al alloys are being developed and show promise as oxidation resistant accident tolerant light water reactor fuel cladding. This study focuses on investigating the weldability of three model alloys in a range of Fe-(13-17.5)Cr-(3-4.4)Al in weight percent with a minor addition of yttrium using laser-welding techniques. A detailed study on the mechanical performance of bead-on-plate welds has been carried out to determine the performance of welds as a function of alloy composition. Laser welding resulted in a defect free weld devoid of cracking or inclusions for all alloys studied. Results indicated a reduction in the yield strength within the fusion zone compared to the base metal. Yield strength reduction was found to be primarily constrained to the fusion zone due to grain coarsening with a less severe reduction in the heat affected zone. No significant correlation was found between the deformation behavior/mechanical performance of welds and the level of Cr or Al in the alloy ranges studied.

  3. Optimized capping layers for EUV multilayers

    DOE Patents [OSTI]

    Bajt, Sasa; Folta, James A.; Spiller, Eberhard A.

    2004-08-24

    A new capping multilayer structure for EUV-reflective Mo/Si multilayers consists of two layers: A top layer that protects the multilayer structure from the environment and a bottom layer that acts as a diffusion barrier between the top layer and the structure beneath. One embodiment combines a first layer of Ru with a second layer of B.sub.4 C. Another embodiment combines a first layer of Ru with a second layer of Mo. These embodiments have the additional advantage that the reflectivity is also enhanced. Ru has the best oxidation resistance of all materials investigated so far. B.sub.4 C is an excellent barrier against silicide formation while the silicide layer formed at the Si boundary is well controlled.

  4. Effects of Fusion Zone Size and Failure Mode on Peak Load and Energy Absorption of Advanced High Strength Steel Spot Welds

    SciTech Connect (OSTI)

    Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2007-01-01

    This paper examines the effects of fusion zone size on failure modes, static strength and energy absorption of resistance spot welds (RSW) of advanced high strength steels (AHSS). DP800 and TRIP800 spot welds are considered. The main failure modes for spot welds are nugget pullout and interfacial fracture. Partial interfacial fracture is also observed. The critical fusion zone sizes to ensure nugget pull-out failure mode are developed for both DP800 and TRIP800 using limit load based analytical model and micro-hardness measurements of the weld cross sections. Static weld strength tests using cross tension samples were performed on the joint populations with controlled fusion zone sizes. The resulted peak load and energy absorption levels associated with each failure mode were studied for all the weld populations using statistical data analysis tools. The results in this study show that AHSS spot welds with fusion zone size of can not produce nugget pullout mode for both the DP800 and TRIP800 materials examined. The critical fusion zone size for nugget pullout shall be derived for individual materials based on different base metal properties as well as different heat affected zone (HAZ) and weld properties resulted from different welding parameters.

  5. Ultrasonic Spot Welding of AZ31B to Galvanized Mild Steel

    SciTech Connect (OSTI)

    Pan, Dr. Tsung-Yu; Franklin, Teresa; Pan, Professor Jwo; Brown, Elliot; Santella, Michael L

    2010-01-01

    Ultrasonic spot welds were made between sheets of 0.8-mm-thick hot-dip-galvanized mild steel and 1.6-mm-thick AZ31B-H24. Lap-shear strengths of 3.0-4.2 kN were achieved with weld times of 0.3-1.2 s. Failure to achieve strong bonding of joints where the Zn coating was removed from the steel surface indicate that Zn is essential to the bonding mechanism. Microstructure characterization and microchemical analysis indicated temperatures at the AZ31-steel interfaces reached at least 344 C in less than 0.3 s. The elevated temperature conditions promoted annealing of the AZ31-H24 metal and chemical reactions between it and the Zn coating.

  6. Plasma effect on weld pool surface reconstruction by shape-from-polarization analysis

    SciTech Connect (OSTI)

    Coniglio, N.; Mathieu, A.

    2014-03-31

    The polarimetric state of the thermal radiations emitted by the weld metal contains geometric information about the emitting surface. Even though the analysed thermal radiation has a wavelength corresponding to a blind spectral window of the arc plasma, the physical presence of the arc plasma itself interferes with the rays radiated by the weld pool surface before attaining the polarimeter, thus modifying the geometric information transported by the ray. In the present work, the effect of the arc plasma-surrounding zone on the polarimetric state and propagation direction of the radiated ray is analyzed. The interaction with the arc plasma zone induces a drop in ray intensity and a refraction of ray optical path.

  7. Weld defect distributions in offshore structures and their influence on structural reliability

    SciTech Connect (OSTI)

    Rogerson, J.H.; Wong, W.K.

