Acoustic emission testing can be used to detect the energy emitted from material fracture and the advantage of this method is the real time monitoring, however the weld metal discontinuities are normally inspected by using conventional NDT methods such as Penetrant Testing (PT), Magnetic particle Testing (MT), Ultrasonic Testing (UT) and Radiographic Testing (RT) after the completion of welding. The weld defect must be repaired, which involves the cost and consumes a lot of time as well as reduce the reliability of manufactures. This paper presents the application of acoustic emission (AE) technique for monitoring and detecting the discontinuities during welding. In this study, gas tungsten arc welding (GTAW) was selected as test process. Carbon steel plate and autogenous welding technique were used to simulate the hot crack. The data acquisition (DAQ) and AE sensor were used to capture the acoustic signal generated during welding. The AE signals were amplified and filtered by using preamplifier. Then, signals were modified by wavelet transforms (WT) technique and classified by Fast Fourier Transform (FFT) technique. The results showed the possibility to use AE technique for monitoring and detecting the low signal amplitude generated from crack by using frequency domain. The advantage of this research is to propose the technique for monitoring the weld metal discontinuities during welding.
This work describes a post-weld heat treatment for a precipitation-hardened nickel alloy. Inconel X-750 is a nickel-based superalloy for gas tungsten arc welding processes. The materials were heat-treated in two steps: solution and aging. The post-weld heat treatment variables examined in this study included post-weld heat treatment temperatures of 705°C, 775°C, and 845°C and post-weld heat treatment time of 2-24 h in 2-h increments. The resulting materials were examined using the full factorial design of experiments to determine the resulting material hardness and observed with optical microscopy, scanning electron microscopy, and energy dispersive X-ray spectroscopy in the fusion zone and heat-affected zone. The results show that a longer post-weld heat treatment time corresponds to larger g 0 precipitates and a smaller amount of Cr 23 C 6 at the grain boundaries, which can decrease the overall hardness. The post-weld heat treatment analysis indicates that an increase in the amount of g 0 results in better mechanical properties for particles with octagonal shapes and a small size. A factorial analysis, which was conducted on the relationship between the post-weld heat treatment temperature and time to the hardness of the fusion zone, had a 95% confidence level.
The transfer modes in gas metal arc welding have important effects on welding quality. However, present study of metal transfer modes is not yet fully understood. In this study, welding arcs was visualised using the optical emission spectroscopy technique. The carbon steel wire electrode was used for welding with 80% Ar + 20% CO 2 shielding gas. The results showed that the globular to spray transition current was 330-350 A. During globular to spray transition, argon,CO 2 and Fe plasma tended to gradually change from localising near the arc axis to a two-layer structure having 11,000 K in high-temperature region away from the arc axis and around 7000 K in lowtemperature region near the arc axis.
Weld metal mechanical properties and weldability of materials are closely related to the microstructure of the weld metal. A significant amount of research has been studied to improve microstructure of weldments such as weld pool stirring by using magnetic arc oscillation and arc pulsation. In this work, the effect of ultrasonic vibration was used to modify weld metal solidification to improve microstructure of the weld metal. Microstructure and mechanical properties of carbon steel weld metal (ER70S-G filler metal) were studied. Filler metal was melted by using Gas Tungsten Arc Welding (GTAW) in a water-cooled copper mold. Ultrasonic vibration with a frequency of 20 kHz was applied during solidification of the weld metal. Microstructure and mechanical properties of weld metal were compared with those of conventional weld metal (no ultrasonic vibration assistance). Scanning Electron Microscopy (SEM) was also used to determine microstructure and phases at high magnification. The results showed that ultrasonic vibration applied during solidification promoted grain refinement in the weld metal. Mechanical properties of weld metal were improved significantly, microstructure analysis correlated well with the mechanical test results.
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