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Feasibility Of Friction Stir Processing (Fsp) As A Method Of Healing Cracks In Irradiated 304l Stainless Steels, Cameron Cornelius Gunter
Feasibility Of Friction Stir Processing (Fsp) As A Method Of Healing Cracks In Irradiated 304l Stainless Steels, Cameron Cornelius Gunter
Theses and Dissertations
The current US fleet of nuclear reactors has been in service for three decades. Over this period, existing welds in stainless steel (SS) shrouds have sustained stress corrosion cracking (SCC) and are in need of repair. Additionally, helium has formed interstitially as a byproduct of proton bombardment. Current repair technology, such as TIG welding, puts extreme amounts of heat into the material and allows for interstitial helium atoms to aggregate and form bubbles/voids at grain boundaries. This significantly weakens the material, proving to be a very counterproductive and ineffective repair technique. Much study has been done on friction stir processing …
Temperature Control In Friction Stir Welding Using Model Predictive Control, Brandon Scott Taysom
Temperature Control In Friction Stir Welding Using Model Predictive Control, Brandon Scott Taysom
Theses and Dissertations
Temperature is a very important process parameter in Friction Stir Welding (FSW), but until lately active control of temperature has not been practiced. Recently, temperature control via a PID controller has proven to be effective. Model Predictive Control (MPC) is a control method that holds promise, but has not been attempted in FSW before. Two different model forms are developed for MPC and are evaluated. The first is a simple first-order plus dead time (FOPDT) model. The second is the Hybrid Heat Source model and is more complex; it combines the heat source method and a 1D discretized thermal model …
Investigating The Relationship Between High Temperature Flow Stress And Friction Stir Weldability In Hsla Steels, David Jordan Walser
Investigating The Relationship Between High Temperature Flow Stress And Friction Stir Weldability In Hsla Steels, David Jordan Walser
Theses and Dissertations
The feed rate at which a defect free friction stir weld can be run (friction stir weldability) on an HSLA steel plate can vary widely between heats that meet the same specified physical properties. Consequently, every time a new heat of HSLA steel is obtained, exploratory welds must be run to determine the proper feed rate for that plate. Previous research suggests that the varying levels of alloying elements related to high temperature physical properties between the different heats causes the observed change in friction stir weldability. Because of this, it was hypothesized that the high temperature physical properties of …
An Investigation Into The Mechanisms Of Formation Of The Hard Zone In Fsw X65, Jacob D. Allred
An Investigation Into The Mechanisms Of Formation Of The Hard Zone In Fsw X65, Jacob D. Allred
Theses and Dissertations
Friction stir welding (FSW) of HSLA steel commonly produces a hard zone (HZ) on the advancing side (AS) of the weld. Despite its detrimental effects on weld toughness, the mechanisms of its formation have not been thoroughly investigated and are not well understood. This paper investigates the various mechanisms in FSW believed to affect the weld HZ, namely: strain, strain-rate, peak temperature and cooling rate. Gleeble tests indicate that strain and strain rate have negligible effects on weld HZ with cooling rate and peak temperature as dominant effects. Jominy tests resulted in cooling rate having 270% greater influence than peak …
The Effect Of Cooling Rate Of Friction Stir Welded High Strength Low Alloy Steel, Scott Anthony Rose
The Effect Of Cooling Rate Of Friction Stir Welded High Strength Low Alloy Steel, Scott Anthony Rose
Theses and Dissertations
The friction stir welding of steel has produced a hard zone in several different alloys. Despite its detrimental effects on weld toughness, the reasons behind neither its formation nor a method of reducing its size or effects have been explored. Recent advances in process control allow for direct heat input control, which combined with the use of backing plates of different thermal conductivity allows for an expansion of the process window. These control methods also affect the HAZ cooling rate by providing greater range (a 60% increase compared to a fixed backing plate) and control (five welds within 16 °C/s). …
The Effect Of Friction Stir Welding Process Parameters On Charpy V-Notch Impact Toughness In Hsla-65, Samuel C. Sanderson
The Effect Of Friction Stir Welding Process Parameters On Charpy V-Notch Impact Toughness In Hsla-65, Samuel C. Sanderson
Theses and Dissertations
HSLA-65 steel (6.4 mm thick) was friction stir welded at various welding speeds and spindle speeds. Varying weld parameters provided a range of heat inputs. Impact toughness was evaluated as a function of the different weld parameters and corresponding weld heat inputs. Charpy V-Notch (CVN) tests were conducted in parent material and at both the weld nugget centerline and heat-affected zone (HAZ) locations. The upper shelf CVN impact energy of the weld nugget was above that of the base metal for all weld parameters. The upper shelf impact toughness in the HAZ was largely unaffected by changing weld parameters. The …
Joining Polycrystalline Cubic Boron Nitride And Tungsten Carbide By Partial Transient Liquid Phase Bonding, Grant O. Cook Iii