    1982-01-01

    Failure by fracture is a serious possible fracture mode of steel offshore structures particularly in hostile, low-temperature environments. Such fracture usually initiates from flaws in regions of stress concentration. For any probabilistic failure analysis to be credible, it is necessary to have a good estimate of the flaw size and distribution. For fixed steel platforms the important flaw size distribution is the distribution of defect height in welds in node connections. Previous work has shown that different structures have similar defect distributions which suggests that a function can be derived for the generality of such structures. Data has been analyzed relating to > 1000 m of weld in one North Sea structure. From this can be seen that a Weibull distribution is the appropriate function to use for defect height. Conclusions also are drawn about the required reliability of even an imperfect inspection and repair technique to significantly reduce failure probability.

  8. Novel concepts in weld science: Role of gradients and composite structure

    SciTech Connect (OSTI)

    Matlock, D.K.; Olson, D.L.

    1992-08-31

    The effects of compositional and microstructural gradients on weld metal properties were investigated. The effects of compositional gradients were analyzed using thermodynamic and composite models. Brittle and ductile cracking behavior were investigated using both binary alloy single crystals and large grain castings. In both cases, the crack propagated along regions where the compositional gradients were the steepest. High temperature deformation of large wavelength compositonally modulated structures vas investigated to understand creep behavior in veld metal. At moderate temperatures, the creep behavior of cored materials was found to follow predictions based on the rule of mixtures composite analysis. At higher temperatures with the advent of dynamic mass transport the creep process is influenced by diffusion-promoted vacancy flow and time-dependent compositional gradient. The investigation found the critical gradient which will promote Kirkendall voids and has reported a creep rate behavior that suggests strong structural dependence, localized stress and vacancy transport influence. Weld metal, based on metal matrix composite, was also demonstrated.

  9. Stability of Y Ti O Precipitates in Friction Stir Welded Nanostructured Ferritic Alloys

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Yu, Xinghua; Mazumder, Baishakhi; Miller, Michael K; David, Stan A; Feng, Zhili

    2015-01-01

    Nanostructured ferritic alloys (NFAs), which have complex microstructures consisting of ultrafine ferritic grains with a dispersion of stable oxide particles and nanoclusters (NC), are promising materials for fuel cladding and structural applications in the next generation nuclear reactor. This study evaluates microstructure of friction stir welded NFA using electron microscopy and atom probe tomography (APT) techniques. APT results revealed NCs are coarsened and inhomogeneously distributed in the stir zone. Three hypotheses on coarsening of NC are presented.

  10. Stability of Y-Ti-O Precipitates in Friction Stir Welded Nanostructured Ferritic Alloys

    Office of Scientific and Technical Information (OSTI)

    Stability of Y-Ti-O Precipitates in Friction Stir Welded Nanostructured Ferritic Alloys X. Yu,1 B. Mazumder,2 M. K. Miller,2 S. A. David,1 and Z. Feng1 'Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831 2Center for Nanophase Materials Sciences, Oak Ridge National Laboratory, Oak Ridge, TN 37831 Abs tract Nanostructured ferritic alloys, which have complex microstructures consisting of ultrafine ferritic grains with a dispersion of stable oxide particles

  11. Ultrasonic Phased Array Technique for Accurate Flaw Sizing in Dissimilar Metal Welds

    SciTech Connect (OSTI)

    Jonathan D Buttram

    2005-03-11

    Described is a manual,portable non-destructive technique to determine the through wall height of cracks present in dissimilar metal welds used in the primary coolling systems of pressure water and boiler light water reactors. Current manual methods found in industry have proven not to exhibit the sizing accuracy required by ASME inspection requirement. The technique described demonstrated an accuracy approximately three times that required to ASME Section XI, Appendix 8 qualification.

  12. Heat-affected zone liquation crack on resistance spot welded TWIP steels

    SciTech Connect (OSTI)

    Saha, Dulal Chandra [Department of Advanced Materials Engineering, Dong-Eui University, 995 Eomgwangno, Busanjin-gu, Busan 614-714 (Korea, Republic of); Chang, InSung [Automotive Production Development Division, Hyundai Motor Company (Korea, Republic of); Park, Yeong-Do, E-mail: ypark@deu.ac.kr [Department of Advanced Materials Engineering, Dong-Eui University, 995 Eomgwangno, Busanjin-gu, Busan 614-714 (Korea, Republic of)

