Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Ocean Engineering; and, (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1979. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Bibliography: leaves 70-73. / by William Vincent Moody. / M.S.

The traditional method of teaching welding has remained unchanged for decades. In this model, an instructor gives demonstrations to a class of students and then helps them individually as they practice the techniques of welding. This traditional instructional method has been effective but is time consuming. Due to a significant increase in the demand for skilled welders within the United States, efforts have been made to develop more efficient methods of providing welding instruction. Various electronic welding guidance systems and virtual welding systems have recently been developed. In this study, the researcher addressed two questions 1) Does the use of an electronic welding guidance system improve the pass rate that entry-level high school students receive on basic gas metal arc weld tests? 2) Will entry-level high school students who learn gas metal arc welding with a guided welding training system learn how to weld faster and/or more proficiently than those taught using the traditional training method? A study was performed in an entry-level high school welding class to determine the effectiveness of a guided welding instruction system in comparison to the traditional method of teaching welding. The results of the study indicated that the traditional method of teaching welding and the use of a guided welding system yielded similar results, both in quality and efficiency, in student ability to produce basic GMAW welds.

Welding is a common industrial practice that has the potential to emit air pollutants. Emission factors are useful indicators to help in the understanding of the extent of pollution from a process and managing them to reduce or minimize health impacts. The objective of this thesis is to determine emission factors applicable to the gas metal arc welding (GMAW), under varying current and voltage conditions. The most used base metals and an electrode for the shipbuilding industry were considered. A weld fume chamber was used to achieve the project goals along with standard sampling and analytical procedures. Three test runs were performed for each sampling scenario to ensure repeatability. The EPA EF average for MS experiments with the ER70S-6 electrode is 5.2 g/kg, and for SS experiments with the ER316L-Si electrode is 3.2 g/kg, while the average results for this study were 6.81 g/kg and 3.28 g/kg respectively.

For the last decades usage of aluminium alloys have been increasing tremendously. They have been used in aerospace industry widely and now aluminium alloys are becoming more and more popular in automotive and defense industries. Consequently / successful welding of aluminium alloys gains importance. In this study a research is carried out on eldability of plates having different thicknesses of composition 5754 aluminium and 6063 aluminium in T-fillet geometry using Gas-metal Arc Welding technique. It was aimed to have a successful joint without using pre-weld and post-weld heat treatments. During tests welding current and voltage were the varying parameters as welding speed was held constant. Macro-examinations were performed to see the penetration of the weld metal. It was seen that the type of filler wire greatly effects weld penetration. Hardness tests, tensile tests were done to compare the mechanical properties of the welded joints with different filler wires. Despite having better penetration in 4043 filler wire used weld joints, 5356 filler wire used weld joints had higher tensile strength and ductility. In the second part of the study, a dynamic loading machine was designed and manufactured to see the behavior of the fillet welds under dynamic loading. The amount of stress and strain given to the specimen on this machine was adjustable but can&rsquo / t be measured. The tests that were made with this machine aimed only to compare the number of cycles of specimens before fracture. For dynamic loading tests two groups of specimens were prepared with filler wire 4043 / each group having been welded with different heat inputs. It was aimed to see the effect of welding heat input on service lifes but no significant difference between cycle numbers of specimen groups having been welded with different heat inputs was observed. Microstructure examinations of these specimens revealed that coarsening the grains, grain boundaries, particles in PMZ and HAZ regions between Al 6063 base metal and weld zone made these areas more susceptible and favorable for crack propogation than Al 6063 base metal.

With the growth in pipeline installations all over the world, there is a great demand for highly productive and robust welding systems. Mechanised pipe welding has been developed over the last 50 years and the present focus is towards development of automated pipeline welding systems. Pipeline welding automation is aimed at reducing costs and improving the installation quality. To attain fully automated pipe welding systems there is a need to rely on sensors and controls systems to mimic human like capabilities, such as visual inspection, in real time. The key aim of this work is to develop and evaluate methods of automatic assessment of weld bead shape and quality during narrow gap GMAW of transmission pipelines. This implies that the measured bead profile will be assessed to determine whether the bead shape will cause defects when the subsequent pass is deposited. Different approaches have been used to conquer the challenge that is emulating human reasoning, all with different objectives in mind. In spite of extensive literature research performed, very little information was found concerning the real time determination and assessment of bead shape quality and none of it was reported to be applied successfully to the pipeline industry. Despite the continuous development of laboratory laser vision systems commercial ones have been on the market for decades, some specifically developed for the welding application. Laser vision sensor systems provide surface profile information, and are the only sensors which can satisfactorily measure bead profile on a narrow groove. In order to be able to use them to automatically assess weld bead shape and quality, a deep understanding of their characteristics and limitations needs to be achieved. Once that knowledge was attained it was then applied to determine the best sensor configuration for this purpose. After that the development of human like judgment algorithms were developed to accomplish the aim that was set. Empirical rules were obtained from an experienced welder regarding the acceptability of bead shapes and were then applied in the developed system with good results. To scientifically evaluate and determine the rules to use in this system, further experiments would be required. The output of the system developed showed very accurate, reliable and consistent results that were true to the external measurements and comparisons performed. The developed system has numerous applications in the pipeline industry and it could easily be implemented on commercial systems.