Joining Polycrystalline Cubic Boron Nitride And Tungsten Carbide By Partial Transient Liquid Phase Bonding, Grant O. Cook Iii
Theses and Dissertations
Friction stir welding (FSW) of steel is often performed with an insert made of polycrystalline cubic boron nitride (PCBN). Specifically, MS80 is a grade of PCBN made by Smith MegaDiamond that has been optimized for the FSW process. The PCBN insert is attached to a tungsten carbide (WC) shank by a compression fitting. However, FSW tools manufactured by this method inevitably fail by fracture in the PCBN. Permanently bonding PCBN to WC would likely solve the fracturing problem and increase the life of PCBN FSW tools to be economically viable. Partial transient liquid phase (PTLP) bonding, a process used to …
Using Design Of Experiments And Electron Backscatter Diffraction To Model Extended Plasticity Mechanisms In Friction Stir Welded Aisi 304l Stainless Steel, Benjamin D. Nelson
Using Design Of Experiments And Electron Backscatter Diffraction To Model Extended Plasticity Mechanisms In Friction Stir Welded Aisi 304l Stainless Steel, Benjamin D. Nelson
Theses and Dissertations
Extended plasticity mechanisms (EPM) allow a metal to undergo extended plastic deformation without failure. These mechanisms are responsible for the extended plastic deformation characteristic of hot working processes. In this thesis it is shown that electron backscatter diffraction (EBSD) is capable of detecting EPM artifacts in the final microstructure of AISI 304L stainless steel (304L). Results also indicate that dislocation cells form in hot worked AISI 304L stainless steel. Additionally, in this study EBSD data collection and analysis is used with a design of experiments approach to model the presence of EPM artifacts in the final microstructure of friction stir …
Friction Stir Welding Of High-Strength Automotive Steel, Eric Michael Olsen
Friction Stir Welding Of High-Strength Automotive Steel, Eric Michael Olsen
Theses and Dissertations
The following thesis is a study on the ability to create acceptable welds in thin-plate, ultra-high-strength steels (UHSS) by way of friction stir welding (FSW). Steels are welded together to create tailor-welded blanks (TWB) for use in the automotive industry. Dual Phase (DP) 590, 780, and 980 steel as well as Transformation-Induced Plasticity (TRIP) 590 steel with thicknesses ranging from 1.2 mm to 1.8 mm were welded using friction stir welding under a variety of processing conditions, including experiments with dissimilar thicknesses. Samples were tested under tensile loads for initial determination if an acceptable weld had been created. Acceptable welds …
An Analysis Of Microstructure And Corrosion Resistance In Underwater Friction Stir Welded 304l Stainless Steel, Tad Dee Clark
An Analysis Of Microstructure And Corrosion Resistance In Underwater Friction Stir Welded 304l Stainless Steel, Tad Dee Clark
Theses and Dissertations
An effective procedure and parameter window was developed for underwater friction stir welding (UWFSW) 304L stainless steel with a PCBN tool. UWFSW produced statistically significant: increases in yield strengths, decreases in percent elongation. The ultimate tensile strength was found to be significantly higher at certain parameters. Although sigma was identified in the UWFSWs, a significant reduction of sigma was found in UWFSWs compared to ambient FSWs. The degree of sensitization in UWFSWs was evaluated using double loop EPR testing and oxalic acid electro-etched metallography. Results were compared to base metal, ambient FSW, and arc welds. Upper and lower sensitization localization …
Statistical Investigation Of Friction Stir Processing Parameter Relationships, Jonathan H. Record
Statistical Investigation Of Friction Stir Processing Parameter Relationships, Jonathan H. Record
Theses and Dissertations
Friction Stir Welding (FSW) is an emerging joining technology in which basic process understanding is still inadequate. Knowledge of FSW parameter relationships is needed to better understand the process and implement proper machine control. This study utilized a 3-factor, 3-level factorial design of experiments to investigate relationships between key process inputs and measured output parameters. All experiments utilized 7075-T7 aluminum and a threaded pin tool with a 25.4 mm shoulder diameter, 4.76 mm pin length, and 7.9 mm pin diameter. Spindle speed, feed rate, and tool depth were varied throughout 54 welds while X, Y, and Z forces, X torque, …
A Finite Element Simulation Of Temperature And Material Flow In Fricton Stir Welding, Mark J. Lasley
A Finite Element Simulation Of Temperature And Material Flow In Fricton Stir Welding, Mark J. Lasley
Theses and Dissertations
The purpose of this research was to use the Transvalor S.A. product, Forge3, to develop a finite element simulation of the friction stir welding process that improves the predictability of temperature evolution and material flow within the plunge portion of the process. Previous modeling created more heating within the billet than experimental results, probably due to the simplification of the simulation with adiabatic boundary conditions. More realistic tooling temperatures were included in this model as these affect heat evolution which is a determining factor in microcrystalline growth. These results were validated by experimental efforts using a billet and tooling instrumented …