Heat-affected zone

About: Heat-affected zone is a research topic. Over the lifetime, 18787 publications have been published within this topic receiving 231744 citations.

Macroporosity free aluminum alloy weldments through numerical simulation of keyhole mode laser welding

Abstract: A transport phenomena-based numerical model is developed to predict the keyhole geometry and temperature profiles in the weldment during laser welding. The model can be used to prevent macroporosity formation during laser welding of aluminum alloys. The experimental results show that the weld metal contains large pores when the welding mode changes from conduction to keyhole mode or vice versa due to changes in welding variables. Based on this observation, the mathematical model predicts macroporosity formation when welding is conducted under conditions where small changes in welding parameters lead to a change in the welding mode. The model has been used to predict the geometry of the keyhole and the fusion zone, and the weldment temperature field for laser beam welding of aluminum alloys 5182 and 5754. The calculated weld pool depth, width, and shape for different welding speeds agreed well with the experimental results. The calculations showed that the keyhole profiles for high-speed welding were asymmetric. Negative beam defocusing resulted in a deeper keyhole than that obtained with positive beam defocusing. The transition from keyhole to conduction mode was more abrupt for negative beam defocusing. The model could predict the formation of macroporosity during laser welding of aluminum alloys 5182 and 5754. The results provide hope that transport phenomena-based models can be useful to prevent the formation of macroporosity during keyhole mode laser welding of aluminum alloys.

Microstructural characterization of simulated heat affected zone in a nitrogen-containing 2205 duplex stainless steel

Abstract: In order to investigate the microstructural evolution in a nitrogen-bearing 2205 duplex stainless steels (DSS) during welding, a simulated weld thermal cycle with 5 kJ cm−1 heat input followed by exposure at 700 °C for different time intervals was performed. The microstructure of high-temperature heat affected zone (HTHAZ) developed with the thermal experience was characterized via optical metallography and transmission electron microscopy (TEM). The duplex structure with equivalent phase components was drastically destroyed by the rapid thermal cycle. In the simulated HTHAZ structure, three different morphologies of newly formed austenite were observed in the coarse-grained δ-ferrite matrix; i.e. allotriomorphic austenite, Widmanstaten autenite and intragranularly nucleated autenite. During the exposure at 700 °C, the intragranularly nucleated austenite got coarse and the Widmanstaten austenite grew progressively. TEM revealed that several variants of rod-like Cr2N were precipitated selectively at intragranular and intergranular sites. From the analyses of diffraction patterns of TEM, Kurdjumov–Sachs orientation relationship was found to describe the interface between intragranularly nucleated autenite and δ-ferrite, while Pitch–Schrader orientation relationship to describe the disposition between hexagonal Cr2N precipitates and δ-ferrite matrix.

Characterization of Joint Quality in Ultrasonic Welding of Battery Tabs

Abstract: Manufacturing of lithium-ion battery packs for electric or hybrid electric vehicles requires a significant amount of joining such as welding to meet desired power and capacity needs. However, conventional fusion welding processes such as resistance spot welding and laser welding face difficulties in joining multiple sheets of highly conductive, dissimilar materials with large weld areas. Ultrasonic metal welding overcomes these difficulties by using its inherent advantages derived from its solid-state process characteristics. Although ultrasonic metal welding is well-qualified for battery manufacturing, there is a lack of scientific quality guidelines for implementing ultrasonic welding in volume production. In order to establish such quality guidelines, this paper first identifies a number of critical weld attributes that determine the quality of welds by experimentally characterizing the weld formation over time. Samples of different weld quality were cross-sectioned and characterized with optical microscopy, scanning electronic microscopy (SEM), and hardness measurements in order to identify the relationship between physical weld attributes and weld performance. A novel microstructural classification method for the weld region of an ultrasonic metal weld is introduced to complete the weld quality characterization. The methodology provided in this paper links process parameters to weld performance through physical weld attributes.Copyright © 2012 by ASME and General Motors

Weld microstructure refinement in a 1441 grade aluminium-lithium alloy

Abstract: Clad 2 mm thick sheets of Russian 1441 grade Al-Li alloys were welded using a gas tungsten arc welding process (GTAW). Comparisons were made between the weld beads obtained under (i) continuous current (CC), (ii) pulsed current (PC), and (iii) arc oscillation (AO) conditions for their macro- and microstructural details. In the case of CC GTAW, sound welds could be produced only under a narrow range of welding parameters. Centre line cracks, which occurred in CC GTAW welds under certain conditions, were halted by switching to PC or AO conditions while the welding was in progress. Microstructural refinement was significant in the case of PC and AO GTA welding.

Hot cracking in Al–Mg–Si alloy laser welding – operating parameters and their effects

Abstract: Hot cracking is a phenomenon that frequently occurs in the laser welding of some “special” alloys, such as the aluminium–magnesium–silicon type. Each occurrence of this phenomenon needs to be studied in itself, taking into account not only the individual, but also the interactive, influences of the various parameters. The advantage of using laser beams in welding processes lies in the speeds that can be reached. The disadvantage, however, is that, owing to the high cooling rates characteristic of the interaction between the laser beam and the material, the welding speed itself becomes a cause of hot cracking. The aim of this paper is to see how this disadvantage may be eliminated. We consider what the most important parameters may be, relating to tensile strength and the quantity of cracks produced, that might influence the presence or absence of hot cracking. The most influential factors in avoiding hot cracking are the welding speed and wire parameters. Also important is welding stability, as instability generates cracks. We can then determine a technological window, useful for industrial applications, which takes into account the values of these influential factors and stability.