Metal-cored arc welding process for joining of modified 9Cr-1Mo (P91) steel

In the present work, metal-cored arc welding process was used for joining of modified 9Cr-1Mo (P91) steel. Metal-cored arc welding process is characterized by high productivity, slag-free process, defect-free weldments that can be produced with ease, and good weldability. Toughness is essential in welds of P91 steel during hydro-testing of vessels. There is a minimum required toughness of 47 J for welds that has to be met as per the EN1557:1997 specification. In the present study, welds were completed using two kinds of shielding gases, each composition being 80% Argon + 20% CO₂, and pure argon respectively. Microstructural characterization and toughness evaluation of welds were done in the as – weld, PWHT at 760 °C – 2 h and PWHT at 760 °C – 5 h conditions. The pure argon shielded welds (‘A2’ and ‘B2’) have higher toughness than 80% argon + 20% CO₂ shielded welds (‘A1’ and ‘B1’). Pure argon shielded welds show less microinclusion content with low volume fraction of δ-ferrite (<2%) phase. Themo-calc windows (TCW) was used for the prediction of equilibrium critical transformation points for the composition of the welds studied. With increase in post-weld heat treatment (PWHT) duration from 2 h to 5 h, there was increase in toughness of welds above 47 J. Using metal-cored arc welding process, it was possible to achieve the required toughness of more than 47 J after PWHT at 760 °C – 2 h in P91 steel welds.     

Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

The objective of this research is to investigate the mechanical properties including bonding, tensile strength, and impact resistance of pure copper welded using friction stir welding (FSW) method and compare them with that of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper, TIG welded copper and FSW welded copper to determine the effect of heat on the hardness of welded coppers. Tensile strength tests and notch tensile strength tests are performed to determine the mechanical properties of different weld process.In this experiment, it is found that the notch tensile strength and the notch strength ratio for FSW (212 MPa, 1.10) are significantly higher than those (190 MPa, 1.02) of TIG welding. For the impact tests, the weld zone and heat-affected zone energy absorption values for FSW (2.87 J, 2.25 J) are higher than those (1.32 J, 0 J) of TIG welding. XRD tests are performed to determine components of copper before and after welding process for TIG and FSW.     

Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections with constant heat input: A study using numerical simulation and experimental validation

The temperature distribution and residual stresses for a GTAW circumferential butt joint of AISI 304 stainless steel using numerical simulation have been evaluated. For evaluation of weld induced residual stresses, the analysis of heat source fitting was carried out with heat inputs ranging from 200 to 500 J/mm to arrive at optimal heat input for obtaining proper weld penetration and heat affected zone (HAZ). For this chosen heat input, the influence of different weld speeds and powers on the temperature distribution and the residual stresses is studied. The heat source analysis revealed the best choice of heat input as 300 J/mm. The residual stresses on the inner and outer surfaces, and along the radial direction were computed. Increase in temperature distribution as well as longitudinal and circumferential residual stresses was observed with the increase in weld speed and power. The validity of the results obtained from numerical simulation is demonstrated with full scale shop floor welding experiments.     

Shared control of robotic friction stir welding in the presence of imperfect joint fit-up

In this paper a shared control strategy is presented that allows a skilled operator to identify irregularities that occur during robotic friction stir welding (FSW) and assist the robotic system in producing an appropriate response. Human operators are adept at identifying disturbances; however, the complexity of the friction stir welding process makes it difficult for the operator to respond. While examining the capabilities of shared control in friction stir welding, this paper focuses on responding to defects that are caused by a lack of workpiece material during butt welding, such as gaps. A compensation strategy is presented that combines the human operator's perceptual strengths with an automated procedure for adjustment of the process parameters (i.e. travel angle and plunge depth). Experiments comparing four control strategies are performed while welding 5083-H116 aluminum. Through our experiments we demonstrate that if the FSW control task is appropriately shared between the human operator and the computer control system, the weld quality (strength) can be improved (from 9 ksi to 31 ksi for a gap size of 2.5 mm) as compared with the nominal case in which no corrections are made.     

