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Due to the increasing global demand for pure silver, native wire silver aggregates in very high purities are gaining more industrial attention. Up to the present, no substantial metallurgical Investigation of natural wire silver exists in the accessible literature. To convey urgently needed cross-disciplinary fundamental knowledge for geoscientists and metallurgical engineers, twenty natural wire silver specimens from eight different ore deposits have been investigated in detail for the first time by EBSD (Electron Back Scattering Diffraction), supported by light microscopy and micro-probe analyses. The improved understanding of the natural silver wire microstructure provides additional Information regarding the growth of natural silver aggregates in comparison to undesired artificial growth on electronic devices. Clear evidence is provided that natural silver curls and hairs exhibit a polycrystalline face-centered cubic microstructure associated with significant twinning. Although the investigated natural wire silver samples have relatively high purity (Ag > 99.7 wt.-%), they contain a variety of trace elements such as, S, Cu, Mn, Ni, Zn, Co and Bi, As and Sb. Additionally, Vickers micro-hardness measurements are provided for the first time which revealed that natural silver wires and curls are softer than it might be expected from conversion of the general Mohs hardness of 2.7.
One of the main factors affecting the use of lasers in the industry for welding thick structures is the process accompanying solidification cracks. These cracks mostly occurring along the welding direction in the welding center, and strongly affect the safety of the welded components. In the present study, to obtain a better understanding of the relation between the weld pool geometry, the stress distribution and the solidification cracking, a three-dimensional computational fluid dynamic (CFD) model was combined with a thermo-mechanical model. The CFD model was employed to analyze the flow of the molten metal in the weld pool during the laser beam welding process. The weld pool geometry estimated from the CFD model was used as a heat source in the thermal model to calculate the temperature field and the stress development and distributions. The CFD results showed a bulging region in the middle depth of the weld and two narrowing areas separating the bulging region from the top and bottom surface. The thermo-mechanical simulations showed a concentration of tension stresses, transversally and vertically, directly after the solidification during cooling in the region of the solidification cracking.
Investigations on weldability often deal with hot cracking as one of the most prevalent failure mechanisms during weld fabrication. The modified varestraint transvarestraint hot cracking test (MVT) is well known to assess the hot cracking susceptibility of materials. The shortcoming of this approach is that the information is only from the very near surface region which inhibits access to the characteristic of the hot crack network in the bulk. Here, we report about an alternative approach to monitor the entire 3D hot crack network after welding by means of microfocus X-ray computer tomography (µCT). However, to provide sufficient high spatial resolution small samples must be sectioned from the MVT-welded joint. The sampling is accompanied by local relaxation of the residual stress distributions that are induced by welding, which can have an impact on the crack volumes prior to the sampling. The studies were carried out to investigate the hot cracking susceptibility of low transformation temperature filler materials (LTT). As high compression residual stresses up to -600 MPa in the area of the crack networks were determined by means of the contour method, stress relaxation caused by sectioning for µCT sample extraction can affect the detectability of the cracks later on. X-ray diffraction studies revealed surface residual stress relaxations up to about 400 MPa due to cutting. To investigate this effect, the specimens with hot cracks were subjected to a load test with known stress states. The results clearly show that local stress relaxations will have a strong impact on the volume images reconstructed from tomography analysis. This effect must be considered during hot crack assessment on basis of µCT data.
The geometry of the melt pool in laser beam welding plays a major role to understand the dynamics of the melt and its solidification behavior. In this study, a butt configuration of 15 mm thick structural steel and transparent quartz glass was used to observe the weld pool geometry by means of high-speed camera and an infrared camera recording. The observations show that the dimensions of the weld pool vary depending on the depth. The areas close to the weld pool surface take a teardrop-shape. A bulge-region and its temporal evolution were observed approximately in the middle of the depth of the weld pool. Additionally, a 3D transient thermal-fluid numerical simulation was performed to obtain the weld pool shape and to understand the formation mechanism of the observed bulging effect. The model takes into account the local temperature field, the effects of phase transition, thermo-capillary convection, natural convection and temperature-dependent material properties up to evaporation temperature. The numerical results showed good accordance and were furthermore used to improve the understanding of the experimentally observed bulging effect.