    2014-07-01

    In this study, the heat affected zone (HAZ) liquation crack and segregation behavior of the resistance spot welded twinning induced plasticity (TWIP) steel have been reported. Cracks appeared in the post-welded joints that originated at the partially melted zone (PMZ) and propagated from the PMZ through the heat affected zone (HAZ) to the base metal (BM). The crack length and crack opening widths were observed increasing with heat input; and the welding current was identified to be the most influencing parameter for crack formation. Cracks appeared at the PMZ when nugget diameter reached at 4.50 mm or above; and the liquation cracks were found to occur along two sides of the notch tip in the sheet direction rather than in the electrode direction. Cracks were backfilled with the liquid films which has lamellar structure and supposed to be the eutectic constituent. Co-segregation of alloy elements such as, C and Mn were detected on the liquid films by electron-probe microanalysis (EPMA) line scanning and element map which suggests that the liquid film was enrich of Mn and C. The eutectic constituent was identified by analyzing the calculated phase diagram along with thermal temperature history of finite element simulation. Preliminary experimental results showed that cracks have less/no significant effect on the static cross-tensile strength (CTS) and the tensile-shear strength (TSS). In addition, possible ways to avoid cracking were discussed. - Highlights: • The HAZ liquation crack during resistance spot welding of TWIP steel was examined. • Cracks were completely backfilled and healed with divorced eutectic secondary phase. • Co-segregation of C and Mn was detected in the cracked zone. • Heat input was the most influencing factor to initiate liquation crack. • Cracks have less/no significant effect on static tensile properties.

  13. Evaluating electric-resistance-welded tubing for refinery and chemical plant applications

    SciTech Connect (OSTI)

    Polk, C.J.; Hotaling, A.C. )

    1993-02-01

    A laboratory technique was developed to assess the potential for preferential attack along the longitudinal seam of electric-resistance-welded (ERW) carbon steel tubing exposed to refinery and chemical plant process streams. Used in conjunction with an evaluation of mill fabrication practices, the test procedure can identify high-quality ERW products that can be used in many applications in place of seamless components at significant cost savings.

  14. Development of Appropriate Spot Welding Practice for Advanced High Strength Steels (TRP 0114)

    SciTech Connect (OSTI)

    Brian Girvin; Warren Peterson; Jerry Gould

    2004-09-17

    This program evaluated the effects of common manufacturing variables on spike-tempering effectiveness. The investigation used design-of-experiment (DOE) techniques, and examined both dual-phase and martensitic grades of high-strength steels (HSS). The specific grades chosen for this project were: Dual-phase (DP) 600, galvannealed (GA), 1.55 mm (DP) 600; Dual-phase (DP) 980 (uncoated), 1.55 mm (DP) 980; and Martensitic (M) 1300, 1.55 mm (M) 1300. Common manufacturing conditions of interest included tempering practice (quench and temper time), button size, simulated part fitup (sheet angular misalignment and fitup), and electrode wear (increased electrode face diameter). All of these conditions were evaluated against mechanical performance (static and dynamic tensile shear). Weld hardness data was also used to examine correlations between mechanical performance and the degree of tempering. Mechanical performance data was used to develop empirical models. The models were used to examine the robustness of weld strength and toughness to the selected processing conditions. This was done using standard EWI techniques. Graphical representations of robustness were then coupled with metallographic data to relate mechanical properties to the effectiveness of spike tempering. Mechanical properties for all three materials were relatively robust to variation in tempering. Major deviations in mechanical properties were caused by degradation of the weld itself. This was supported by a lack of correlation between hardness data and mechanical results. Small button sizes and large electrode face diameters (worn electrodes) produced large reductions in both static and dynamic strength levels when compared to standard production setups. Dynamic strength was further degraded by edge-located welds.

  15. Inkjet Deposition of Layer-by-Layer Assembled Films

    SciTech Connect (OSTI)

    Andres, C. M.; Kotov, Nicholas A.

    2010-09-23

    Layer-by-layer assembly (LBL) can create advanced composites with exceptional properties unavailable by other means, but the laborious deposition process and multiple dipping cycles hamper their utilization in microtechnologies and electronics. Multiple rinse steps provide both structural control and thermodynamic stability to LBL multilayers, but they significantly limit their practical applications and contribute significantly to the processing time and waste. Here we demonstrate that by employing inkjet technology one can deliver the necessary quantities of LBL components required for film buildup without excess, eliminating the need for repetitive rinsing steps. This feature differentiates this approach from all other recognized LBL modalities. Using a model system of negatively charged gold nanoparticles and positively charged poly(diallyldimethylammonium) chloride, the material stability, nanoscale control over thickness, and particle coverage offered by the inkjet LBL technique are shown to be equal or better than the case of multilayers made with traditional dipping cycles. The opportunity for fast deposition of complex metallic patterns using a simple inkjet printer is also shown. The additive nature of LBL deposition based on the formation of insoluble nanoparticle-polyelectrolyte complexes of various compositions provides an excellent opportunity for versatile, multicomponent, and noncontact patterning for the simple production of stratified patterns that are much needed in advanced devices.

