Showing papers on "Filler metal published in 1980"

Metallurgy of Welding

Abstract: The effect of surface forces on the bonding of materials. Solid-phase welding and adhesive joining. Soldering and brazing. The joining of ceramics: microjoining. Fusion welding: processes. Fusion welding: mass and heat flow. Metallurgical effects of the weld thermal cycle. Carbon and ferritic alloy steels. Austenitic and high-alloy steels. Non-ferrous metals. The behaviour of welds in service.

Homogeneous ductile brazing foils

Abstract: Brazing of metal parts employing a homogeneous, ductile, filler metal foil is disclosed. The brazing foil, useful for brazing stainless steels, has a composition consisting essentially of 0 to about 4 atom percent iron, 0 to about 21 atom percent chromium, 0 to about 16 atom percent boron, 0 to about 19 atom percent silicon, 0 to about 22 atom percent phosphorus and the balance nickel and incidental impurities. In addition to containing the foregoing elements within the above-noted composition ranges, the composition must be such that the total of iron, chromium and nickel ranges from about 76 to 84 atom percent and the total of boron, silicon and phosphorus ranges from about 16 to 24 atom percent. The ductile foil permits fabrication of preforms of complex shapes which do not require binders and/or fluxes necessary for brazing powders presently used to braze stainless steels and nickel base alloys.

Composite wire for gas shielded arc welding

Abstract: PURPOSE: To execute vertical up welding with high efficiency and to obtain the composite wire which has the good migratability of droplets and decreases the amt. of the spatters to be generated by specifying the grain size constitution, incorporating TiO 2 at a specific ratio into the wire and incorporating specific components at specific ratios therein. CONSTITUTION: A flux is filled in the sheath made of a steel. The grain size constitution is so specified that the particles having the grain size exceeding 149μ are incorporated into the wire at 10wt.% and the particles having 44μ grain size or below at ≤30wt.%. The TiO 2 is incorporated into the wire at 3.5W7.0wt.% of the total weight of the wire. Further, contains 0.4W1.0wt.% ZrO 2 , 0.1W1.0wt.% Al 2 O 3 , 0.3W1.0wt.% Si, 1.2W3.2wt.% Mn, 0.1W0.6wt.% Al, 0.03W0.3wt.% total of 1 or 2 kinds of Na, K:Na, K, and 0.01W0.2wt.% F. The vertical up welding is thereby executed with high efficiency and the amt. of the spatters to be generated is decreased; in addition, the working efficiency of welding is improved. COPYRIGHT: (C)1989,JPO&Japio

Solidification behavior of austenitic stainless steel filler metals

Abstract: Thermal analysis and interrupted solidification experiments on selected austenitic stainless steel filler metals provided an understanding of the solidification behavior of austenitic stainless steel welds. The sequences of phase separations found were for type 308 stainless steel filler metal, L + L + delta + L + delta + ..gamma.. ..-->.. ..gamma.. + delta, and for type 310 stainless steel filler metal, L ..-->.. L + ..gamma.. ..-->.. ..gamma... In type 308 stainless steel filler metal, ferrite at room temperature was identified as either the untransformed primary delta-ferrite formed during the initial stages of solidification or the residual ferrite after Widmanstaetten austenite precipitation. Microprobe and scanning transmission electron microscope microanalyses revealed that solute extensively redistributes during the transformation of primary delta-ferrite to austenite, leading to enrichment and stabilization of ferrite by chromium. The type 310 stainless steel filler metal investigated solidifies by the primary crystallization of austenite, with the transformation going to completion at the solidus temperature. In our samples residual ferrite resulting from solute segregation was absent at the intercellular or interdendritic regions.

Nickel-base welding alloy

Abstract: A welding alloy particularly directed to use as a wrought filler metal and contains selected percentages of chromium, molybdenum, manganese, columbium, magnesium, a number of trace elements and the balance essentially nickel.

Homogeneous ductile brazing foils

Abstract: Metal parts are brazed by means of an amorphous filler metal foil. The brazing foil, useful for brazing stainless steels, has a composition consisting essentially of about 0-10 atom percent iron, about 0-20 atom percent chromium, about 3-5 atom percent molybdenum, about 5-35 atom percent cobalt, about 14-19 atom percent boron and the balance nickel and icidental impurities. The ductile foil permits fabrication of preforms of complex shapes which do not require binders and/or fluxes necessary for brazing powders presently used to braze stainless steels and nickel base alloys, and exhibits excellent braze-metal and high-temperature strengths.

