Characterization of GMAW (Gas Metal Arc Welding) Penetration Using Ultrasonics.

Welding defects such as lack of penetration, undercutting, crater crack, burn-through and porosity can occur during manufacturing. Assessing weld quality using nondestructive evaluation methods is important for the quality assurance of welded parts. In this paper, the measurement of weld penetration, which is directly related to weld integrity, is investigated by means of ultrasonics. Both linear and nonlinear ultrasonic methods are studied to assess their sensitivities to weld penetration. Welded plates with different penetration depths controlled by changing weld heat input are manufactured using gas metal arc welding (GMAW). Microscopic properties are assessed after the ultrasonic measurements are completed. Numerical models are built using the weld profile obtained from macrographs to explain the relationship between linear ultrasonic and weld penetration. A quantitative correlation between weld morphology (shape, width and depth) and the energy of linear ultrasonic signal is determined, where the increase of weld bead penetration exceeding the plate thickness results in decrease of the energy of the ultrasonic signal. Minimum detectable weld morphology using linear ultrasonics is defined depending on the selected frequency. Microhardness measurement is conducted to explain the sensitivity of nonlinear ultrasonics to both weld penetration and heterogeneity in weld. The numerical and experimental results show that the weld geometry influences the ultrasonic measurement other than the materials' properties.

The Detection of Burn-Through Weld Defects Using Noncontact Ultrasonics.

Nearly all manufactured products in the metal industry involve welding. The detection and correction of defects during welding improve the product reliability and quality, and prevent unexpected failures. Nonintrusive process control is critical for avoiding these defects. This paper investigates the detection of burn-through damage using noncontact, air-coupled ultrasonics, which can be adapted to the immediate and in-situ inspection of welded samples. The burn-through leads to a larger volume of degraded weld zone, providing a resistance path for the wave to travel which results in lower velocity, energy ratio, and amplitude. Wave energy dispersion occurs due to the increase of weld burn-through resulting in higher wave attenuation. Weld sample micrographs are used to validate the ultrasonic results.

Interfacial effects on lithium superoxide disproportionation in Li-O2 batteries.

During the cycling of Li-O2 batteries the discharge process gives rise to dynamically evolving agglomerates composed of lithium-oxygen nanostructures; however, little is known about their composition. In this paper, we present results for a Li-O2 battery based on an activated carbon cathode that indicate interfacial effects can suppress disproportionation of a LiO2 component in the discharge product. High-intensity X-ray diffraction and transmission electron microscopy measurements are first used to show that there is a LiO2 component along with Li2O2 in the discharge product. The stability of the discharge product was then probed by investigating the dependence of the charge potential and Raman intensity of the superoxide peak with time. The results indicate that the LiO2 component can be stable for possibly up to days when an electrolyte is left on the surface of the discharged cathode. Density functional calculations on amorphous LiO2 reveal that the disproportionation process will be slower at an electrolyte/LiO2 interface compared to a vacuum/LiO2 interface. The combined experimental and theoretical results provide new insight into how interfacial effects can stabilize LiO2 and suggest that these interfacial effects may play an important role in the charge and discharge chemistries of a Li-O2 battery.

Raman Evidence for Late Stage Disproportionation in a Li-O2 Battery.

Raman spectroscopy is used to characterize the composition of toroids formed in an aprotic Li-O2 cell based on an activated carbon cathode. The trends in the Raman data as a function of discharge current density and charging cutoff voltage provide evidence that the toroids are made up of outer LiO2-like and inner Li2O2 regions, consistent with a disproportionation reaction occurring in the solid phase. The LiO2-like component is found to be associated with a new Raman peak identified in the carbon stretching region at ∼1505 cm(-1), which appears only when the LiO2 peak at 1123 cm(-1) is present. The new peak is assigned to distortion of the graphitic ring stretching due to coupling with the LiO2-like component based on density functional calculations. These new results on the LiO2-like component from Raman spectroscopy provide evidence that a late stage disproportionation mechanism can occur during discharge and add new understanding to the complexities of possible processes occurring in Li-O2 batteries.