The effect of thermomechanical welding on the microstructure and mechanical properties of S700MC steel welds.

Grain refinement by plastic deformation during conventional TIG welding can help to compensate for the loss of mechanical properties of welded joints. The thermomechanical welding (TMW) tests were performed on S700MC steel with different combinations of TIG arc energy and high frequency hammering over three target cooling times (t8/5 = 5s, 15s, and 25s). Additionally, the effect of initial microstructures on the weld joint quality was analysed by testing three materials conditions: hot-rolled (as-received) and cold-rolled with 10% and 30% thickness reductions, respectively. The effects of plastic deformation and the mechanical vibration on the grain refinement were studied separately. Optical microscopy, electron backscattered diffraction, and Vickers hardness were used to characterise the weld microstructure heterogeneity. The weld width and depth and the mean grain size were correlated as the function of cooling time t8/5. The results show that the weld dimensions increase with increasing the t8/5. The weld microstructures transformed from the mixed martensite and bainite into mixed ferrite and bainite with increasing the t8/5 time, and the related mean grain size increased gradually. The TMW welds exhibit smaller grains compared to TIG welds due to the coupled effects of mechanical vibration and plastic deformation. The mechanical vibration contributes to weld metal homogenisation, accelerating TiN precipitation in the fusion zone. The proposed TMW process can refine the weld microstructure of S700MC steel, enhancing its mechanical properties.

Selection of Parameters for Optimized WAAM Structures for Civil Engineering Applications.

Using the CMT (Cold Metal Transfer, F. Fronius, Upper Austria) welding process, wire arc additive manufacturing (WAAM) enables companies to fabricate steel components in a resource-saving manner (additive vs. subtractive) by properly reinforcing existing steel components. Two fundamental questions are discussed in the current work. The first focus is on the general geometric possibilities offered by this process. The influence of various parameters, such as wire feed speed, travel speed, and torch inclination on the seam shape and build-up rate are presented. The microstructure of the manufactured components is evaluated through metallography and hardness testing. Based on the first results, print strategies are developed for different requirements. Moreover, suitable process parameter sets are recommended in terms of energy input per unit length, weld integrity and hardness distribution. The second focus is on testing and determining joint properties by analyzing the microhardness of the welded structures. The chosen parameter sets will be investigated, and steel quality equivalents according to ÖNORM EN ISO 18265 will be defined.

Influence of Beam Figure on Porosity of Electron Beam Welded Thin-Walled Aluminum Plates.

Welded aluminum components in the aerospace industry are subject to more stringent safety regulations than in other industries. Electron beam welding as a highly precise process fulfills this requirement. The welding of aluminum poses a challenge due to its high tendency to pore formation. To gain a better understanding of pore formation during the process, 1.5 mm thick aluminum AW6082 plates were welded using specially devised beam figures in different configurations. The obtained welds were examined with radiographic testing to evaluate the size, distribution, and the number of pores. Cross-sections of the welds were investigated with light microscopy and an electron probe microanalyzer to decipher the potential mechanisms that led to porosity. The examined welds showed that the porosity is influenced in various ways by the used figures, but it cannot be completely avoided. Chemical and microstructural analyzes have revealed that the main mechanism for pore formation was the evaporation of the alloying elements Mg and Zn. This study demonstrates that the number of pores can be reduced and their size can be minimized using a proper beam figure and energy distribution.

Wire-Based Additive Manufacturing of Ti-6Al-4V Using Electron Beam Technique.

Electron beam freeform fabrication is a wire feed direct energy deposition additive manufacturing process, where the vacuum condition ensures excellent shielding against the atmosphere and enables processing of highly reactive materials. In this work, this technique is applied for the α + ß-titanium alloy Ti-6Al-4V to determine suitable process parameter for robust building. The correlation between dimensions and the dilution of single beads based on selected process parameters, leads to an overlapping distance in the range of 70%-75% of the bead width, resulting in a multi-bead layer with a uniform height and with a linear build-up rate. Moreover, the stacking of layers with different numbers of tracks using an alternating symmetric welding sequence allows the manufacturing of simple structures like walls and blocks. Microscopy investigations reveal that the primary structure consists of epitaxial grown columnar prior ß-grains, with some randomly scattered macro and micropores. The developed microstructure consists of a mixture of martensitic and finer α-lamellar structure with a moderate and uniform hardness of 334 HV, an ultimate tensile strength of 953 MPa and rather low fracture elongation of 4.5%. A subsequent stress relief heat treatment leads to a uniform hardness distribution and an extended fracture elongation of 9.5%, with a decrease of the ultimate strength to 881 MPa due to the fine α-lamellar structure produced during the heat treatment. Residual stresses measured by energy dispersive X-ray diffraction shows after deposition 200-450 MPa in tension in the longitudinal direction, while the stresses reach almost zero when the stress relief treatment is carried out.

Hydrogen-induced plasticity in nanoporous palladium.

The mechanical strain response of nanoporous palladium (npPd) upon electrochemical hydrogenation using an in situ dilatometric technique is investigated. NpPd with an average ligament diameter of approximately 20 nm is produced via electrochemical dealloying. A hydrogen-induced phase transition from PdHß to PdHα is found to enable internal-stress plasticity (or transformation-mismatch plasticity) in nanoporous palladium, which leads to exceptionally high strains without fracture as a result of external forces. The high surface stress in the nanoporous structure in combination with the internal-stress plasticity mechanism leads to a peculiar strain response upon hydrogen sorption and desorption. Critical potentials for the formation of PdHα and PdHß in npPd are determined. The theoretical concepts to assess the plastic strain response of nanoporous samples are elucidated, taking into account characteristics of structure and deformation mechanism.

In situ characterization of hydrogen absorption in nanoporous palladium produced by dealloying.

Palladium is a frequently used model system for hydrogen storage. During the past few decades, particular interest was placed on the superior H-absorption properties of nanostructured Pd systems. In the present study nanoporous palladium (np-Pd) is produced by electrochemical dealloying, an electrochemical etching process that removes the less noble component from a master alloy. The volume and electrical resistance of np-Pd are investigated in situ upon electrochemical hydrogen loading and unloading. These properties clearly vary upon hydrogen ad- and absorption. During cyclic voltammetry in the hydrogen regime the electrical resistance changes reversibly by almost 10% upon absorbing approximately 5% H/Pd (atomic ratio). By suitable loading procedures, hydrogen concentrations up to almost 60% H/Pd were obtained, along with a sample thickness increase of about 5%. The observed reversible actuation clearly exceeds the values found in the literature, which is most likely due to the unique structure of np-Pd with an extraordinarily high surface-to-volume ratio.