Gas tungsten arc welding torch and welding process

Abstract: A gas tungsten arc welding torch having an elongated gas nozzle (18) with an oblong cross section designed for deep groove, narrow gap welding is coupled to a main torch body (16). A gas passage is formed along the welding electrode (10), which includes a detachable end section (42) which captures and supports a replaceable gas lens (30) disposed within the gas passage of the nozzle. The nozzle (18) is sealably mounted (38) to the main torch body and readily detachable for easy replacement during the welding process in which successively wider nozzles (18) are used as the gap to be welded becomes wider with successive weld passes.

Composite brazing sheet for heat exchanger made of al alloy

Abstract: PURPOSE: To provide a composite brazing sheet of superior local corrosion resistance by interposing an Al-Zn type alloy material of a specific composition as a sacrifice anode material between an Al-Mn type alloy made core material and an Al-Si type alloy made brazing material thereby forming a 3-ply clad material. CONSTITUTION: The composite brazing sheet for heat exchangers for radiators of automobiles, motorcycles, etc. is produced by using an Al-Mn type alloy contg. 0.3W2.0% Mn as a core material and using a brazing filler metal of Al-Si type alloy contg. 7W15% Si. In this case, an Al alloy contg. 0.3W2.0% Zn, or further 0.1W0.8% Mg and 0.1W2.0% Mn or an Al alloy contg. 0.01W0.15% one or two kinds of Zr, Cr according to need other than 0.3W2.0% Zn and 0.1W2.0% Mn is interposed at the intermediate of the core material and the brazing filler metal, as a sacrifice anode material to form a 3-ply clad material and the composite brazing sheet made in this way is used. Heat exchangers of superior local corrosion resistance are produced. COPYRIGHT: (C)1982,JPO&Japio

Horizontal electro-slag welding process for surfacing

Abstract: Surfacing is conducted with horizontal electro-slag welding by using a strip electrode, and by applying a magnetic field, having component perpendicular to a base metal, to a molten metal and slag pool to control the flow of the molten pool.

Devices and method for delivery of solder and brazing material

Abstract: A soldering device having a guide body for receiving and delivering a filler metal to form a weldment. The guide body has an end portion which is positioned in the path of the heat from the burner to preheat the filler metal therein. The temperature of the filler metal in the end portion is sensed by a thermocouple and delivered to a memory unit for comparison with a preset temperature for operating a device for feeding the filler metal to the end portion. A cooling area upstream from the end portion having collant circulating therethrough is also controlled from the memory unit. A screen movable between the burner and the end portion to control the flow of heat to the latter is also controlled by the memory unit. The temperature of the burner flame and of the workpiece can also be sensed to assure proper working conditions upon delivery of the filler metal. Additionally, the burner and the feed of a reducing gas can be automatically terminated while changing workpieces.

Process for the submerged-arc welding of light metals such as aluminum and aluminum alloys

Abstract: A welding process for joining aluminum materials in a horizontal welding position, without preheating, this process being highly economical and characterized by minimal environmental pollution, good strength and toughness of the welded joint, in which process the arc, as in submerged arc welding of steel plates, is covered by a flux layer and burns in a closed cavity, this process being realized by the use of a flux having a flux composition of 20-70% potassium chloride (KCl), 20-70% of an alkaline earth metal chloride, preferably calcium chloride and/or magnesium chloride (CaCl 2 and/or MgCl 2 ), 1-20% of calcium fluoride (CaF 2 ) and preferably 1-15% of a substance capable of lowering the melting point and/or releasing gas.

Gelatinous coating for arc welding and method for underwater welding

Abstract: A gelatinous coating comprising particles of electrode coating and thermite suspended in a gel for use as an insulating coating and fluxing agent in underwater arc welding. Also, a method for underwater welding in which the gelatinous coating is scorched and the electric arc is initiated and sustained so as to weld the workpiece. Alternatively, a method for arc welding in flammable or explosive atmospheres.

Welding of a textile material and method of welding such a material

Abstract: This welding of lap material presents welding areas of which the mass exceeds 80% of the mass of corresponding areas of the lap and of which the shearing resistance is higher than 10% of the tensile strength of the laps and the peeling resistance is higher than 5% of that strength. The ultrasonic welding process comprises the transmission of ultrasounds to the material parts to be welded via a heat insulating material, particularly a sheet material such as a paper sheet interposed between an anvil, respectively a welding sonotrode and a textile material. This process is applicable to all textile materials having more than 50% of thermoplastic fiber material.

