In-Situ Observations of Phase Transformations During Welding of 1045 Steel using Spatially Resolved and Time Resolved X-Ray Diffraction

Synchrotron-based methods have been developed at Lawrence Livermore National Laboratory (LLNL) for the direct observation of microstructure evolution during welding. These techniques, known as spatially resolved (SRXRD) and time resolved (TRXRD) x-ray diffraction, allow in-situ experiments to be performed during welding and provide direct observations of high temperature phases that form under the intense thermal cycles that occur. This paper presents observations of microstructural evolution that occur during the welding of a medium carbon AISI 1045 steel, using SRXRD to map the phases that are present during welding, and TRXRD to dynamically observe transformations during rapid heating and cooling. SRXRD was further used to determine the influence of welding heat input on the size of the high temperature austenite region, and the time required to completely homogenize this region during welding. These data can be used to determine the kinetics of phase transformations under the steep thermal gradients of welds, as well as benchmark and verify phase transformation models

Effect of Fluid Flow on Inclusion Coarsening in Low-Alloy Steel Welds

Oxide inclusions form in welds because of deoxidation reactions in the weld pool. These inclusions control the weld microstructure development. Thermodynamic and kinetic calculation of oxidation reaction can describe inclusion characteristics such as number density, size, and composition. Experimental work has shown that fluid-flow velocity gradients in the weld pool can accelerate inclusion growth by collision and coalescence. Moreover, fluid flow in welds can transport inclusions to different temperature regions that may lead to repeated dissolution and growth of inclusions. These phenomena are being studied with the help of computational coupled heat transfer, fluid-flow, thermodynamic, and kinetic models. The results show that the inclusion formation in steel welds can be described as a function of the welding processes, process parameters, and steel composition

Comparative genomics of two super-shedder isolates of Escherichia coli O157:H7

Shiga toxin-producing Escherichia coli O157:H7 (O157) are zoonotic foodborne pathogens and of major public health concern that cause considerable intestinal and extra-intestinal illnesses in humans. O157 colonize the recto-anal junction (RAJ) of asymptomatic cattle who shed the bacterium into the environment through fecal matter. A small subset of cattle, termed super-shedders (SS), excrete O157 at a rate (104 CFU/g of feces) that is several orders of magnitude greater than other colonized cattle and play a major role in the prevalence and transmission of O157. To better understand microbial factors contributing to super-shedding we have recently sequenced two SS isolates, SS17 (GenBank accession no. CP008805) and SS52 (GenBank accession no. CP010304) and shown that SS isolates display a distinctive strongly adherent phenotype on bovine rectal squamous epithelial cells. Here we present a detailed comparative genomics analysis of SS17 and SS52 with other previously characterized O157 strains (EC4115, EDL933, Sakai, TW14359). The results highlight specific polymorphisms and genomic features shared amongst SS strains, and reveal several SNPs that are shared amongst SS isolates, including in genes involved in motility, adherence, and metabolism. Finally, our analyses reveal distinctive patterns of distribution of phage-associated genes amongst the two SS and other isolates. Together, the results of our comparative genomics studies suggest that while SS17 and SS52 share genomic features with other lineage I/II isolates, they likely have distinct recent evolutionary histories. Future comparative and functional genomic studies are needed to decipher the precise molecular basis for super shedding in O157

Advances in welding science - a perspective

The ultimate goal of welding technology is to improve the joint integrity and increase productivity. Over the years, welding has been more of an art than a science, but in the last few decades major advances have taken place in welding science and technology. With the development of new methodologies at the crossroads of basic and applied sciences, enormous opportunities and potential exist to develop a science-based tailoring of composition, structure, and properties of welds with intelligent control and automation of the welding processes

Direct observations of austenite, bainite, and martensite formation during arc welding of 1045 steel using time-resolved X-ray diffraction - Phase transformations were tracked in real time using a synchrotron accelerator

ABSTRACT. In-situ time-resolved X-ray diffraction (TRXRD) experiments were performed during stationary gas tungsten arc (GTA) welding of AISI 1045 C-Mn steel. These real-time synchrotron-based experiments tracked phase transformations in the heat-affected zone of the weld under rapid heating and cooling conditions. The diffraction patterns were recorded at 100 ms intervals, and were later analyzed using diffraction peak profile analysis to determine the relative fraction of ferrite (tx) and austenite (y) phases in each diffraction pattern. Lattice parameters and diffraction peak widths were also measured throughout the heating and cooling cycle of the weld, providing additional information about the phases that were formed. The experimental results were coupled with temperatures calculated by a thermo-fluids weld model, allowing the transformation kinetics of the ct~, phase transformation to be evaluated. During heating, complete austenitization was observed in the heat-affected zone of the weld, and the kinetics of the ct~'/phase transformation were modeled using a Johnson-Mehl-Avrami (JMA) approach. The results from the 1045 steel weld were compared to those of a 1005 low-carbon steel from a previous study. Differences in austenitization rates of the two steels were attributed to differences in the base metal microstructures, particularly the relative amounts of pearlite and the extent of the allotriomorphic ferrite phase. During weld cooling, the austenite transformed to a mixture of bainite and martensite. In situ diffraction was able to distinguish between these two nonequilib-J. IV.. ELMER and T. A. PALMER rium phases based on differences in their lattice parameters, diffraction peak widths, and their transformation rates, resulting in the first real-time X-ray diffraction observations of bainite and martensite formation made during welding

Virtual Welded-Joint Design Integrating Advanced Materials and Processing Technologies