Additive Manufacturing (AM) through the Selective Laser Melting (SLM) route offers ample scope for producing geometrically complex parts compared to the conventional subtractive manufacturing strategies. Nevertheless, the residual stresses which develop during the fabrication can limit application of the SLM components by reducing the load bearing capacity and by inducing unwanted distortion, depending on the boundary conditions specified during manufacturing. The present study aims at characterizing the residual stress states in the SLM parts using different diffraction methods. The material used is the nickel based superalloy Inconel 718. Microstructure as well as the surface and bulk residual stresses were characterized. For the residual stress analysis, X-ray, synchrotron and neutron diffraction methods were used. The measurements were performed at BAM, at the EDDI beamline of -BESSY II synchrotronand the E3 line -BER II neutron reactor- of the Helmholtz-Zentrum für Materialien und Energie (HZB) Berlin. The results reveal significant differences in the residual stress states for the different characterization techniques employed, which indicates the dependence of the residual state on the penetration depth in the sample. For the surface residual stresses, longitudinal and transverse stress components from X-ray and synchrotron agree well and the obtained values were around the yield strength of the material. Furthermore, synchrotron mapping disclosed gradients along the width and length of the sample for the longitudinal and transverse stress components. On the other hand, lower residual stresses were found in the bulk of the material measured using neutron diffraction. The longitudinal component was tensile and decreased towards the boundary of the sample. In contrast, the normal component was nearly constant and compressive in nature. The transversal component was almost negligible. The results indicate that a stress re-distribution takes place during the deposition of the consecutive layers. Further investigations are planned to study the phenomenon in detail.
Submerged arc welded (SAW) components of creep-resistant low-alloyed Cr-Mo-V steels are used for thick-walled heavy petrochemical reactors (wall-thickness up to 475 mm) as well as employed in construction of modern high-efficient fossil fired power plants. These large components are accompanied by significant restraints during welding fabrication, especially at positions of different thicknesses like welding of nozzles. As a result, residual stresses occur, playing a domi-nant role concerning so-called stress relief cracking (SRC) typically during post weld heat treat-ment (PWHT). Besides specific metallurgical factors (like secondary hardening due to re-precipitation), high tensile residual stresses are a considerable influence factor on SRC. For the assessment of SRC susceptibility of certain materials mostly mechanical tests are applied which are isolated from the welding process. Conclusions regarding the influence of mechanical factors are rare so far. The present research follows an approach to reproduce loads, which occur during welding of real thick-walled components scaled to laboratory conditions by using tests designed on different measures. A large-scale slit specimen giving a high restraint in 3 dimensions by high stiffness was compared to a medium-scale multi-pass welding U-profile specimen showing a high degree of restraint in longitudinal direction and a small-scale TIG-re-melted specimen. The small-scale specimens were additionally subjected to mechanical bending to induce loads that are found during fabrication on the real-scale in heavy components. Results show for all three cases compa-rable high tensile residual stresses up to yield strength with high gradients in the weld metal and the heat affected zone. Those high tensile stresses can be significant for cracking during further PWHT.
Commercial grade-1 titanium samples (Ti, 99.6%) were treated using three alternative methods, (i) femtosecond laser processing, (ii) thermal heat treatment, and (iii) electrochemical anodization, respectively, resulting in the formation of differently conditioned superficial titanium oxide layers. The laser processing (i) was carried out by a Ti:sapphire laser (pulse duration 30 fs, central wavelength 790 nm, pulse repetition rate 1 kHz) in a regime of generating laser-induced periodic surface structures (LIPSS). The experimental conditions (laser fluence, spatial spot overlap) were optimized in a sample-scanning setup for the processing of several square-millimeters large surface areas covered homogeneously by these nanostructures. The differently oxidized titanium surfaces were characterized by optical microscopy, micro Raman spectroscopy, variable angle spectroscopic ellipsometry, and instrumented indentation testing. The tribological performance was characterized in the regime of mixed friction by reciprocating sliding tests against a sphere of hardened steel in fully formulated engine oil as lubricant. The specific tribological performance of the differently treated surfaces is discussed with respect to possible physical and chemical mechanisms.
A transient simulation including the impact of the laser energy, the melting of the metal and the development of the weld pool was conducted to observe the evolution of the vapor capillary and the solidification of the melt in pulsed laser beam welding of AISI 304 steel. The phase field method was implemented to investigate the evolution and behavior of the liquid-gas interface during welding and to describe the condensed and vapor phases. The effects of phase transition, recoil pressure, thermo-capillary and natural convection, vaporization and temperature dependent material properties were taken into account. A Gaussian-like heat source under consideration of the Fresnel absorption model was used to model the energy input of the laser beam. The heat source model was extended by a newly developed empirical approach of describing multiple beam reflections in the keyhole. To validate this new model, the numerical results were compared to experimental data and good agreement regarding the size and shape of the weld pool was observed.