  16. Fabrication Flaw Density and Distribution In Repairs to Reactor Pressure Vessel and Piping Welds

    SciTech Connect (OSTI)

    GJ Schuster, FA Simonen, SR Doctor

    2008-04-01

    The Pacific Northwest National Laboratory is developing a generalized fabrication flaw distribution for the population of nuclear reactor pressure vessels and for piping welds in U.S. operating reactors. The purpose of the generalized flaw distribution is to predict component-specific flaw densities. The estimates of fabrication flaws are intended for use in fracture mechanics structural integrity assessments. Structural integrity assessments, such as estimating the frequency of loss-of-coolant accidents, are performed by computer codes that require, as input, accurate estimates of flaw densities. Welds from four different reactor pressure vessels and a collection of archived pipes have been studied to develop empirical estimates of fabrication flaw densities. This report describes the fabrication flaw distribution and characterization in the repair weld metal of vessels and piping. This work indicates that large flaws occur in these repairs. These results show that repair flaws are complex in composition and sometimes include cracks on the ends of the repair cavities. Parametric analysis using an exponential fit is performed on the data. The relevance of construction records is established for describing fabrication processes and product forms. An analysis of these records shows there was a significant change in repair frequency over the years when these components were fabricated. A description of repair flaw morphology is provided with a discussion of fracture mechanics significance. Fabrication flaws in repairs are characterized using optimized-access, high-sensitivity nondestructive ultrasonic testing. Flaw characterizations are then validated by other nondestructive evaluation techniques and complemented by destructive testing.

  17. Phase transformation and mechanical behavior in annealed 2205 duplex stainless steel welds

    SciTech Connect (OSTI)

    Badji, Riad Bouabdallah, Mabrouk; Bacroix, Brigitte; Kahloun, Charlie; Belkessa, Brahim; Maza, Halim

    2008-04-15

    The phase transformations and mechanical behaviour during welding and subsequent annealing treatment of 2205 duplex stainless steel have been investigated. Detailed microstructural examination showed the presence of higher ferrite amounts in the heat affected zone (HAZ), while higher amounts of austenite were recorded in the centre region of the weld metal. Annealing treatments in the temperature range of 800-1000 deg. C resulted in a precipitation of {sigma} phase and M{sub 23}C{sub 6} chromium carbides at the {gamma}/{delta} interfaces that were found to be preferential precipitation sites. Above 1050 deg. C, the volume fraction of {delta} ferrite increases with annealing temperature. The increase of {delta} ferrite occurs at a faster rate in the HAZ than in the base metal and fusion zone. Optimal mechanical properties and an acceptable ferrite/austenite ratio throughout the weld regions corresponds to annealing at 1050 deg. C. Fractographic examinations showed that the mode of failure changed from quasi-cleavage fracture to dimple rupture with an increase in the annealing temperature from 850 to 1050 deg. C.

  18. Evaluation of the feasibility of a pipeline field weld real-time radiography (radioscopy) inspection system

    SciTech Connect (OSTI)

    Tucker, J.E.; Rudarmel, M.W.; Sayler, G.C.; Garrison, L.E.

    1996-02-01

    Inspection of pipeline field girth welds during pipeline construction is accomplished by film radiographic methods. Film radiography of materials is a 70 year old technology. There have been many advances in that 70 year history in equipment and films, but the process of making the radiograph is essentially the same. The film radiography process is time-consuming, costly, environmentally impacting and very operator (inspector) dependent. There are recent and almost daily advances in technologies using x-ray imaging other than film. Double-jointed pipe welds at pipe mills and at double-joint operations have been inspected with stationary real-time radioscopic systems for many years. This electronic imaging technology, known as {open_quotes}radioscopy{close_quotes}, has the potential to significantly improve pipeline project schedules and cost by eliminating some of the shortcomings of film radiography. Radioscopy is currently accepted for use by many nationally accepted standards including API-5L, Specification for Line Pipe, and API-1104, Welding of Pipelines and Related Facilities. Seven years ago PRC contracted Southwest Research Institute (SwRI) to research radioscopy for field application. This effort did not yield a suitable field system even though the study by SwRI concluded that it was feasible and would be cost effective.

  19. Processing ultrasonic inspection data from multiple scan patterns for turbine rotor weld build-up evaluations

    SciTech Connect (OSTI)

    Guan, Xuefei; Zhou, S. Kevin; Rasselkorde, El Mahjoub; Abbasi, Waheed

    2015-03-31

    The study presents a data processing methodology for weld build-up using multiple scan patterns. To achieve an overall high probability of detection for flaws with different orientations, an inspection procedure with three different scan patterns is proposed. The three scan patterns are radial-tangential longitude wave pattern, axial-radial longitude wave pattern, and tangential shear wave pattern. Scientific fusion of the inspection data is implemented using volume reconstruction techniques. The idea is to perform spatial domain forward data mapping for all sampling points. A conservative scheme is employed to handle the case that multiple sampling points are mapped to one grid location. The scheme assigns the maximum value for the grid location to retain the largest equivalent reflector size for the location. The methodology is demonstrated and validated using a realistic ring of weld build-up. Tungsten balls and bars are embedded to the weld build-up during manufacturing process to represent natural flaws. Flat bottomed holes and side drilled holes are installed as artificial flaws. Automatic flaw identification and extraction are demonstrated. Results indicate the inspection procedure with multiple scan patterns can identify all the artificial and natural flaws.