Strength assessment using destructive testing on MIAB welded alloy steel tubes and subsequent techno-economical evaluation

In this study, an attempt is being made to determine the feasibility of Magnetically Impelled Arc Butt (MIAB) welding process for joining alloy steel tubes in pressure parts. In view of this, a specially made state of art MIAB welding unit (MD1) available at WRI, BHEL, Tiruchirappalli has been employed and adequate number of welding trials is conducted to weld alloy steel tubes of 6–7 mm thickness for boiler applications. The combination of a set of values provided as input is varied for each trial. The welding current and the welding time are divided into three and four stages respectively. For each trial, either the current in stage II is varied or the time for stage III is varied while maintaining the other input parameters constant. These trials are carried out mainly to develop an optimum window (working range) for the process parameters. Further, the strength of MIAB welded specimens are examined by subjecting the welded specimens to various destructive tests. It is observed that the weld region is stronger than the base metal in most of the cases.In the next part of the study, the characteristics of MIAB welded joints for T11 steel tubes are compared with those using flash butt welding and induction pressure welding that is presently employed for alloy steel tube joining in pressure parts. It is found that the manufacturing time and incurred cost per weld drastically reduces while simultaneously increasing the productivity. Hence, the feasibility of MIAB welding process for pressure part is established.     

Hermetic joining of 316L stainless steel using a patterned nickel nanoparticle interlayer

This paper evaluates the use of a nickel nanoparticle (NiNP) interlayer for making hermetic joints in 316L stainless steel substrates via diffusion brazing. Different NiNP inks were prepared using commercial nanopowder (～9 nm) and in-house synthesized nanoparticles. Syringe pump deposition of ～9 nm NiNP ink and diffusion brazing at 900 °C for 30 min under 2 MPa resulted in a hermetic joint up to the tested pressure of 70 psi. In-house synthesis of NiNPs was carried out in ethylene glycol by the reduction of NiCl₂·6H₂O in the presence of hydrazine (N₂H₄) as a reducing agent. X-ray diffraction (XRD) analysis and transmission electron microscopy (TEM) results confirm the presence of pure fcc-Ni with an average particle size of 5.4 ± 0.9 nm. An as-synthesized suspension of NiNPs was patterned onto 316L stainless steel laminae via automated dispensing to a thickness of ～3 μm and bonded at 800 °C for 30 min at a pressure of 2 MPa. The diffusion-brazed test article was also found to be hermetic up to 70 psi. An examination of the bond line using scanning electron microscopy (SEM) showed good uniformity and continuity.     

Effect of oxide-based fluxes on mechanical and metallurgical properties of Dissimilar Activating Flux Assisted-Tungsten Inert Gas Welds

Present investigation is to study the “Effect of Activating Fluxes on Mechanical and Metallurgical Properties of Dissimilar Activated Flux-Tungsten Inert Gas Welds”. Effect of current, welding speed, joint gap and electrode diameter on weld bead dimensions on 6 mm thick dissimilar weld between carbon steel to stainless steel, was studied under Activated Flux-Tungsten Inert Gas Welding process. During this investigation three different types of oxide powders were used-TiO₂, ZnO and MnO₂. After welding samples were subject to mechanical testing, in addition to characterization via micro hardness and microstructures of Normal Tungsten Inert Gas Welds and Activated Flux-Tungsten Inert Gas Welds. Activating fluxes TiO₂ and ZnO are effective fluxes for Activated Flux-Tungsten Inert Gas Welding of dissimilar weld between CS to SS. Highest depth/width (D/W) ratio reported under TiO₂ and ZnO fluxes compare to Normal-Tungsten Inert Gas Welds. Lowest angular distortion was observed under TiO₂ flux compare to Normal-Tungsten Inert Gas Welds. Mechanical properties, Joint Efficiency of Activated Flux-Tungsten Inert Gas Welds are higher than normal-Normal Tungsten Inert Gas Welds. Tensile Test specimens of both the processes failed from the parent metal (carbon steel side). Carbon migration from CS to SS, had occurred which led to failure of weld joints from CS side.     

A method for double-sided friction stir spot welding

A rotating anvil similar to a pinless friction stir welding (FSW) tool can be applied to friction stir spot welding (FSSW) of thin metal plates. FSSW is a solid-state joining process that is currently being used by automotive manufacturers as an alternative to rivets and traditional resistance spot welding. The principal detractor of this process is the keyhole left by pin extraction, which can be detrimental to the weld strength. A pinless tool can be used to eliminate the keyhole. However, this approach is limited to joining thin sheet (≤1 mm). Using a rotating anvil with the FSSW process permits the joining of thicker cross sections, improves the mechanical strength of the spot weld and reduces the reaction forces on the spot welding frame. A numerical model of the process, tensile shear tests and macrosection analysis are used to evaluate the spot welds.Macrosection and numerical analysis reveals that the material flow between the pinless tool and rotating anvil is complex and unique to this process. It has been found that the use of a rotating anvil for FSSW is a viable means to create quality spot welds in thicker weldments.     

