Effect of weld parameters on porosity formation in electron beam welded Zircaloy-4 joints: X-ray tomography study

Bandi, Bharath; Dinda, Soumitra Kumar; Kar, Jyotirmaya; Roy, Gour Gopal; Srirangam, Prakash

doi:10.1016/j.vacuum.2018.09.060

Cited by 35 publications

(7 citation statements)

References 27 publications

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“…During solidification, bubbles do not have time to leave the weld pool and turn into pores, so larger weld pool and slow cooling are beneficial for low porosity. For high intensity beam welding processes, such as laser welding and electron beam welding, it has been proven that reducing the welding speed can reduce the porosity [237]. For arc welding, Wiesner et al [87] demonstrated that a lower welding speed was also effective in reducing porosity during welding of aluminium castings, and it could eliminate more gas pockets from the weld pool, which lowered the quantity of pores in the weld bead.…”

Section: Porositymentioning

confidence: 99%

Joining Technologies for Aluminium Castings—A Review

Slater

Cai

et al. 2023

Coatings

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Aluminium castings have been widely used in many industries, including automotive, aerospace, telecommunication, construction, consumer products, etc., due to their lightweight, good electric and thermal conductivity, and electromagnetic interference/radio frequency interference (EMI/RFI) shielding properties. The main applications of aluminium castings are in automotive industry. For lighweighting purposes, more and more aluminium castings are used in the automotive vehicle structures to reduce weight, improve fuel efficiency, and reduce greenhouse gas emissions. However, due to the features of cast aluminium, such as porosity, poor surface quality, a tendency toward hot cracking, and low ductility, joining these materials is problematic. In this paper, the joining technologies for aluminium castings and the related issues, mainly cracking and porosity, are reviewed. The current state-of-the-art of joining technologies is summarized, and areas for future research are recommended.

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Section: Porositymentioning

confidence: 99%

Joining Technologies for Aluminium Castings—A Review

Slater

Cai

et al. 2023

Coatings

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“…The tensile properties of Zr-4 alloy electron beam welded joints are not inferior to those of the parent material [ 19 ], but the presence of pores in the weld may affect the corrosion performance of the joint [ 20 ]. Bandi et al [ 21 ] demonstrated through Raman spectroscopy that the pores in the Zr-4 electron beam welded joint are mainly hydrogen pores. Zhang et al [ 22 ] found that the EBW joint of Zr-702 alloy is composed of α-Zr and β-Zr, and β-Zr small blocks are distributed along the edges of layered α-Zr, which indicates that the joint has better corrosion resistance than the BM.…”

Section: Introductionmentioning

confidence: 99%

Study of Microstructure and Performance Evaluation of Zr-Sn-Nb Joints by Electron Beam Welding

Zhao,

Zhang,

Yue

et al. 2024

Materials

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In this work, Zr-Sn-Nb alloy was joined by electron beam welding (EBW). A defect-free Zr-Sn-Nb joint with sound appearance was obtained. The grains in the weld zone (WZ) and heat-affected zone (HAZ) are significantly coarsened. The columnar grains with a maximum grain size of 0.5 mm are distributed in the upper region of the WZ, while the equiaxed grains are almost located in the bottom region of the WZ. The WZ is mainly composed of the dominant α-Zr, α′-Zr and a few β phases. The grain orientation of WZ and HAZ is uniform, indicating that no obvious preferred orientation existed. Coarse grains and fine acicular α′ phases increase the strength of the joint, but reduce the plasticity and toughness of the joint. The tensile strengths of the joints at room temperature (RT) and 375 °C were 438 MPa and 313 MPa, respectively. The RT impact energy of the joint is 18.5 J, which is only 58.3% of the BM. The high purity of the EBW process and unsignificant grain orientation minimizes damage to the corrosion resistance of Zr-Sn-Nb alloy joints. The corrosion weight gain of the joint specimen and the BM specimen were 12.91 mg/dm2 and 12.64 mg/dm2, respectively, and the thicknesses of the cross-section corrosion layer were 12–15 μm and 9–12 μm, respectively.

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“…Moreover, they have suggested the use of beam oscillation to reduce porosity formation. XCT and Raman spectroscopy has been performed by Bandi et al [15] to investigate micro-porosity during EBW of Zircaloy-4 alloys. They have also reported a significant reduction in porosity by using an oscillating beam.…”

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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Effect of weld parameters on porosity formation in electron beam welded Zircaloy-4 joints: X-ray tomography study

Cited by 35 publications

References 27 publications

Joining Technologies for Aluminium Castings—A Review

Joining Technologies for Aluminium Castings—A Review

Study of Microstructure and Performance Evaluation of Zr-Sn-Nb Joints by Electron Beam Welding

Study of micro-porosity in electron beam butt welding

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