  20. The stress corrosion cracking behavior of alloys 690 and 152 WELD in a PWR environment.

    SciTech Connect (OSTI)

    Alexandreanu, B.; Chopra, O. K.; Shack, W. J.

    2009-01-01

    Alloys 690 and 152 are the replacement materials of choice for Alloys 600 and 182, respectively. The latter two alloys are used as structural materials in pressurized water reactors (PWRs) and have been found to undergo stress corrosion cracking (SCC). The objective of this work is to determine the crack growth rates (CGRs) in a simulated PWR water environment for the replacement alloys. The study involved Alloy 690 cold-rolled by 26% and a laboratory-prepared Alloy 152 double-J weld in the as-welded condition. The experimental approach involved pre-cracking in a primary water environment and monitoring the cyclic CGRs to determine the optimum conditions for transitioning from the fatigue transgranular to intergranular SCC fracture mode. The cyclic CGRs of cold-rolled Alloy 690 showed significant environmental enhancement, while those for Alloy 152 were minimal. Both materials exhibited SCC of 10{sup -11} m/s under constant loading at moderate stress intensity factors. The paper also presents tensile property data for Alloy 690TT and Alloy 152 weld in the temperature range 25--870 C.

  1. ARM - Measurement - Planetary boundary layer height

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    govMeasurementsPlanetary boundary layer height ARM Data Discovery Browse Data Comments? We would love to hear from you! Send us a note below or call us at 1-888-ARM-DATA. Send Measurement : Planetary boundary layer height Top of the planetary boundary layer; also known as depth or height of the mixing layer. Categories Atmospheric State Instruments The above measurement is considered scientifically relevant for the following instruments. Refer to the datastream (netcdf) file headers of each

  2. In-Situ Phase Mapping and Direct Observations of Phase Transformations During Arc Welding of 1045 Steel

    SciTech Connect (OSTI)

    Elmer, J; Palmer, T

    2005-09-13

    In-situ Spatially Resolved X-Ray Diffraction (SRXRD) experiments were performed during gas tungsten arc (GTA) welding of AISI 1045 C-Mn steel. Ferrite ({alpha}) and austenite ({gamma}) phases were identified and quantified in the weld heat-affected zone (HAZ) from the real time x-ray diffraction data. The results were compiled along with weld temperatures calculated using a coupled thermal fluids weld model to create a phase map of the HAZ. This map shows the {alpha} {yields} {gamma} transformation taking place during weld heating and the reverse {gamma} {yields} {alpha} transformation taking place during weld cooling. Superheating is required to complete the {alpha} {yields} {gamma} phase transformation, and the amount of superheat above the A3 temperature was shown to vary with distance from the centerline of the weld. Superheat values as high as 250 C above the A3 temperature were observed at heating rates of 80 C/s. The SRXRD experiments also revealed details about the {gamma} phase not observable by conventional techniques, showing that {gamma} is present with two distinct lattice parameters as a result of inhomogeneous distribution of carbon and manganese in the starting pearlitic/ferritic microstructure. During cooling, the reverse {gamma} {yields} {alpha} phase transformation was shown to depend on the HAZ location. In the fine grained region of the HAZ, at distances greater than 2 mm from the fusion line, the {gamma} {yields} {alpha} transformation begins near the A3 temperature and ends near the A1 temperature. In this region of the HAZ where the cooling rates are below 40 C/s, the transformation occurs by nucleation and growth of pearlite. For HAZ locations closer to the fusion line, undercoolings of 200 C or more below the A1 temperature are required to complete the {gamma} {yields} {alpha} transformation. In this region of the HAZ, grain growth coupled with cooling rates in excess of 50 C/s causes the transformation to occur by a bainitic mechanism.

  3. Temperature and Material Flow Prediction in Friction-Stir Spot Welding of Advanced High-Strength Steel

    SciTech Connect (OSTI)

    Miles, Michael; Karki, U.; Hovanski, Yuri

    2014-10-01

    Friction-stir spot welding (FSSW) has been shown to be capable of joining advanced high-strength steel, with its flexibility in controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding if tool life is sufficiently high, and if machine spindle loads are sufficiently low that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8 kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11–14 kN. Therefore, in the current work, tool speeds of 5000 rpm were employed to generate heat more quickly and to reduce welding loads to acceptable levels. Si3N4 tools were used for the welding experiments on 1.2-mm DP 980 steel. The FSSW process was modeled with a finite element approach using the Forge* software. An updated Lagrangian scheme with explicit time integration was employed to predict the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate. Material flow was calculated from a velocity field that is two-dimensional, but heat generated by friction was computed by a novel approach, where the rotational velocity component imparted to the sheet by the tool surface was included in the thermal boundary conditions. An isotropic, viscoplastic Norton-Hoff law was used to compute the material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures to within percent, and the position of the joint interface to within 10 percent, of the experimental results.