The primary goal of this project is to increase the fatigue life of a welded-joint by 10 times and to reduce energy use by 25% through product performance and productivity improvements using an integrated modeling approach. The fatigue strength of a welded-joint is currently the bottleneck to design high performance and lightweight welded structures using advanced materials such as high strength steels. In order to achieve high fatigue strength in a welded-joint it is necessary to manage the weld bead shape for lower stress concentration, produce preferable residual stress distribution, and obtain the desired microstructure for improved material toughness and strength. This is a systems challenge that requires the optimization of the welding process, the welding consumable, the base material, as well as the structure design. The concept of virtual welded-joint design has been proposed and established in this project. The goal of virtual welded-joint design is to develop a thorough procedure to predict the relationship of welding process, microstructure, property, residual stress, and the ultimate weld fatigue strength by a systematic modeling approach. The systematic approach combines five sub-models: weld thermal-fluid model, weld microstructure model, weld material property model, weld residual stress model, and weld fatigue model. The systematic approach is thus based on interdisciplinary applied sciences including heat transfer, computational fluid dynamics, materials science, engineering mechanics, and material fracture mechanics. The sub-models are based on existing models with further development. The results from modeling have been validated with critical experiments. The systematic modeling approach has been used to design high fatigue resistant welds considering the combined effects of weld bead geometry, residual stress, microstructure, and material property. In particular, a special welding wire has been developed in this project to introduce compressive residual stress at weld toe for weld fatigue resistance

Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing

Artificial intelligence (AI) embedded within digital models of manufacturing processes can be used to improve process productivity and product quality significantly. The application of such advanced capabilities particularly to highly digitalized processes such as metal additive manufacturing (AM) is likely to make those processes commercially more attractive. AI capabilities will reside within Digital Twins (DTs) which are living virtual replicas of the physical processes. DTs will be empowered to operate autonomously in a diagnostic control capacity to supervise processes and can be interrogated by the practitioner to inform the optimal processing route for any given product. The utility of the information gained from the DTs would depend on the quality of the digital models and, more importantly, their faster-solving surrogates which dwell within DTs for consultation during rapid decision-making. In this article, we point out the exceptional value of DTs in AM and focus on the need to create high-fidelity multiscale-multiphysics models for AM processes to feed the AI capabilities. We identify technical hurdles for their development, including those arising from the multiscale and multiphysics characteristics of the models, the difficulties in linking models of the subprocesses across scales and physics, and the scarcity of experimental data. We discuss the need for creating surrogate models using machine learning approaches for real-time problem-solving. We further identify non-technical barriers, such as the need for standardization and difficulties in collaborating across different types of institutions. We offer potential solutions for all these challenges, after reflecting on and researching discussions held at an international symposium on the subject in 2019. We argue that a collaborative approach can not only help accelerate their development compared with disparate efforts, but also enhance the quality of the models by allowing modular development and linkages that account for interactions between the various sub-processes in AM. A high-level roadmap is suggested for starting such a collaboration.The main sponsor of the Symposium was the CSIRO Research Office. Co-sponsors were The University of Melbourne, RMIT University, and the software companies associated with ThingWorx, Solvia, MSC Simufact, Materialise and Flow-3D

On key technologies for realising digital twins for structural dynamics applications

The term digital twin has gained increasing popularity over the last few years. The concept, loosely based on a virtual model framework that can replicate a particular system for contexts of interest over time, will require the development and integration of several key technologies in order to be fully realised. This paper, focusing on vibration-related problems in mechanical systems, discusses these key technologies as the building blocks of a digital twin. The example of a simulation digital twin that can be used for asset management is then considered. After briefly discussing the building blocks required, the process of data-augmented modelling is selected for detailed investigation. This concept is one of the defining characteristics of the digital twin idea, and using a simple numerical example, it is shown how augmenting a model with data can be used to compensate for the inherent model discrepancy. Finally the implications of this type of data augmentation for future digital twin technology is discussed

Bacteriophages to control Shiga toxin-producing E. coli safety and regulatory challenges

Shiga toxin-producing Escherichia coli (STEC) are usually found on food products due to contamination from the fecal origin, as their main environmental reservoir is considered to be the gut of ruminants. While this pathogen is far from the incidence of other well-known foodborne bacteria, the severity of STEC infections in humans has triggered global concerns as far as its incidence and control are concerned. Major control strategies for foodborne pathogens in food-related settings usually involve traditional sterilization/disinfection techniques. However, there is an increasing need for the development of further strategies to enhance the antimicrobial outcome, either on food-contact surfaces or directly in food matrices. Phages are considered to be a good alternative to control foodborne pathogens, with some phage-based products already cleared by the Food and Drug Administration (FDA) to be used in the food industry. In European countries, phage-based food decontaminants have already been used. Nevertheless, its broad use in the European Union is not yet possible due to the lack of specific guidelines for the approval of these products. Furthermore, some safety concerns remain to be addressed so that the regulatory requirements can be met. In this review, we present an overview of the main virulence factors of STEC and introduce phages as promising biocontrol agents for STEC control. We further present the regulatory constraints on the approval of phages for food applications and discuss safety concerns that are still impairing their use.The authors thank the Portuguese Foundation for Scienceand Technology (FCT) through the strategic funding of UID/BIO/04469/2019 unit, and the project PhageSTEC [PTDC/CVT-CVT/29628/2017], under the scope of COMPETE 2020 [POCI-01-0145-FEDER-029628]. The author GP acknowledges theFCT grant [SFRH/BD/117365/2016].info:eu-repo/semantics/publishedVersio