On wear resistance of tool steel

Maintaining a reasonably low cutting tool wear when producing forming tools is a general challenge in the development of new forming tool materials. The tool life of a hot forming tool steel (H13) has been significantly improved by reducing its Si-content from 1.0 to 0.06 wt.%. However, this modified H13 (MH13) also displays a reduced cutting tool life due to higher cutting forces and a stronger tendency to form built up layers (BUE) on the cutting edge. This paper explains why.Gleeble tests of MH13 revealed a significantly higher flow stress in the 820–900 °C temperature interval in MH13 compared to H13. Thermo-Calc simulations showed that when reducing the Si-content from 1.0 to 0.06 wt.% the initial temperature for ferrite-to-austenite transformation (A1) was reduced from 900 °C to 820 °C. Knowing that austenite has totally different mechanical and thermal properties than ferrite, the difference in A1 between the two steels explains the higher cutting forces and higher tendency for BUE-formation. The conclusion is that the difference in machinability between H13 and MH13 is primarily related to their difference in A1.An attempt was also made to find a new tool material composition that can combine the wear resistance of MH13 and the good machinability of H13. Thermo-Calc simulations were performed with slightly modified alloying content without changing its properties as a good forming tool material, with the aim to increase A1. For instance, reducing the Mn content from 0.5 to 0.05 wt.% proved to increase A1 from 820 to 850 °C.     

Metallurgical and mechanical characterization of electron beam welded super-duplex stainless steel UNS 32750

This paper addresses the weldability of 6 mm thick plates of super-duplex stainless steel by electron beam welding (EBW) process. Microstructure investigations conducted using optical and SE microscopy showed the presence of large ferrite grains with intra- and inter-granular austenite. Ferrite content studies on the weld zone estimated that there is no significant element partitioning between austenite and ferrite phases. Hardness studies portrayed that the weld hardness is found to be greater than the parent metal which is acquainted due to the solid solution strengthening effect. Tensile results corroborated that the joints obtained by EB welding process have better strength than the base metal. A detailed structure–property relationships has also been carried out through point and line mapping EDAX analysis across the weldment to substantiate the discussions.     

Process modification in the scouring process of textile industry

The effects of scouring parameters on the scouring efficiency, including the weight ratio of de-sizing agent and fabric (5–80 g/g fabric), temperature of de-sizing agent tank (60–90 °C) and dipping time (2–8 s), were investigated. The results demonstrated that weight loss of sizing agent was significantly observed only in the de-sizing agent tank particularly in the first de-sizing tank and was found to a small extent in water tank. The optimum condition in the scouring machine was found at a de-sizing agent to fabric ratio of 20 g/g fabric, with a temperature of the first de-sizing agent tank of 80 °C, a temperature of the second de-sizing agent tank of 90 °C, and dipping time of fabric of 7 s. According to these conditions, more than 89% of the sizing agent was eliminated and only 3.52 mg/g fabric of sizing agent remained in the scoured fabric which was in an acceptable range for feeding to the down stream process known as dyeing process. Application of our results to actual textile plant has shown that there is a cost reduction due to improved utilization of rinse water, chemicals and energy in the process and consequent decreases in the generation of wastewater. Furthermore, the production capacity was increased from 30 m/min to 34.4 m/min.     

Innovative cleaner production for steel phosphorization using Zn–Mn phosphating solution

Phosphating prior to coating for steel is usually needed. In this paper, an innovative cleaner production has been developed for steel surface treatment using Zn–Mn phosphating solution in which there was no nitrite. The mass of the Zn–Mn layer deposited in this new process was about 1.1 g m^?2 when the temperature ranged from 3 to 35 °C. The corrosion time for the color phosphating layer in the copper sulfate spot test was in the range of 72–145 s. Adhesion test showed that the coating layers achieved a higher adhesion load than those produced by conventional methods. Washing using water was not necessary in this cleaner phosphorization, which usually follows phosphorization in traditional processes of steel phosphorization. Consequently, wastewater discharge was reduced greatly.     

Effects of different diets on utilization of nitrogen from cattle slurry applied to grassland on a sandy soil in The Netherlands