  4. Biaxially textured metal substrate with palladium layer

    DOE Patents [OSTI]

    Robbins, William B.

    2002-12-31

    Described is an article comprising a biaxially textured metal substrate and a layer of palladium deposited on at least one major surface of the metal substrate; wherein the palladium layer has desired in-plane and out-of-plane crystallographic orientations, which allow subsequent layers that are applied on the article to also have the desired orientations.

  5. Review of Dissimilar Metal Welding for the NGNP Helical-Coil Steam Generator

    SciTech Connect (OSTI)

    John N. DuPont

    2010-03-01

    The U.S. Department of Energy (DOE) is currently funding research and development of a new high temperature gas cooled reactor (HTGR) that is capable of providing high temperature process heat for industry. The steam generator of the HTGR will consist of an evaporator economizer section in the lower portion and a finishing superheater section in the upper portion. Alloy 800H is expected to be used for the superheater section, and 2.25Cr 1Mo steel is expected to be used for the evaporator economizer section. Dissimilar metal welds (DMW) will be needed to join these two materials. It is well known that failure of DMWs can occur well below the expected creep life of either base metal and well below the design life of the plant. The failure time depends on a wide range of factors related to service conditions, welding parameters, and alloys involved in the DMW. The overall objective of this report is to review factors associated with premature failure of DMWs operating at elevated temperatures and identify methods for extending the life of the 2.25Cr 1Mo steel to alloy 800H welds required in the new HTGR. Information is provided on a variety of topics pertinent to DMW failures, including microstructural evolution, failure mechanisms, creep rupture properties, aging behavior, remaining life estimation techniques, effect of environment on creep rupture properties, best practices, and research in progress to improve DMW performance. The microstructure of DMWs in the as welded condition consists of a sharp chemical concentration gradient across the fusion line that separates the ferritic and austenitic alloys. Upon cooling from the weld thermal cycle, a band of martensite forms within this concentration gradient due to high hardenability and the relatively rapid cooling rates associated with welding. Upon aging, during post weld heat treatment (PWHT), and/or during high temperature service, C diffuses down the chemical potential gradient from the ferritic 2.25Cr 1Mo steel toward the austenitic alloy. This can lead to formation of a soft C denuded zone near the interface on the ferritic steel, and nucleation and growth of carbides on the austenitic side that are associated with very high hardness. These large differences in microstructure and hardness occur over very short distances across the fusion line (~ 50 100 ?m). A band of carbides also forms along the fusion line in the ferritic side of the joint. The difference in hardness across the fusion line increases with increasing aging time due to nucleation and growth of the interfacial carbides. Premature failure of DMWs is generally attributed to several primary factors, including: the sharp change in microstructure and mechanical properties across the fusion line, the large difference in coefficient of thermal expansion (CTE) between the ferritic and austenitic alloys, formation of interfacial carbides that lead to creep cavity formation, and preferential oxidation of the ferritic steel near the fusion line. In general, the large gradient in mechanical properties and CTE serve to significantly concentrate the stress along the fusion where a creep susceptible microstructure has evolved during aging. Presence of an oxide notch can concentrate the stress even further. Details of the failure mechanism and the relative importance of each factor varies.

  6. Dense, layered membranes for hydrogen separation

    DOE Patents [OSTI]

    Roark, Shane E.; MacKay, Richard; Mundschau, Michael V.

    2006-02-21

    This invention provides hydrogen-permeable membranes for separation of hydrogen from hydrogen-containing gases. The membranes are multi-layer having a central hydrogen-permeable layer with one or more catalyst layers, barrier layers, and/or protective layers. The invention also relates to membrane reactors employing the hydrogen-permeable membranes of the invention and to methods for separation of hydrogen from a hydrogen-containing gas using the membranes and reactors. The reactors of this invention can be combined with additional reactor systems for direct use of the separated hydrogen.

  7. Solar cell with silicon oxynitride dielectric layer

    DOE Patents [OSTI]

    Shepherd, Michael; Smith, David D

    2015-04-28

    Solar cells with silicon oxynitride dielectric layers and methods of forming silicon oxynitride dielectric layers for solar cell fabrication are described. For example, an emitter region of a solar cell includes a portion of a substrate having a back surface opposite a light receiving surface. A silicon oxynitride (SiO.sub.xN.sub.y, 0layer is disposed on the back surface of the portion of the substrate. A semiconductor layer is disposed on the silicon oxynitride dielectric layer.

  8. Effect of long-term thermal aging on the fracture toughness of austenitic stainless steel base and weld metals

    SciTech Connect (OSTI)

    Huang, F.F.