Gas Metal Arc Welding (GMAW) is one of the main methods used to join structural members. One of the largest challenges involved in production of welds is ensuring the quality of the weld. One of the main factors attributing to weld quality is penetration depth. Automatic control of the welding process requires non-contact, non-destructive sensors that can operate in the presence of high temperatures and electrical noise found in the welding environment. Inspection using laser generation and electromagnetic acoustic transducer (EMAT) reception of ultrasound was found to satisfy these conditions. Using this technique, the time of flight of the ultrasonic wave is measured and used to calculate penetration depth. Previous works have shown that penetration depth measurement performance is drastically reduced when performed during welding. This work seeks to realize in-process penetration depth measurement by compensating for errors caused by elevated temperature. Neuro-fuzzy models are developed that predict penetration depth based on in-process time of flight measurements and the welding process input. Two scenarios are considered in which destructive penetration depth measurements are or are not available for model training. Results show the two scenarios are successful. When destructive measurements are unavailable, model error is comparable to that of offline ultrasonic measurements. When destructive measurements are available, measurement error is reduced by 50% compared to offline ultrasonic measurements. The two models can be effectively applied to permit in-process penetration depth measurements for the purpose of real-time monitoring and control. This will reduce material, production time, and labor costs and increase the quality of welded parts.

The objective of this research is to develop a method to evaluate important weld dimensions in thin plates by using laser generated ultrasounds and EMAT receiver. The superimposed laser sources (SLS) technique is developed to generate narrowband Lamb waves with fixed wavelengths in thin plates. The method permits the flexibility of selecting desired wavelength. The signal processing procedure that combines wavenumber-frequency (k-w) domain filtering and synthetic phase tuning (SPT) is used to further reduce the complexity of Lamb waves. The k-w domain filtering technique helps to filter out the unwanted wave components traveling at the direction that is not of interest to us and the SPT technique is applied to amplify and isolate a particular Lamb wave mode. The signal processing procedure facilitates the calculation of reflection coefficients of Lamb waves that result from the presence of weld joints. The SLS and signal processing procedure are then applied to measure reflection coefficients in butt welds and lap welds. Two methods, the direct method and indirect method, are used to develop models that use reflection coefficients as predictors to predict these weld dimensions. The models developed in this research are shown to accurately predict weld dimensions in thin plates.

This thesis describes advancements in the modelling, optimisation, process control and mechanical performance of novel high deposition rate gas metal arc welding processes for large scale additive manufacturing applications. One of the main objectives of this study was to develop fundamental understanding of the mechanisms involved during processing with particular focus on single layer welds made of carbon steel using both pulsed-current gas metal arc welding and cold metal transfer processes. The effects of interactions between critical welding process variables and weld bead and plate fusion characteristics are studied for single and multi-layers. It was shown that several bead and plate fusion characteristics are strongly affected by the contact tip to work distance, TRIM, wire feed speed, wire feed speed to travel speed ratio, and wire diameter in pulsed-current gas metal arc welding. The arc-length control, dynamic correction and the contact tip to work distance are shown to strongly influence the weld bead geometry in the cold metal transfer process. This fundamental knowledge was essential to ensure the successful development of predictive interaction models capable of determining the weld bead geometry from the welding process parameters. The models were developed using the least-squares analysis and multiple linear regression method. The gas tungsten constricted arc welding process was utilised for the first time for out-of-chamber fabrication of a large scale and high-quality Ti-6Al-4V component. The main focus was, however, in the use of the cold metal transfer process for improving out-of-chamber deposition of Ti-6Al-4V at much higher deposition rates. The effect of the cold metal transfer process on the grain refinement features in the fusion zone of single layer welds under different torch gas shielding conditions was investigated. It was shown that significant grain refinement occurs with increasing helium content. The morphological features and static mechanical performance of the resulting multi-layered Ti-6Al-4V walls were also examined and compared with those in gas tungsten constricted arc welding. The results show that a considerable improvement in static tensile properties is obtained in both testing directions with cold metal transfer over gas tungsten constricted arc welding. It was suggested that this improvement in the mechanical behaviour could be due to the formation of more fine-grained structures,which are therefore more isotropic. The average ultimate tensile strength and yield strength of the as-deposited Ti-6Al-4V material processed via cold metal transfer meet the minima specification values recommended for most Ti-6Al-4V products. Neutron diffraction technique was used to establish the effect of repeated thermo-mechanical cycling on the generation, evolution and distribution of residual stresses during wire and arc additive manufacturing. The results show a significant redistribution of longitudinal residual stresses along both the substrate and multi-bead with repeated deposition. However, a nearly complete relaxation occurs along the built, once the base plate constraint is removed.

An experimental program was developed to test various unreinforced RHS-to-RHS 90° T-connections subject to branch in-plane bending moment with the objective of determining the effectiveness of the welded joint. Twelve unique test specimens were designed to be weld-critical and the results from the full-scale tests revealed that the current equation for the effective elastic section modulus for in-plane bending, S_ip, given in Table K4.1 of ANSI/AISC 360 (2010) is conservative. A modification to the current requirements that limit the effective width of the transverse weld elements is proposed, resulting in a safe and more economical weld design method for RHS-to-RHS T-, Y- and X- connections subject to branch axial load or bending moment. It is also concluded that the fillet weld directional strength enhancement factor, (1.00 + 0.50sin1.5Ө), should not be used for strength calculations of welded joints to square and rectangular hollow structural sections.

An experimental program was developed to test various unreinforced RHS-to-RHS 90° T-connections subject to branch in-plane bending moment with the objective of determining the effectiveness of the welded joint. Twelve unique test specimens were designed to be weld-critical and the results from the full-scale tests revealed that the current equation for the effective elastic section modulus for in-plane bending, S_ip, given in Table K4.1 of ANSI/AISC 360 (2010) is conservative. A modification to the current requirements that limit the effective width of the transverse weld elements is proposed, resulting in a safe and more economical weld design method for RHS-to-RHS T-, Y- and X- connections subject to branch axial load or bending moment. It is also concluded that the fillet weld directional strength enhancement factor, (1.00 + 0.50sin1.5Ө), should not be used for strength calculations of welded joints to square and rectangular hollow structural sections.