Search Results (1,410)

This paper summarizes the results of investigations into heterogeneous P23/P91 welds after long-term creep exposure at temperatures of 500, 550 and 600 °C. Two variants of welds were studied: In Weld A, the filler material corresponded to P91 steel, while in Weld B, the chemical composition of the consumable material matched P23 steel. The creep rupture strength values of Weld A exceeded those of Weld B at all testing temperatures. Most failures in the cross-weld samples occurred in the partially decarburized zones of P23 or WM23 steel. The results of the investigations on the minor phases were in good agreement with kinetic simulations that considered a 0.1 mm fusion zone. Microstructural studies proved that carburization occurred in the P23/P91 weld fusion zones. The partial decarburization of P23 steel or WM23 was accompanied by the dissolution of M₇C₃ and M₂₃C₆ particles, and detailed studies revealed the precipitation of the Fe₂ (W, Mo) Laves phase in decarburized areas. Thermodynamic simulations proved that the appearance of this phase in partially decarburized P23 steel or WM23 is related to a reduction in the carbon content in these areas. According to the results of creep tests, the EBSD investigations revealed a better microstructural stability of the partially decarburized P23 steel in Weld A. Full article

High energy density technologies for welding processes provide opportune solutions to joint metal materials and repair components in several industrial applications. Their high-performance levels are related to the high penetration depth and welding speed achievable. Moreover, the localized thermal input helps in reducing distortion and residual stresses in the welds, minimizing the extension of the fusion zone and heat-affected zone. The use of these welding technologies can be decisive in the employment of sophisticated alloys such as Ni-based superalloys, which are notoriously excellent candidates for industrial components subjected to high temperatures and corrosive work conditions. Nonetheless, the peculiar crystallographic and chemical complexity of Ni-based superalloys (whether characterized by polycrystalline, directionally solidified, or single-crystal microstructure) leads to high susceptibility to welding processes and, in general, challenging issues related to the microstructural features of the welded joints. The present review highlights the advantages and drawbacks of high energy density (Laser Beam and Electron Beam) welding techniques applied to Ni-based superalloy. The effects of process parameters on cracking susceptibility have been analyzed to better understand the correlation between them and the microstructure-mechanical properties of the welds. The weldability of three different polycrystalline Ni superalloys, one solid solution-strengthened alloy, Inconel 625, and two precipitation-strengthen alloys, Nimonic 263 and Inconel 718, is reviewed in detail. In addition, a variant of the latter, the AF955 alloy, is also presented for its great potential in terms of weldability. Full article

The increasing challenges related to the reliability and durability of steel pipeline infrastructure necessitate a detailed understanding of degradation and failure mechanisms. This study focuses on selective corrosion and erosion as critical factors, analyzing their impact on pipeline integrity using advanced methods, including macroscopic analysis, corrosion testing, microscopic examination, tensile strength testing, and finite element method (FEM) modeling. Selective corrosion in the heat-affected zones (HAZs) of longitudinal welds was identified as the dominant degradation mechanism, with pit depths reaching up to 6 mm, leading to tensile strength reductions of 30%. FEM analysis showed that material loss exceeding 8 mm in weld areas under standard operating pressure (16 bar) induces critical stress levels, risking pipeline failure. Erosion was found to exacerbate selective corrosion, accelerating degradation in high-stress zones. Practical recommendations include the use of corrosion-resistant materials, such as duplex steels, and implementing integrated monitoring strategies combining non-destructive testing with FEM-based predictive modeling. These insights contribute to developing robust preventive measures to ensure the safety and longevity of pipeline infrastructure. Full article

TC17 titanium alloy is widely used in the aviation industry for dual-performance blades, and linear friction welding (LFW) is a key technology for its manufacturing and repair. However, accurate evaluation of the mechanical properties of TC17−LFW joints and research on their joint fracture behavior are still not clear. Therefore, this paper used the finite element numerical simulation method (FEM) to investigate the mechanical behavior of the TC17−LFW joint with a complex micro−structure during the tensile processing, and predicted its mechanical properties and fracture behavior. The results indicate that the simulated elastic modulus of the joint is 108.5 GPa, the yield strength is 1023.2 MPa, the tensile strength is 1067.5 MPa, and the elongation is 1.98%. The deviations from measured results between simulated results are less than 2%. The stress and strain field studies during the processing show that the material located at the upper and lower edges of the joint in the WZ experiences stress and strain concentration, followed by the extending of the stress and strain concentration zone toward the center of the WZ. And finally, the strain concentration zone covered the entire WZ. The fracture behavior studies show that the material necking occurs in the TMAZ of TC17(α + β) and WZ, while cracks first appear in the WZ. Subsequently, joint cracks propagate along the TC17(α + β) side of the WZ until fracture occurs. There are obvious tearing edges formed by the partial tearing of the WZ structure in the simulated fracture surface, and there are fracture surfaces with different height differences at the center of the joint crack, indicating that the joint has mixed fracture characteristics. Full article

Forging additive hybrid manufacturing integrated the high efficiency of forging and the great flexibility of additive manufacturing, which has significant potential in the construction of reactor pressure vessels (RPVs). In the components, the heat-affected zone (HAZ, also called as bonding zone) between the forged substrate zone and the arc deposition zone was key to the final performance of the components. In this study, the Mn-Mo-Ni welding wire was deposited on the 16MnD5 substrate with a submerged arc heat source. The in situ reheat cycle effect of the submerged arc heat source on the microstructure and mechanical properties of the HAZ were studied. The results showed that the HAZ underwent four heat treatment processes, including two full austenitizing stages, one high-temperature stage, and continuous low-temperature tempering, which formed a homogenized microstructure in the HAZ and was mainly composed of tempered sorbite (Tempered-S). The HAZ microhardness is around 278.7 HV, which is about 150 HV lower than the microhardness only conducted by one thermal cycle. Furthermore, the effects of preheating the substrate and adjusting the heat inputs on the HAZ were studied. The results indicated that the clustered cementite was precipitated, which destroys the low-temperature impact toughness of the HAZ after preheating. A suitable heat input not only homogenized the microstructure within the HAZ but also promoted the transformation of grains into equiaxed grains. The −60 °C impact toughness of the HAZ was significantly increased from 96.7 J to 113 J. Full article

The grain growth in the fusion zone (FZ) and heat-affected zone (HAZ) of metal inert gas (MIG) welding processes negatively affect the mechanical properties of aluminum alloy MIG welds used in automotive components. Although the addition of Sc- and Zr-based filler wires can refine weld microstructures and enhance the mechanical properties, conditions resembling actual automotive component joints have not been sufficiently investigated. In this study, 5083-O aluminum alloy base material was welded into butt and lap joints using conventional 5000-series aluminum alloy filler wires (Al-5.0Mg) and wires containing Sc and Zr (Al-4.8Mg-0.7Sc-0.3Zr) under various heat input conditions. The mechanical properties of the welds were evaluated via tensile tests, and the microstructures in the FZ and HAZ were analyzed. In butt joints, Al-4.8Mg-0.7Sc-0.3Zr exhibited a finer and more uniform grain structure with increased tensile strength compared with those welded using Al-5.0Mg. The microstructure became coarser with the increased heat input, and the tensile strength tended to decrease. In lap joints, the tensile-shear strength of Al-4.8Mg-0.7Sc-0.3Zr was higher than that of Al-5.0Mg; it further increased with the increase in the amount of deposited metal. The coarsening of the microstructure with the increased heat input was disadvantageous for the tensile-shear strength, and the increased weld size offset the adverse effects of the coarse microstructure. These results indicate that the heat input and the amount of deposited metal must be optimized to ensure stiffness in various joints of automotive components. Full article

Super-duplex stainless steels (SDSSs) were introduced in the oil and gas industry due to their high resistance to pitting corrosion, promoted by the high content of alloying elements. The welding process can cause an unbalanced ferrite/austenite microstructure and, consequently, the possibility of deleterious phases, increasing the risk of failure. The aim of this work is to investigate the behavior of the heat-affected zone (HAZ) of SDSS UNS S32750 steel produced with different thermal inputs simulated in a Gleeble^® welding simulator and correlate these findings with its corrosion properties. The pitting resistance was investigated by electrochemical techniques in sodium chloride solution, and the critical pitting temperature (CPT) was calculated for each evaluated microstructure. The material as received presents 46.19 vol% ferrite and a high corrosion resistance, with a CPT of 71.54 °C. HAZ-simulated cycles resulted in similar ferrite percentages, between 54.09 vol% and 57.25 vol%. A relationship was found between heat input, ferrite content, and CPT: increasing the heat input results in greater ferrite content and lowers the CPT, which may favor the pitting corrosion process. Therefore, it is concluded that the ferrite content directly influences the pitting behavior of the material. Full article