Dietary adjustments have been suggested as a means to reduce N losses from dairy systems. Differences in fertilizing value of dairy slurry as a result of dietary adjustments were evaluated in a 1-year grassland experiment and by long-term modelling. Slurry composition of non-lactating dairy cows was manipulated by feeding diets with extreme high and low levels of dietary protein and energy. C:N_total ratio of the produced slurries ranged from 5.1 to 11.4. To evaluate their short-term fertilizer N value, the experimental slurries (n = 8) and slurries from commercial farms with variable composition (n = 4), were slit-injected in two grassland fields on the same sandy soil series in the north of The Netherlands (53°10′N, 6°04′E), with differences in sward age and ground water level. The recently established grassland field (NEW) was characterized by lower soil OM, N and moisture contents, less herbs and more modern grass varieties compared to the older grassland field (OLD). Slurry was applied in spring (100 kg N ha⁻¹) and after the first cut (80 kg N ha⁻¹) while in total four cuts were harvested. Artificial fertilizer N treatments were included in the experiment to calculate the mineral fertilizer equivalent (MFE) of slurry N. The OLD field showed a higher total N uptake whereas DM yields were similar for the two fields. Average MFE of the slurries on the OLD field (47%) was lower than on the NEW field (56%), probably as a result of denitrification of slurry N during wet conditions in spring. Slurries from high crude protein diets showed a significantly higher MFE (P < 0.05) compared to low crude protein diets. No significant differences in MFE were observed between slurries from high and low energy diets. On both fields, MFE appeared to be positively related to the ammonium content (P < 0.001) and negatively to the C:N_total ratio of the slurry DM (P = 0.001). Simulation of the effect of long-term annual application of 180 kg N ha⁻¹ with highest and lowest C:N_total ratio suggested that both slurries would lead to an increase in annual soil N mineralization. Both soil N mineralization and SOC appeared to be substantially higher in equilibrium state for the slurry with the highest C:N_total ratio. It is concluded that in a situation with slit-injection, the reduced first-year N availability of slurry with a high C:N_total ratio as observed in the grassland experiment will only be compensated for by soil N mineralization on the very long term.     

Reduction of hexavalent chromium by polypyrrole-modified steel mesh electrode

Adherent polypyrrole (ppy) films were electropolymerized from a para-toluenesulfonic sodium (PTS) solution on stainless steel mesh (SSM). Reduced ppy-modified SSM electrode can transfer Cr(VI) to Cr(III) effectively. Lower pH (<2) or higher temperature (>35 °C) is beneficial for the removal of Cr(VI). Electro-reduction achieved 90% removal efficiency after 21 min by cyclic voltammetry. The removal efficiency is 96–56% for one–six contact cycles between ppy and Cr(VI). SEM shows that ppy films on SSM have regular morphology with small nucleus of less than 1 μm in diameter.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.     

Using micro deep drawing with ironing stages to form stainless steel 304 micro cups

The needs of stainless steel 304 micro cups have been increasing tremendously due to the trend of miniaturization in medical and electronic devices, etc. For application purpose, it is highly desired to have stainless steel micro cups with high CH/OD (cup height/outer diameter) ratios. Due to the constraints of the limit draw ratio (LDR) of stainless steel 304 sheets in micro deep drawing, forming a micro cup with high CH/OD ratio at room temperature cannot be achieved by using a single stage deep drawing die. A process consisting of one micro deep drawing and two ironing stages was proposed for achieving this goal; three micro dies were designed, fabricated and used for experimental validation. A series of experiments were conducted by using the stainless steel 304 sheets of 200 μm thickness annealed at four different temperatures to understand the influence of size effects on this process for generating knowledge, know-how and technologies to form high quality stainless steel micro cups with large CH/OD ratio. No lubricant was used in this study. It was proven that the proposed process is a robust process as long as the sheets are annealed at the temperature no less than 900 °C for more than 3 min.     

Biogas production from maize and dairy cattle manure—Influence of biomass composition on the methane yield

There is an increasing world wide demand for energy crops and animal manures for biogas production. To meet these demands, this research project aimed at optimising anaerobic digestion of maize and dairy cattle manures. Methane production was measured for 60 days in 1 l eudiometer batch digesters at 38 °C. Manure received from dairy cows with medium milk yield that were fed a well balanced diet produced the highest specific methane yield of 166.3 Nl CH₄ kg VS⁻¹. Thirteen early to late ripening maize varieties were grown on several locations in Austria. Late ripening varieties produced more biomass than medium or early ripening varieties. On fertile locations in Austria more than 30 Mg VS ha⁻¹ can be produced. The methane yield declined as the crop approaches full ripeness. With late ripening maize varieties, yields ranged between 312 and 365 Nl CH₄ kg VS⁻¹ (milk ripeness) and 268–286 Nl CH₄ kg VS⁻¹ (full ripeness). Silaging increased the methane yield by about 25% compared to green, non-conserved maize. Maize (Zea mays L.) is optimally harvested, when the product from specific methane yield and VS yield per hectare reaches a maximum. With early to medium ripening varieties (FAO 240–390), the optimum harvesting time is at the “end of wax ripeness”. Late ripening varieties (FAO ca. 600) may be harvested later, towards “full ripeness”. Maximum methane yield per hectare from late ripening maize varieties ranged between 7100 and 9000 Nm³ CH₄ ha⁻¹. Early and medium ripening varieties yielded 5300–8500 Nm³ CH₄ ha⁻¹ when grown in favourable regions. The highest methane yield per hectare was achieved from digestion of whole maize crops. Digestion of corns only or of corn cob mix resulted in a reduction in methane yield per hectare of 70 and 43%, respectively. From the digestion experiments a multiple linear regression equation, the Methane Energy Value Model, was derived that estimates methane production from the composition of maize. It is a helpful tool to optimise biogas production from energy crops. The Methane Energy Value Model requires further validation and refinement.     