Due to rapid, localized heating and cooling, distortions accumulate in additive manufactured laser metal deposition (LMD) components, leading to a loss of dimensional accuracy or even cracking. Numerical welding simulations allow the prediction of these deviations and their optimization before conducting experiments. To assess the viability of the simulation tool for the use in a predictive manner, comprehensive systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to Cluster these products in new assembly oriented product families for the optimization.
The performance and safety of welded high-strength low-alloyed steel (HSLA) components are substantially affected by the stresses occurring during and after welding fabrication, especially if welding shrinkage and distortion are severely restrained. The surrounding structure of the whole component affects loads in the far-field superimposing with welding stresses in the near-field of the weld. In this study a unique testing facility was used to restrain shrinkage and bending while analyse multiaxial far-field loads (max. 2 MN) during assembly of thick-walled component. A novel approach for the assessment of the in-situ-measured far-field data in combination with the actual weld geometry was elaborated. For the first time, analyses of the global bending moments of restrained welds based on the neutral axis of the actual weld load bearing section were achieved. Hence, far-field measurements offered the possibility to determine critical near-field stresses of the weld crosssections for the entire joining process. This work presents the approach for far-to-near field in-situ determination of stresses in detail for the 2-MN-testing system based on an extensive experimental work on HSLA steel welds, which demonstrates sources and consequences of these high local welding stresses. Thus, it was clarified, why the first weld beads are crucial regarding welding stresses and cold cracking, which is well known, but has never been measured so far. Accompanying analyses using X-ray diffraction (XRD) after welding show effects on local residual stress distributions. These analyses indicated viable prospects for stress reduction during assembly of thick-walled HSLA steel components.
The hybrid laser arc welding (HLAW) process provides many advantages such as improved gap bridgeability, deep penetration and misalignment of edges, that is why the process is used increasingly in industrial applications e.g. shipbuilding, power plant industry and line-pipe manufacturing. The obvious encountered problem for single pass welding in flat position is the gravity drop-out at low welding velocities. With the usage of an electromagnetic weld pool support system, which is based on generating Lorentz forces within the weld pool, wide seams followed by reduced welding velocities could be achieved in this study leading to the realization of a gap bridgeability up to 1 mm, misalignment of edges up to 2 mm and a single pass weld up to 28 mm thickness with a 20-kW fibre laser. These developments expand the boundaries of the HLAW process for different industrial applications. As a result, less accurate preparation of the edges would be sufficient, which saves time for manufacturing.
The laser hybrid welding process offers many advantages regarding deep penetration, increased welding velocity and with the help of the supplied filler wire an improved bridgeability to gap and misalignment tolerances. High power laser systems with a power of approx. 30 kW are already available on the market. Nevertheless, multi-layer technology with an arc process is still used for welding of plates from a thickness from 20 mm. A potential cause is the process instability with increasing laser power. It is inevitable that gravity drop-out due to the high hydrostatic pressure at increasing wall thickness especially at welding in flat position and with a low welding speed. The surface tension decreases with increasing root width resulting from low welding velocities. To prevent such inadmissible defects of the seam a use of weld pool support is required. Usual weld pool support systems such as ceramic or powder supports require a mechanical detachment which is time-consuming. The electromagnetic weld pool support system described in this work shows an alternative weld pool support which works contactless. It is based on generating Lorentz forces in the weld pool due to oscillating magnetic field and induced eddy currents. This innovative technology offers single pass welds up to 28 mm in flat position and reduced welding velocity with a laser power of just 19 kW. It also leads to improved mechanical-technological properties of the seams because of the slow cooling rate. With usage of an electromagnetic weld pool support the limitation of the hybrid laser arc welding process in the thick sheet metal will be extend.
The paper deals with the integration of a light emitting diode (LED) into an additive manufactured metal component. Selective laser melting (SLM) and laser metal deposition (LMD) are used. The material used is the chrome-nickel steel 316L. The basic component is manufactured by means of SLM and consists of a solid body and an area with grid structure. The solid body includes a duct in the shape of a groove with a recess for the positioning of the power cable. The LED is embedded in the grid structure via an inlet from the solid body. In further processing, the groove is filled with LMD. Two strategies with different parameter combinations were investigated. It shows that a high energy input near the power cable leads to its destruction. By using multiple parameter combinations during the manufacturing process, this destruction can be prevented. There was a comparison of both strategies with regard to the necessary number of tracks and duration of welding time.