Builddup welding method

Abstract: PURPOSE:To stabilize opposite polarity arc and improve welding efficiency by forming oxide film on the surface of filler metal and supplying the same to molten pool. CONSTITUTION:In performing opposite polarity welding by a welding torch 1, filler metal 3 is fed into molten pool 5 at the specified speed by plural feed rollers, etc. At this time, the filler metal 3 is perheated by using a TIG welding torch 7 (an electric heater is equally well) and an oxide film 32 is formed on the surface of the filler metal 3 by the O2 and CO2 contained in the shield gas 8. If the balance of the forming speed at the cathode point of the filler metal 3 and the supply state of the oxide film 32 is maintained, the cathode point always stagnate near the molten drop 31 of the filler metal 3 and generates the arc 2, thereby enabling the formation of beads 6.

Method for forming pipe joint in in-furnace brazing

Abstract: PURPOSE: To form the joint of flat pipes of heat exchangers, etc. in a good fitting state through sure brazing by forming a cylindrical part and a drawn part in the end part of a flat pipe, fitting a tubular body clad with a brazing filler metal onto the drawn part and joining these by brazing in a furnace. CONSTITUTION: A cylindrical part 3a, a drawn part 3b and an approximately horizontal step part 3b are formed in the end part of a flat tubular body 1 made of Al. A tubular body 1 clad with a brazing filler material 2 is fitted onto this drawn part 3b and its end face is abutted on the step part 3c. When these are loaded into a furnace and are heated, the brazing filler metal 2 on the surface of the tubular body 1 melts and flows into the contact part of both. At this time, the step part 3c blocks the flow of the brazing filler metal 2 and therefore the metal 2 forms a fillet 2c in the step part 3b, whereby the sure brazing is accomplished. By this method, fitting of the flat pipe to other tubular body is made easy, and the joint which is surely brazed with less possibility of loosening of the joint is formed. COPYRIGHT: (C)1981,JPO&Japio

Production of heat exchanger made of al alloy

Abstract: PURPOSE: To improve the corrosion resistance of a heat exchanger made of Al alloys by using an Al-Zn alloy for either one or both of pipe material and fin materials, and subjecting the same to Zn diffusion heat treatment after brazing by using Al-Si type brazing filler metals, in manufacturing said heat exchanger. CONSTITUTION: Al or an Al alloy such as Al-Mn or an Al alloy contg. 0.2W2.0% Zn for the purpose of imparting pitting resistance is used as a pipe material. A clad material of a core material of Al, or an Al alloy such as Al-Mn, or an Al alloy contg. 0.5W3.0% Zn for the purpose of giving sacrifice anode effect and a brazing filler metal of an Al-Si type alloy is used as a fin material. Namely, the heat exchanger made by using the Zn-contg. Al alloy for either one or both of the pipe material and fin materials and brazing these at 580W650°C in a vacuum of 10 -3 W 10 -6 torr is heated and held at 300W570°C in the atmosphere or an inert gas atmosphere of 10 -1 W1atm, whereby it is subjected to Zn diffusion heat treatment. COPYRIGHT: (C)1982,JPO&Japio

Production of brazing filler metal

Abstract: PURPOSE:To easily produce brazing filler metal capable of brazing firmly, by mixing Cu, Sn, Fe, Ni, Si, Zn by specified ratio and melting, then solidifying into bar or powder form. CONSTITUTION:Cu; 65 to 58%, Sn; 2 to 0.5%, Fe; 1.5 to 0.5%, Ni; 1.5 to 0.5%, Si; 1.5 to 0.2%, and Zn; 29 to 41.3% are mixed and melted, then solidified to produce brazing filler metal in bar or powder form. When this brazing filler metal is used for brazing of iron base matal, the action of Si in the brazing metal is restricted by Fe in the same metal, making it difficult to alloy with Fe in the iron base metal to form FeSi, so that a firm junction may be obtained.