The welding of the bottom-locking structure in a detector receptacle plays an essential role in ensuring the safety of nuclear equipment. A pulsed TIG–laser hybrid welding method is proposed to address the problem of welding pores in locking structural parts. The effects of the pulse frequency on the escape of porosity and of porosity on the mechanical properties of the hybrid welding joint were investigated. The results were compared to those of direct current (0 Hz), showing that the pulse frequency affects the stability of the arc. With an increase in pulse frequency, the grain size of the fusion zone gradually decreases, and the flow in the middle area of the molten pool increases. This subjects bubbles in the molten pool to a thrust force, which causes the bubbles to escape to the surface of the molten pool. Compared with 0 Hz, the tensile strength of the joint increased by 67%. This provides a new solution for obtaining reliable welded joints for the bottom-locking structure of detector storage tanks. Full article

Reducing CO₂ emissions is one of the major challenges facing the modern world. The overall goal is to limit global warming and prevent catastrophic climate change. One of the many methods for reducing carbon dioxide emissions involves capturing, utilizing, and storing it at the source. The Carbon Capture in Molten Salts (CCMS) technique is considered potentially attractive and promising, although it has so far only been tested at the laboratory scale. This study evaluates the wear of the main structural components of a prototype for CO₂ capture in molten salts—a device designed and tested in the laboratories of AGH University of Kraków. The evaluation focused on a gas barbotage lance and a reactor chamber (made from Nickel 200 Alloy), which were in continuous, long-term (800 h) contact with molten salts CaCl₂-CaF₂-CaO-CaCO₃ at temperatures of 700–940 °C in an atmosphere of N₂-CO₂. The research used light microscopy, SEM, X-ray, computed tomography (CT), and 3D scanning. The results indicate the greatest wear on the part of the lance submerged in the molten salts (3.9 mm/year). The most likely wear mechanism involves grain growth and intergranular corrosion. Nickel reactions with the aggressive salt environment and its components cannot be ruled out. Additionally, the applied research methods enabled the identification of material discontinuities in the reactor chamber (mainly in welded areas), pitting on its surface, and uneven wear in different zones. Full article

AISI 304 is widely regarded as the most common austenitic stainless steel and is utilized in various household and industrial applications, including food handling equipment, machinery components, and heat exchangers. Its popularity stems from its excellent mechanical properties, corrosion resistance, and ease of manufacturing. Given its diverse applications, it is crucial to study the microstructural evolution and mechanical properties of the welded zone, especially considering the potential for weld decay during fusion welding. In this context, two critical thermal-dependent factors for ensuring high-quality welds are grain growth and hardness variation in the heat-affected zone (HAZ) during the welding process. This paper presents an innovative finite element (FE) model developed to analyze the grain growth and hardness reduction that occur in the HAZ during plasma arc welding (PAW) of AISI 304 steel for solid expansion tube (SET) technology. Using the commercial FE software SFTC DEFORM-3D™, a user subroutine was created that integrates a physics-based model with the Hall–Petch (H-P) equation to predict changes in grain size and hardness. This study introduces a comprehensive numerical model, encompassing the user subroutine, heat source fitting, and geometry, which accurately predicts the thermal phenomena associated with grain coarsening and hardness reduction in the HAZ during the welding of austenitic stainless steel. The results from the numerical model, including the customized user routines, show good agreement with experimental data, leading to a maximum error prediction of 10 HV in hardness, 30 µm in grain size, and 10% in HAZ extension. Full article

The Changbaishan volcano is well known for its major caldera-forming Millennium Eruption (ME) in 946 CE (Common Era). We report Hf–O isotopes of zircon grains from pre-caldera Qixiangzhan (QXZ) and syn-caldera eruptions of the Changbaishan (Baitoushan) volcano to constrain magma chamber processes. Zircon grains from the pre-caldera QXZ comendite lavas have δ¹⁸O ranging from 4.46 to 5.16 (lower than mantle values) and ε_Hf ranging from −4.47 to +4.37. Zircon grains from the syn-caldera ME1 charcoal-bearing non-welded comendite pyroclastic flow deposits have δ¹⁸O ranging from 2.25 (lower than mantle values) to 5.51 and ε_Hf from −3.75 to +3.31. By comparison, zircon grains from the ME2 welded trachytes have δ¹⁸O ranging from 5.66 to 6.20 (higher than mantle zircon values) and ε_Hf from −1.97 to +6.23. There are no correlations between O and Hf isotopes for all zircon grains in QXZ and ME1 comendites and ME2 trachyte. The ubiquitous occurrence of low-δ¹⁸O zircon grains in QXZ and ME1 comendites indicates shallow remelting of hydrothermally altered low-δ¹⁸O juvenile rocks. By contrast, ME2 trachyte zircons (except for two zircon grains) have normal δ¹⁸O (5.66 to 6.10) values, indicating a lack of remelting processes. Similar zircon Hf–O isotopes between pre-caldera QXZ comendites and syn-caldera ME1 comendites indicate tapping of the upper portion of a zoned magma chamber. Higher δ¹⁸O in ME2 trachyte zircons indicate tapping of the deeper portion of a zoned magma chamber free from shallow remelting. The lack of significant correlations between zircon O and Hf isotopes, and the relatively high εHf values for all Changbai zircon grains, argue against partial melting of ancient continental crust or significant contaminations by ancient crustal rocks as an origin for these felsic magmas. The QXZ and ME1 comendites were formed by shallow remelting of hydrothermally altered juvenile volcanic rocks, and ME2 trachytes were formed by evolution of mantle-derived basaltic magmas free of hydrothermal assimilations. A proto-caldera likely formed prior to the generation of QXZ lavas at 10 ka. Full article