Laser-Metal-Deposition (LMD) and Plasma-Transferred-Arc (PTA) are well known Technologies which can be used for cladding purposes. The prime objective in combining LMD and PTA as a Hybrid Metal Deposition-Technology (HMD) is to achieve high Deposition rates at low thermal Impact. Possible applications are coatings for wear protection or repair welding for components made of steel. The two energy sources (laser and Plasma arc) build a Joint process Zone and are configurated to constitute a stable process at laser powers between 0.4-1 kW (defocused) and Plasma currents between 75-200 A. Stainless steel 316L serves as filler material. For this HMD process, a Plasma Cu-nozzle is designed and produced by powder bed based Selective Laser Melting. The potential of the HMD Technology is investigated and discussed considering existing process. This paper demonstrates how the interaction of the two energy sources effects the following application-relevant properties: Deposition rate, powder Efficiency and energy Input.
A simplified model for numerical simulation of laser metal deposition process with beam oscillation
(2018)
A model of laser metal deposition with beam oscillation has been developed. The proposed model consists of two coupled sub-models calculating the heat transfer in the deposited part and the free surface of the molten pool, respectively. The heat transfer simulation of the deposited part solves a three-dimensional quasi-stationary heat conduction problem. The free surface of the molten pool are determined by solving the Laplace-Young equation. The developed model enables the layer-by-layer prediction of the shape of the deposited part and the resulting temperature field. It is shown that for an oscillation amplitude equal to the beam radius the peak value of the heat flux decreases by about 53% and 73% in the case of lateral oscillation and circular oscillation, respectively. Lateral oscillating laser beam results in a higher penetration depth due to the higher thermal efficiency. The amplitude of the laser beam oscillation effects the shape of the deposited wall and the deposition rate. A good correlation between the numerically calculated and experimentally observed results is obtained.
This paper represents the results for proposed optical flow method based on the Lucas-Kanade (LK) algorithm applied to two different problems. The following observations can be made:
- The estimated strain and displacement for conducted tensile test are generally very close to those measured with conventional DIC-technique.
- The LK technique allows measurement of strain or displacement without special selection of a region of interest.
Using a novel optical measurement technique together with the optical flow algorithm, a twodimensional deformation analysis during welding was conducted. This technique is the first to provide a measurement of the full strain field locally in the immediate vicinity of the solidification front. Additionally, the described procedure of the optical measurement allows the real material-dependent values of critical strain characterizing the transition to hot cracking during laser welding processes to be determined.
To increase the competitiveness of jacket substructures compared to monopiles a changeover from an individual towards a serial jacket production based on automated manufactured tubular joints combined with standardized pipes has to be achieved. Therefore, this paper addresses fatigue tests of automatically welded tubular X-joints focusing on the location of the technical fatigue crack. The detected location of the technical crack is compared to numerical investigations predicting the most fatigue prone notch considering the structural stress approach as well as the notch stress approach. Besides, the welding process of the automated manufactured tubular X-joints is presented.
Um ein tieferes Verständnis über die Schallemission bei der Entstehung und Ausbreitung von Rissen in Stahlrohrleitungen zu erlangen, wurde ein Stahlrohr der Güte S355J2H im Vierpunkt-Biegeversuch quasistatisch bis hin zum Wanddurchbruch (Leckage) belastet und mittels Schallemissionsmessung und Gleichstrompotentialmessung überwacht. Das Rohrsegment wurde durch einen 90°- Außenumfangskerb in der Mitte der Rohrlänge definiert vorgeschädigt, um davon ausgehend ein stabiles Risswachstum zu induzieren und die Analyse von Schallemission aus Rissereignissen, die am Kerb eintraten, sicherzustellen. Für die Schallemissionsmessung wurden vier Breitbandsensoren max. 105 mm vom Kerb entfernt montiert. Die Signalaufzeichnung erfolgte kontinuierlich und schwellwertunabhängig. Für die Gleichstrompotentialmessung wurde ein Gleichstrom von 300 A eingeleitet und der Potentialabfall über dem Kerb mit fünf Sonden entlang des Kerbs gemessen. Beide Messverfahren identifizieren die Rissinitiierung sowie Veränderungen im Risswachstum. Die detektierten Schallemissionsereignisse werden, unter Berücksichtigung spektraler Eigenschaften, mit fortschreitender Belastung und Rissentwicklung analysiert. Diese Studien wurden im Rahmen des interdisziplinären Forschungsprojekts AGIFAMOR, Aging infrastructure - Faseroptisches Monitoring von Rohrleitungen, an der BAM durchgeführt.