    1995-09-27

    Compact tension specimens taken from FFTF primary piping materials (Type 316 stainless steel (SS) and 16-8-2 SS weld metal) and from reactor vessel materials (304 SS and 308 SS weld metal) were heated in laboratory furnaces from 100,000 hours. Fracture toughness testing was performed on these specimens, which are 7.62- and 25.4-mm thick, respectively at the aging temperature (482 and 427 degrees). Results were analyzed with the multiple-specimen method. Thermal aging continues to reduce the fracture toughness of FFTF component materials. Results show that thermal aging has a strong effect on the toughness degradation of weld metals, particularly for 16-8-2 SS weld whose aged/unaged Jc ratio is only 0.31 after 100,000-hour aging. The fracture toughness of the 308 and 16-8-2 SS weld metals fluctuated during 20,000 to 50,000-hour aging but deteriorated as the aging time increased to 100,000 hours; the toughness degradation is significant. Fracture control based on a fracture mechanics approach should be considered

  9. Effect of rapid solidification on stainless steel weld metal microstructures and its implications on the Schaeffler diagram

    SciTech Connect (OSTI)

    David, S.A.; Vitek, J.M.; Reed, R.W.; Hebble, T.L.

    1987-09-01

    An investigation was carried out to determine the effect of rapid solidification on the weld metal microstructure of austenitic stainless steels and its implication on the ferrite constitution diagram. A wide variety of stainless steels were laser welded at different welding speeds and laser power levels. Results indicate that both weld pool cooling rate and the postsolidification solid state cooling rates have a profound effect on the microstructures. For the steels investigated, the microstructures ranged from duplex austenite (..gamma..) + ferrite (delta) to fully austenitic or fully ferritic. These microstructures were found to be sensitive to both cooling rates and composition. The observed results are rationalized based on rapid solidification theory. This investigation indicates that solidification rates and postsolidification cooling rates have a profound effect on the observed microstructures, thus making it impossible to predict the microstructures of rapidly cooled weld metal from the conventional constitution diagrams. The influence of the observations made in this investigation on the Schaeffler diagram is demonstrated, and possible corrections to the constitution diagram incorporating the cooling rate effects are proposed. 23 refs., 17 figs., 4 tabs.

  10. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; Payzant, E. Andrew; Kolbus, Lindsay M.

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stirmore » zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.« less

  11. Multi Layer Contaminant Migration Model

    Energy Science and Technology Software Center (OSTI)

    1999-07-28

    This computer software augments and enhances certain calculation included in the previously copyrighted Vadose Zone Contaminant Migration Model. The computational method used in this model recognizes the heterogenous nature of the soils and attempts to account for the variability by using four separate layers to simulate the flow of water through the vadose zone. Therefore, the pore-water velocity calculated by the code will be different than the previous model because it accounts for a widermore » variety of soil properties encountered in the vadose zone. This model also performs an additional screening step than in the previous model. In this model the higher value of two different types of Soil Screening Levels are compared to soil concentrations of contaminants. If the contaminant concentration exceeds the highest of two SSLs, then that contaminant is listed. This is consistent with USEPA's Soil Screening Guidance.« less

  12. Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531)

    SciTech Connect (OSTI)

    Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2007-03-01

    This paper examines the effects of fusion zone size on failure modes, static strength and energy absorption of resistance spot welds (RSW) of advanced high strength steels (AHSS). DP800 and TRIP800 spot welds are considered. The main failure modes for spot welds are nugget pullout and interfacial fracture. Partial interfacial fracture is also observed. The critical fusion zone sizes to ensure nugget pull-out failure mode are developed for both DP800 and TRIP800 using the limit load based analytical model and the micro-hardness measurements of the weld cross sections. Static weld strength tests using cross tension samples were performed on the joint populations with controlled fusion zone sizes. The resulted peak load and energy absorption levels associated with each failure mode were studied using statistical data analysis tools. The results in this study show that the conventional weld size of 4 t1/2 can not produce nugget pullout mode for both the DP800 and TRIP800 materials. The results also suggest that performance based spot weld acceptance criteria should be developed for different AHSS spot welds.

  13. Gelatin based on Power-gel.TM. as solders for Cr.sup.4+laser tissue welding and sealing of lung air leak and fistulas in organs

    DOE Patents [OSTI]

    Alfano, Robert R.; Tang, Jing; Evans, Jonathan M.; Ho, Peng Pei

    2006-04-25

    Laser tissue welding can be achieved using tunable Cr.sup.4+ lasers, semiconductor lasers and fiber lasers, where the weld strength follows the absorption spectrum of water. The use of gelatin and esterified gelatin as solders in conjunction with laser inducted tissue welding impart much stronger tensile and torque strengths than albumin solders. Selected NIR wavelength from the above lasers can improve welding and avoid thermal injury to tissue when used alone or with gelatin and esterified gelatin solders. These discoveries can be used to enhance laser tissue welding of tissues such as skin, mucous, bone, blood vessel, nerve, brain, liver, pancreas, spleen, kidney, lung, bronchus, respiratory track, urinary tract, gastrointestinal tract, or gynecologic tract and as a sealant for pulmonary air leaks and fistulas such as intestinal, rectal and urinary fistulas.