This investigation focuses on Selective Laser Melting (SLM)-fabricated thin-walled Ta10W alloy components. Given the inherent limitations of SLM in producing large-scale, complex components in a single operation, laser welding was investigated as a viable secondary processing method for component integration. The study addresses the critical issue of weldability in additively manufactured tantalum-tungsten alloys, which frequently exhibit internal defects due to process imperfections. Comprehensive analyses were conducted on weldability, microstructural evolution, texture intensity, and mechanical properties for welds oriented along both traveling and building directions. Results demonstrate that welds oriented along the traveling direction exhibit superior performance characteristics, including enhanced tensile strength, increased yield strength, improved elongation, and reduced texture intensity compared to building direction welds. Notably, grain orientation alignment between the weld zone and base material was observed consistently in both directional configurations. Full article

Despite the extensive use of 7xxx aluminum alloys in aerospace, intergranular corrosion is yet to be appropriately addressed. In this work, in situ rolling friction stir welding (IRFSW) was proposed to improve the corrosion resistance of joints via microstructural design. A gradient-structured layer was successfully constructed on the surface of the joint, and the corrosion resistance was improved by in situ rolling. The intergranular corrosion depth of the IRFSW joint was reduced by 59.8% compared with conventional joints. The improved corrosion resistance was attributed to the redissolved precipitates, the disappearance of precipitate-free zones, and the discontinuous distribution of grain boundary precipitates. This study offers new insights for enhancing the corrosion resistance of aluminum alloy FSW joints. Full article

The microstructure and impact toughness of a steel material subjected to multi-layer and multi-pass welding with varying secondary peak temperatures were investigated using welding thermal simulation. The detailed microstructures and fracture morphologies were examined by SEM, TEM, and EBSD. When the secondary peak temperature reaches 650 °C, the microstructure resembles that of a primary thermal cycle at 1300 °C, characterized by coarse grains and straight grain boundaries. As the temperature increases to 750 °C, chain-like structures of bulky M/A (martensite/austenite) constituents form at grain boundaries, widening them significantly. At 850 °C, grain boundaries become discontinuous, and large bulky M/A constituents disappear. At 1000 °C, smaller austenitic grains form granular bainite during cooling. However, at 1200 °C, grain coarsening occurs due to the significant increase in peak temperature, accompanied by a lath martensite structure at higher cooling rates. In terms of toughness, the steel exhibits better toughness at 850 °C and 1000 °C, with ductile fracture characteristics. Conversely, at 650 °C, 750 °C, and 1200 °C, the steel shows brittle fracture features. Microscopically, the fracture surfaces at these temperatures exhibit quasi-cleavage fracture characteristics. Notably, chain-like M/A constituents at grain boundaries significantly affect impact toughness and are the primary cause of toughness deterioration in the intercritical coarse-grained heat-affected zone. Full article

This study investigates the residual stresses arising from welding and machining processes, recognizing their adverse implications in manufacturing. Employing experimental analysis and simulation techniques, the research scrutinizes residual stress alterations resulting from sequential butt welding and subsequent machining. Utilizing MSC Marc Mentat software(version 2016), three-dimensional models are developed to simulate these processes. The finite element model from welding simulation seamlessly integrates into cutting simulations via the pre-state option. The experimental procedures involve 100 × 100 × 10 mm AISI 304 steel plates subjected to sequential welding and machining, with residual stresses measured at each stage. A comparative analysis between experimental and simulation results elucidates variations in residual stresses induced by sequential processes. The study focuses on examining the initial stress state post-welding and numerically assessing stress modifications due to milling. The results suggest minimal material removal insignificantly affects stress distribution and magnitude at the weld centerline. However, increased material removal leads to noticeable changes in through-thickness transverse stress within the weld zone, contrasting with marginal alterations in through-thickness longitudinal stress. Regions distanced from the weld seam show substantial increases in through-thickness longitudinal stress compared to marginal changes in through-thickness transverse stress. Full article