Method and furnace for aluminum brazing using protective atmosphere

Abstract: PURPOSE:To prevent the attack of base metals by brazing filler metals by performing the temp elevation of materials to be treated through force circulation of an atmosphere and radiation heating and holding the materials at the treating temponly through the radiation heating during brazing in Al brazing work using a protecting atmosphere CONSTITUTION:The work W to be brazed is put in a drying chamber 2 and preheated and dried to about 200 degC Next, the work W is loaded into a vestibule 4, and after the inside of the vestibule 4 is evacuated and degassed to a vacuum, gaseous nitrogen as an inert gas is introduced to decompress and purge the furnace inside, whereby the work W is cleaned Thereafter, the work W is loaded into a brazing furnace 6, where the work W is quickly heated up to around the melting temp of a brazing filler metal through the radiation heating by a heater 9 and the convection heating by a circulation fan revolving at high speeds Next, the fan 11 is stopped, and the work is heated up to the brazing temp only through the radiation heating by the heater 9, whereby it is brazed There is no material degration of the brazing filler matal owing to the impurities in the circulating gaseous atmosphere, and the corrosion of the brazed material is prevented

Metal articles brazed with a homogeneous, ductile cobalt based brazing material

Abstract: Brazing of metal parts employing a homogeneous, ductile, filler metal foil is disclosed. The brazing foil, useful for brazing cobalt based alloys, has a composition consisting essentially of 0 to about 4 atom percent iron, 0 to about 26 atom percent chromium, 0 to about 20 atom percent nickel, 0 to about 4 atom percent tungsten, 0 to about 4 atom percent molybdenum, 0 to about 20 atom percent boron, 0 to about 12 atom percent silicon, 0 to about 2 atom percent carbon and the balance essentially cobalt and incidental impurities. In addition to containing the foregoing elements within the above-noted composition ranges, the composition must be such that the total of iron, chromium, nickel, tungsten, molybdenum and cobalt ranges from about 75 to 85 atom percent and the total of boron, silicon and carbon ranges from about 15 to 25 atom percent. The ductile foil permits fabrication of preforms of complex shapes which do not require binders and/or fluxes necessary for brazing powders presently used to braze cobalt and nickel based alloys.

Formation of porous layer on metallic surface

Abstract: PURPOSE: To form a porous layer having high heat transfer perfomance on a metallic surface by mixing a binder with metallic powder and brazing filler metal powder of specific grain sizes to prepare a slurry, and coating the slurry on the metallic surface then heating the same in a non-oxidative atmosphere thereby brazing and joining the same. CONSTITUTION: A binder is mixed with metallic powder of 20W500μm diameters and brazing filler metal powder of 20W200μm diameters. The binder is preferably a plastic. Suitable liquid is mixed with this mixture to prepare a slurry having uniform and moderate viscosities. The weight ratio of the brazing filler metal powder and the metallic powder is preferably about 1:8. The slurry of the mixture is coated on a metallic surface. Depending upon the thicknesses of the object to be coated, the thickness of the porous layer is controlled. Thence, the coated object is heated in a vacuum, non-oxidative or reducing atmosphere, whereby it is brazed and joined, and the porous layer is formed inexpensively and easily on the metallic surface. COPYRIGHT: (C)1982,JPO&Japio

Flux-cored wire for vertical and horizontal position arc welding of stainless steel

Abstract: PURPOSE:To increase the viscosity of slag and molten metal and prevent the dripping of beads by mixing the metal powder contg. a specific amount of Ti in the flux of a flux-cored wire used for welding stainless steel in a horizontal vertical position. CONSTITUTION:The flux composition of the flux-cored wire used for welding stainless steel in a vertical or horizontal position by automatic or semiautomatic arc welding is made as follows: The flux is constituted of 20-45% the metal powder of Fe, Cr, Ni, etc. contg. 10-15% TiO2 or in total of one or more kinds of TiO2 and Fe2O, 0.5-4% in total of one or more kinds of LiCO3 and Na2CO3, 2-4% in total of one or more kinds of CaCO3, BaCO3 and MgCO3, 0.5-1.0% in total of one or more kinds of SiO2, Al2O3, and MgO, and 0.1-3% Ti. Ti acts as a deoxidizer, a denitrifier and an arc stabilizer, and increases the viscosity of the slag and metal melted by low-current arc welding, thereby enabling dripping of beads and undercut to be prevented.

Welding Stainless Steels for Structures Operating at Liquid Helium Temperature

Abstract: Superconducting magnets for fusion energy reactors require mas­ sive monolithic stainless steel weld­ ments which must operate at extreme­ ly low temperatures under stresses approaching 100 ksi (700 MPa). A three-year study was conducted to determine the feasibility of producing heavy-section welds having usable levels of strength and toughness at 4.2 K (-452°F) for fabrication of these structures in Type stainless steel 304LN plate. Seven welding processes were eval­ uated. Test weldments in full-thick­ ness plate were made under severe restraint to simulate that of actual structures. Type 316L stainless steel filler metal was used for most welds. There are welds that are deposited under some conditions and solidify as primary austenite, exhibiting inter­ granular embrittlement at 4.2 K. This is believed to be associated with grain boundary metal carbides or carboni- trides precipitated during reheating of already deposited beads by subse­ quent passes. Weld deposits which solidify as primary delta ferrite appear immune.