  14. Spectral changes in layered f -electron systems induced by Kondo...

    Office of Scientific and Technical Information (OSTI)

    Spectral changes in layered f -electron systems induced by Kondo hole substitution in the boundary layer Title: Spectral changes in layered f -electron systems induced by Kondo ...

  15. Nanomanufacturing : nano-structured materials made layer-by-layer.

    SciTech Connect (OSTI)

    Cox, James V.; Cheng, Shengfeng; Grest, Gary Stephen; Tjiptowidjojo, Kristianto; Reedy, Earl David, Jr.; Fan, Hongyou; Schunk, Peter Randall; Chandross, Michael Evan; Roberts, Scott A.

    2011-10-01

    Large-scale, high-throughput production of nano-structured materials (i.e. nanomanufacturing) is a strategic area in manufacturing, with markets projected to exceed $1T by 2015. Nanomanufacturing is still in its infancy; process/product developments are costly and only touch on potential opportunities enabled by growing nanoscience discoveries. The greatest promise for high-volume manufacturing lies in age-old coating and imprinting operations. For materials with tailored nm-scale structure, imprinting/embossing must be achieved at high speeds (roll-to-roll) and/or over large areas (batch operation) with feature sizes less than 100 nm. Dispersion coatings with nanoparticles can also tailor structure through self- or directed-assembly. Layering films structured with these processes have tremendous potential for efficient manufacturing of microelectronics, photovoltaics and other topical nano-structured devices. This project is designed to perform the requisite R and D to bring Sandia's technology base in computational mechanics to bear on this scale-up problem. Project focus is enforced by addressing a promising imprinting process currently being commercialized.

  16. Evaluation of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

    SciTech Connect (OSTI)

    Anderson, Michael T.; Diaz, Aaron A.; Doctor, Steven R.

    2012-06-01

    During a recent inservice inspection (ISI) of a dissimilar metal weld (DMW) in an inlet (hot leg) steam generator nozzle at North Anna Power Station Unit 1, several axially oriented flaws went undetected by the licensee's manual ultrasonic testing (UT) technique. The flaws were subsequently detected as a result of outside diameter (OD) surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the DMW. Further ultrasonic tests were then performed, and a total of five axially oriented flaws, classified as primary water stress corrosion cracking (PWSCC), were detected in varied locations around the weld circumference.

  17. A comparative evaluation of laser and GTA welds in a high-strength titanium alloy -- Ti-6-22-22S

    SciTech Connect (OSTI)

    Baeslack, W.A. III; Hurley, J.; Paskell, T.

    1994-12-31

    Titanium alloy Ti-6Al-2Sn-2Zr-2Mo-2Cr-025Si (hereafter designated Ti-6-22-22S)is an alpha-beta titanium alloy developed for deep hardenability, high strength, intermediate temperature creep resistance, and moderate toughness. As a potential structural material for next-generation aircraft and aerospace systems, the weldability of Ti-6-22-22S has recently become a subject of increasing importance and concern. In the welding of titanium sheet, achieving satisfactory ductility is the principal limitation to alloy weldability, with poor ductility promoted by a coarse beta grain structure in the weld fusion and near-heat-affected zones. Square-butt welds were produced in 1.6 mm thick Ti-6-22-22S sheet using automatic GTA and CO{sub 2} laser welding systems. Microstructure analysis and DPH hardness traverses were performed on mounted. polished and etched specimens. Three-point bend and tensile tests were performed on transverse-weld and longitudinal-weld oriented specimens. Microstructure analysis of the laser welds revealed a fine, columnar fusion zone beta grain macrostructure and a fully-martensitic transformed-beta microstructure. Consistent with the microstructural similarities, fusion zone hardnesses of the laser welds were comparable (385 and 390 DPG, respectively) and greater than that of the base metal (330 DPH). In general, laser welds did not exhibit markedly superior ductilities relative to the GTAW, which was attributed to differences in the nature of the intragranular transformed-beta microstructures, being coarser and softer for the GTAW, the response of these as-welded microstructures to heat treatment, and interactions between the transformed-beta microstructure and the beta grain macrostructure.

  18. Air-injection field tests to determine the effect of a heat cycle...

    Office of Scientific and Technical Information (OSTI)

    the effect of a heat cycle on the permeability of welded tuff Citation Details In-Document Search Title: Air-injection field tests to determine the effect of a heat cycle on the ...

  19. Field air injection tests to determine the effect of a heat cycle...

    Office of Scientific and Technical Information (OSTI)

    Field air injection tests to determine the effect of a heat cycle on the permeability of welded tuff Citation Details In-Document Search Title: Field air injection tests to ...

  20. Air-injection field tests to determine the effect of a heat cycle...

    Office of Scientific and Technical Information (OSTI)

    Air-injection field tests to determine the effect of a heat cycle on the permeability of welded tuff Citation Details In-Document Search Title: Air-injection field tests to ...