Lodging in rice can be alleviated by atmospheric CO2 enrichment

The projected increase of atmospheric CO₂ concentration [CO₂] is expected to increase yield of agricultural C₃ crops, but little is known about effects of [CO₂] on lodging that can reduce yield. This study examined the interaction between [CO₂] and nitrogen (N) fertilization on the lodging of rice (Oryza sativa L.) using free-air CO₂ enrichment (FACE) systems installed in paddy fields at Shizukuishi, Iwate, Japan (39°38′N, 140°57′E). Rice plants were grown under two levels of [CO₂] (ambient = 365 μmol mol⁻¹; elevated [CO₂] = 548 μmol mol⁻¹) and three N fertilization regimes: a single initial basal application of controlled-release urea (8 g N m⁻², CRN), split fertilization with a standard amount of ammonium sulfate (9 g N m⁻², MN), and ample N (15 g N m⁻², HN). Lodging score (six ranks at 18° intervals, with larger scores indicating greater bending), yield, and yield components were measured at maturity. The lodging score was significantly higher under HN than under CRN and MN, but lodging was alleviated by elevated [CO₂] under HN. This alleviation was associated with the shortened and thickened lower internodes, but was not associated with a change in the plant's mass moment around the culm base. A positively significant correlation between lodging score and ripening percentage indicated that ripening percentage decreased by 4.5% per one-unit increase in lodging score. These findings will be useful to develop functional algorithm that can be incorporated into mechanistic crop models to predict rice production more accurately in a changing climate and with different cultural practices.     

Insertable thin film thermocouples for in situ transient temperature monitoring in ultrasonic metal welding of battery tabs

Real-time monitoring and control of temperature in ultrasonic joining of battery tabs and coupons are important for the quality improvement and cost reduction of battery assembly. However, there have always been difficulties in accurate and real-time measurement of temperature by conventional sensors for practical implementation. In this study, an innovative method is developed to provide an enabling technology for the in situ transient temperature monitoring, which could provide reliable feedback signals for potential control of ultrasonic joining processes. Micro thin film thermocouples (TFTCs) were fabricated on thin silicon substrates, which were then inserted in the welding anvil as a permanent feature so that the sensors were always located about 100 μm directly under the welding spot during joining of multilayer Ni-coated Cu thin sheets for battery assembly. Good repeatability was demonstrated while a temperature rise of up to 650 °C was obtained due to the closeness of the sensors to the welding spot. The inserts with thin film sensors remained functional after welding experiments. This method has a great potential for in situ transient temperature monitoring, and thus the control of ultrasonic joining processes to realize a practical smart joining system.     

The Satoyama Index: A biodiversity indicator for agricultural landscapes

Agricultural development to meet rapidly growing demands for food and biofuel and the abandonment of traditional land use have had major impacts on biodiversity. Habitat diversity is one of the most important factors influencing biodiversity in agricultural landscapes. In this study we propose an ecological index of ecosystem or habitat diversity in agricultural landscapes – the Satoyama Index (SI) – that is discernible under appropriate spatial units (e.g., 6 km × 6 km) from 1 km × 1 km gridded land-cover data available from an open-access web site. A high SI value is an indicator of high habitat diversity, which is characteristic of traditional agricultural systems, including Japanese satoyama landscapes, while a low value indicates a monotonic habitat condition typical of extensive monoculture landscapes. The index correlated well with the spatial patterns of occurrence of a bird of prey (Butastur indicus) and species richness of amphibians and damselflies in Japan. The values of the SI also corresponded well to the spatial patterns of typical traditional agricultural landscapes with high conservation value in other countries, for example, the dehesas of the Iberian Peninsula and shade coffee landscapes in Central America. Globally, the pattern of East/South-East Asian paddy belts with their high index values contrasts markedly with the low values of the Eurasian, American, and Australian wheat or corn belts. The SI, which correlates landscapes with biodiversity through potential habitat availability, is highly promising for assessing and monitoring the status of biodiversity irrespective of scale.