Welding electrode with a fluoride based slag system

Abstract: A gas shielded, flux-cored welding electrode for vertical or overhead welding as well as for horizontal or flat welding is disclosed having a generally tubular metal sheath and a core defined within the sheath, wherein the core includes a slag forming system based, primarily, on about 2-7.5% of the fluorides of calcium and/or strontium.

On the elaboration of a new submerged arc welding flux for titanium

Abstract: The present work describes a new CaF 2 -based flux, containing 10% SrCl 2 and 3% LiCl, for the submerged arc welding of titanium and titanium-based alloys. The flux protects the base metal from oxidation during the welding operations and makes it possible to produce defect-free uncontaminated joints. The mechanical behaviour of the welded plates (T35, T40 and TA6V) demonstrates good ductility of the welded zone, compatible with the usual specifications for titanium-welded joints.

Three o*clock plasma keyhole welding method

Abstract: PURPOSE:To push up and hold molten metal with a plasma arc and prevent the formation of under-cuts and blowholes by tilting the plasma torch upward to the works and welding the works. CONSTITUTION:A plasma torch 1 is tilted upward with respect to horizontal by making its angle alpha to the works 3, 3' at 0

Joining method for pipe material

Abstract: PURPOSE: To form a joined part having high joining strength in a short time by press-fitting a pipe material wound with a brazing filler metal into the other pipe material and brazing these by means of resistance heating, in joining two pieces of pipe materials with a brazing filler metal. CONSTITUTION: In joining pipes 1 and 4, a brazing filler metal 2 is wound on the opening end of the pipe 1, and this is plastically worked to make the outside diameter of the metal 2 and the outside diameter of the pipe 1 the same. Further, the part to be press-fitted of the outside surface thereof is beforehand knurled 3. After such pipe 1 is press-fitted into the pipe 4, large electric current is flowed from a transformer 5 for resistance welding to the electricity conducting electrodes 7a, 7b mounted to both pipes 1, 4 to heat the pipe 1 of small thermal capacity red hot, thence the pipe 4 is shifted gradually to melt the ring-like metal 2. The molten brazing filler metal spreads over the entire surface of the press fitting part of the pipe materials on account of the capillarity in the knurling seams of the fitting part, whereby both pipes 1, 4 are brazed. COPYRIGHT: (C)1982,JPO&Japio

Tig welding method and tungsten electrode used for this

Abstract: PURPOSE:To obtain the TIG welding method of high reliability by forming the tungsten electrode to the hollow shape provided with a central hole and vibrating and stirring the molten metal in molten pool. CONSTITUTION:Direct current or alternating current is supplied to a tungsten electrode 2 through a contact tip 3 to generate arc 6 and melt part of filler metal 7 or base metal 1, whereby a molten pool 8 is formed. At the same time, shielding gas from a lead-in port 5 is spouted from a nozzle 4. As a result of this, bead appearance becomes extremely beautiful. Further, a rotary valve 11 is rotated to lead the control gas composed of inert gas from a cylinder 15 into an electrode inside hole 9 and let it be spouted in a pulsation manner into the molten pool 8 from the electrode end. As a result of this, the molten metal in the molten pool is vibrated and stirred and the development of columnar crystal structure of molten metal is hampered; at the same time, nucleus production is accelerated, whereby tesseral granular crystal structure is formed.

Pipe welding method and welded joint pipe used in said method

Abstract: PURPOSE:To form welded joint part excelling in joint shape and strength, by placing a joint pipe of the same aperture and same material between the pipes to be welded, and welding the joint at two positions using the fitting part thereof as the filler metal, when butt-welding the pipes by nonconsumable electrode arc welding method. CONSTITUTION:When butt-welding pipes 1, 1', the both pipes 1, 1' are connected together by means of a joint pipe 7 of a short width having the same aperture and material as the pipes. At both ends of the joint pipe 7 are provided ring projections 9, 9' which are to fit to the end outer edges of the pipes 1, 1' so as to connect with the pipes 1, 1'. In the central part of the pipe body 7 is formed a ring projection 10 for determining the welding position, and the position of electrodes 13, 13' is set by a positioning clamp 12. The both pipes 1, 1' are secured with clamps 11, 11', and arc welding is performed by using the projections 9, 9' as the filler metal. Thus, a welded joint having normal joint shape and excellent strength may be obtained.