Effect of beam oscillation on porosity and intermetallics of electron beam welded DP600-steel to Al 5754-alloy

Dinda, Soumitra Kumar; Kar, Jyotirmaya; Jana, Subhodeep; Roy, Gour Gopal; Srirangam, Prakash

doi:10.1016/j.jmatprotec.2018.10.026

Cited by 50 publications

(12 citation statements)

References 29 publications

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“…During this study, µ-CT has been confirmed as a powerful investigation tool for revealing internal defects such as pores. Dinda et al [21] utilized µ-CT scans for optimization of electron beam welded DP600 steel and Al 5754-joints. Based on the computed tomography, obtaining of the quantified information of weld defects was performed.…”

Section: X-ray Computed Tomography Of Weldmentsmentioning

confidence: 99%

Electron beam welding of rectangular copper wires applied in electrical drives

Tóth

Hensel

Thiemer³

et al. 2021

Weld World

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The so-called hairpin winding technology, which is specially tailored to electrical traction components, deploys rectangular plug-in copper wires in the stator. The fusion welding of the adjacent wire ends is associated with challenges due to the high thermal conductivity as well as the porosity formation of the copper. During this study, the electron beam (EB) welding of electrolytic tough pitch (ETP) and oxygen-free electronic grade (OFE) copper connectors was investigated. Subsequently, the specimens underwent X-ray computed tomography (CT) and metallographic examinations to characterize the joints. It was discovered that the residual oxygen content of the base material is responsible for the pore formation. With only a very low level of oxygen content in the copper, a porosity- and spatter-free welding can be reproducibly realized using the robust EB welding technology, especially for copper materials. By optimizing the parameters accordingly, joints exhibiting a low level of porosity were achieved even in the case of the alloy containing a high amount of residual oxygen. Beyond this, detailed analyses in terms of pore distribution were carried out and a good correlation between technological parameters and welding results was determined.

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Section: X-ray Computed Tomography Of Weldmentsmentioning

confidence: 99%

Electron beam welding of rectangular copper wires applied in electrical drives

Tóth

Hensel

Thiemer³

et al. 2021

Weld World

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“…They have also reported a significant reduction in porosity by using an oscillating beam. X-ray Diffraction (XRD), SEM, XCT, and micro-hardness tester have been used by Dinda et al [16] to study the distribution of porosity and intermetallic compounds (IMCs) in dissimilar EBW of DP600-steel to 5754 Al-alloy. They have also observed a significant reduction in the porosity due to beam oscillation.…”

Section: Introductionmentioning

confidence: 99%

Study of micro-porosity in electron beam butt welding

Das

Dinda

Das

et al. 2022

Int J Adv Manuf Technol

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As complete elimination of porosity from the weld is very difficult, the next option available is to minimize this weld porosity, which is crucial for the safe performance of the welded components. However, this investigation through experiments alone is very tedious and time consuming. Additionally, very limited models are available in the literature for accurate prediction of different porosity attributes. The present study, thus, addressees both the experimental as well as modelling aspect on the study of micro-porosity during Electron Beam Welding (EBW) of SS304 plates. Welding parameters are reported to have significant influence on the micro-porosity. Hence, the influences of these parameters on micro-porosity attributes, namely pores number, average diameter, and sphericity are extensively studied experimentally employing optical microscopy (OM), scanning electron microscopy (SEM), X-ray computed tomography (XCT), and Raman spectroscopy. This is followed by an elaborate modelling through seven popular and wellrecognized Machine Learning Algorithms (MLAs) namely, Multi-Layer Perceptron (MLP), Support Vector Regression (SVR), M5P model trees regression, Reduced Error Pruning Tree (REPTree), Random Forest (RF), Instance-based k-nearest neighbor algorithm (IBk) and Locally Weighted Learning (LWL). These different techniques enhance the chance of obtaining the better predictions of the said micro-porosity attributes by overcoming the effect of data-dependence and other limitations of individual MLAs. The different model-predicted micro-porosity data are also validated through experimental data. Statistical tests and Monte-Carlo reliability analysis are additionally utilized to evaluate the performances of the employed algorithms. IBk and MLP are overall found to perform well.

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“…Joining processes that involve melting such as electron beam welding (EBW) and brazing; and solid-state processes such as friction stir welding (FSW), friction welding (FRW) and explosion welding (EXW) can also be used to join aluminum to steel. EBW is a high-energy-density and very precise welding process [21] and has been successfully used to obtain dissimilar aluminum-steel joints [22]. However, EBW requires a vacuum environment, which is not necessary for LBW [23].…”

Section: Introductionmentioning

confidence: 99%

Recent Developments in Laser Welding of Aluminum Alloys to Steel

Wallerstein

Salminen

Lusquiños

et al. 2021

Metals

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The development of high-performance dissimilar aluminum–steel joints is necessary to promote the feasibility of multi-material design and lightweight manufacturing. However, joining aluminum to steel is a challenging task mainly due to the formation of brittle intermetallic compounds (IMC) at the joint interface. Laser welding is considered a very promising joining process for dissimilar materials, although its application in industry is still limited by the insufficient mechanical performance of the joints. The present paper aims to give a comprehensive review of relevant recent research work on laser joining of aluminum to steel, contributing to highlighting the latest achievements that could boost acceptance of laser joining of dissimilar materials by the modern industries. To this end, the most important challenges in laser joining of aluminum to steel are presented, followed by recent approaches to overcome these challenges, the state-of-art of comprehension of IMC formation and growth, and the different strategies to minimize them.

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Effect of beam oscillation on porosity and intermetallics of electron beam welded DP600-steel to Al 5754-alloy

Cited by 50 publications

References 29 publications

Electron beam welding of rectangular copper wires applied in electrical drives

Electron beam welding of rectangular copper wires applied in electrical drives

Study of micro-porosity in electron beam butt welding

Recent Developments in Laser Welding of Aluminum Alloys to Steel

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