This work was primarily motivated by the industrial need for control of problems associated with the Gas Tungsten Arc Welding (GTAW) of small bore titanium and austenitic stainless steel tubes. These include: pore creation and entrapment in the weld zone, and variability of the fusion zone geometry. The primary aim of this study was the development of a low current orbital plasma welding capability using a structured approach which could lead to defect minimisation. The methodology should also have the potential to be used in a number of different conditions, extending the use of plasma welding in both melt-in and keyhole modes for the orbital welding of small bore tubes. The project originally involved the modification of a totally enclosed orbital GTAW welding head for low current welding operations. It was established that for the current range required for small bore and small to medium thickness tubes, the use of a solid copper torch was sufficient to provide the required heat absorption. A stable arc was produced even for very low current values (down to 7A) while arc voltages were within the operating range of a standard GTA welding power source. Procedural (i.e. off line) control was adopted for identification and optimisation of welding parameters. Since no procedure was available for the proposed welds it was necessary to generate the parameters required for the production of consistent weld profiles. Simultaneously, an expert system has been developed for the determination of optimum process parameters based on empirical models, developed using statistical techniques. Parameter combinations were selected based on physical as well as statistical relevance, providing a measure of confidence when predicting the required weld bead output characteristics. The approach also indicates the influence of the major input parameters on weld bead geometry and defect formation, such as undercut. Two quality acceptance criteria were employed during this investigation, weld bead dimensional accuracy, and the type and seriousness of defects present (penetration / burn-through, porosity and undercut). Off line programming was utilised to control heat build up and to ensure welds were obtained with the desired geometry and minimal defect levels. The end result was the development of a prototype system for low current orbital plasma welding (in both melt-in and keyhole mode) of small bore tubes in a totally enclosed head. Tolerant procedures for low current orbital melt-in and particularly keyhole welding have been generated and a systematic methodology for the prediction and optimisation of welding procedures based on predetermined criteria has been developed.

Thesis (M. S.)--Ohio State University, 2008. / Title from first page of PDF file. Includes bibliographical references (p. 168-170).

This master's thesis deals with the selection and evaluation of the appropriate welding technology for stainless steel and titanium alloys. Describes advantages and disadvantages of selected technologies. The experiment compares the mechanical properties, the heat input and the resulting surface structure of the welded samples. In conclusion, the thesis deals with the technical - economic evaluation of selected welding technologies.

Orientador: Carlos Alberto Cimini Júnior / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-24T13:05:51Z (GMT). No. of bitstreams: 1 Nascimento_NataliciodeMedeiros_M.pdf: 37176226 bytes, checksum: 4fbe964ff4a98beca09e3f5d3f4dffc6 (MD5) Previous issue date: 2013 / Resumo: A soldagem por atrito com pino não consumível (SAPNC), tem se mostrado muito útil na possível solução de limitações apresentadas por outros processos de soldagem, gerando juntas soldadas com menor nível de tensão residual e menor distorção final, permitindo soldar ligas metálicas não soldáveis por outros processos e apresentando a vantagem de não necessitar de material consumível. Porém, para uma possível aplicação prática desta tecnologia, se torna importante o conhecimento de parâmetros de resistência mecânica, resistência à fadiga e resistência à fratura da junta soldada. Dentro deste contexto, este trabalho procurou avaliar experimentalmente a medida da tenacidade à fratura de juntas de aço inoxidável supermartensítico via SAPNC por meio de ensaios padronizados de CTOD (Crack Tip Opening Displacement) de acordo com a norma BS 7448. Para isto, foi necessária a preparação de corpos de prova de tamanho padronizado em função da espessura da chapa. As chapas utilizadas foram usinadas com espessura de 17,7±0,2mm e posteriormente unidas por soldagem SAPNC, sendo a partir destas retirados corpos de prova de ensaio de flexão de três pontos. Procedendo-se a aplicação de uma carga senoidal sobre a amostra obtida, foram produzidas os pré-trincamentos necessários ao ensaio. Destes, se obtiveram resultados que, mostram que a soldagem deste material produz juntas com valores CTOD abaixo daqueles apresentadas pelo material de base, fragilizando acentuadamente a junta soldada somente na chamada região de avanço. Além disso, o modo de fratura se mostrou dúctil, com a geometria do trincamento sendo fortemente influenciada pelas alterações microestruturais geradas pelo processo / Abstract: The friction welding with non-consumable pin (SAPNC), has proved very useful in the solution of possible limitations presented by other welding processes, generating welded joints with lower residual stress and lower distortion, allowing welding of alloys not weldable by other processes and having the advantage of requiring no consumables. However, for a possible practical application of this technology, it becomes important to know the mechanical strength, fatigue strength and resistance to fracture of the welded joint. Within this context, this study sought to experimentally measure the fracture toughness of supermartensitic stainless steel joints made via SAPNC through standardized CTOD (Crack Tip Opening Displacement) tests in accordance with BS 7448 standard. For this was necessary to prepare specimens of standardized size as a function of plate thickness. The plates used were machined with a thickness of 17.7 ± 0.2 mm and subsequently joined by SAPNC welding being removed from these three point bending assay specimens. Proceeding applying a sinusoidal load on the obtained samples were produced precracks needed for testing. From these, were obtained results that show that the welding of this material produces joints with CTOD values below those presented by the base material, markedly weakening the welded joint only in the region called advancing side. Furthermore, the fracture mode showed being ductile, and the geometry of the cracking being strongly influenced by the microstructural changes generated by the process / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica