Comparative study of evolution of residual stress state by local mechanical tensioning and laser processing of ferritic and austenitic structural steel welds.

Complex thermal stresses generated in welded structures are undesirable but inevitable in fusion welding. The presence of residual stresses can be detrimental to the integrity of a welded joint. In this research, redistribution of residual stress magnitude and profile was studied and compared in two multi-pass welded structural alloys (API X100 and 304L stainless steel) after cold rolling and laser processing. The residual stress field was studied by neutron diffraction using the SALSA strain scanner at their reactor neutron source at ILL, Grenoble. In addition to a complex distribution of residual stress state, multi-pass welds also forms dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. Dendritic grain structure is weaker and segregation of alloying elements may result in formation of corrosion microcells as well as reduction in overall corrosion prevention due to depletion of alloying elements in certain areas. The modification of as-welded residual stress state was done by cold rolling which was followed by laser processing to create a recrystallized microstructure to minimise segregation. The main objective of this study is to understand the suitability of this novel manufacturing technique to create a stress free weldment with recrystallised grain structure. Hardness evolution in the welded structures was scanned following welding, post weld cold rolling and cold rolling followed by laser processing. Hardness distribution in both the structural alloys showed a significant evidence of plastic deformation near the cap pass of the weld metal. Residual stress redistribution was observed up to 4 mm from the capping pass for ferritic steel, while in austenitic steel weld, post weld cold rolling was effective in modifying the residual stress redistribution throughout the entire thickness. Laser processing in both cases reinstated the as-welded residual stress distribution and resulted in softening of the strained area

Fiber Bragg Grating sensors for deformation monitoring of GEM foils in HEP detectors

Fiber Bragg Grating (FBG) sensors have been so far mainly used in high energy physics (HEP) as high precision positioning and re-positioning sensors and as low cost, easy to mount, radiation hard and low space- consuming temperature and humidity devices. FBGs are also commonly used for very precise strain measurements. In this work we present a novel use of FBGs as flatness and mechanical tensioning sensors applied to the wide Gas Electron Multiplier (GEM) foils of the GE1/1 chambers of the Compact Muon Solenoid (CMS) experiment at Large Hadron Collider (LHC) of CERN. A network of FBG sensors has been used to determine the optimal mechanical tension applied and to characterize the mechanical stress applied to the foils. The preliminary results of the test performed on a full size GE1/1 final prototype and possible future developments will be discussed.Comment: Four pages, seven figures. Presented by Michele Caponero at IWASI 2015, Gallipoli (Italy

Residual stress of as-deposited and rolled Wire + Arc Additive Manufacturing Ti–6Al–4V components

Wire + arc additive manufacturing components contain significant residual stresses, which manifest in distortion. High-pressure rolling was applied to each layer of a linear Ti–6Al–4V wire + arc additive manufacturing component in between deposition passes. In rolled specimens, out-of-plane distortion was more than halved; a change in the deposits' geometry due to plastic deformation was observed and process repeatability was increased. The Contour method of residual stresses measurements showed that although the specimens still exhibited tensile stresses (up to 500 MPa), their magnitude was reduced by 60%, particularly at the interface between deposit and substrate. The results were validated with neutron diffraction measurements, which were in good agreement away from the baseplate

Application of local mechanical tensioning and laser processing to improve structural integrity of multi-pass welds

Multi-pass fusion welding by a filler wire (welding electrode) is normally carried out to join thick steel sections used in most engineering applications. Welded joints in an installation, is the area of critical importance, since they are likely to contain a higher density of defects than the parent metal and their physical properties can differ significantly from the parent metal. Fusion arc welding process relies on intense local heating at a joint where a certain amount of the parent metal is melted and fused with additional metal from the filler wire. The intense local heating causes severe transient thermal gradients in the welded component and the resulting uneven cooling that follows produces a variably distributed residual stress field. In multi-pass welds, multiple thermal cycles resulted in a variably distribution of residual stress field across the weld and through the thickness. These complex thermal stresses generated in welds are undesirable but inevitable during fusion welding. Presence of such tensile residual stresses can be detrimental to the service integrity of a welded structure. In addition to a complex distribution of residual stress state, multi-pass welds also forms dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. Dendritic grain structure is weaker and segregation of alloying elements would result in formation of corrosion microcells as well as reduction in overall corrosion prevention due to depletion of alloying elements

Investigation of thermal techniques to mitigate buckling distortion in welding panels

This thesis describes the advancements of the application of thermal tensioning techniques to different weld geometries in order to eliminate buckling distortion. The main goal of this work is to better understand these techniques through experimental and numerical investigation and increase their technological maturity to aid industrial implementation. The thermal tensioning techniques investigated in this work are Thermal Tensioning by Cooling and Thermal Tensioning by Heating. The investigation for both techniques encompasses thermal source characterisation, application to different weld geometries and residual stress measurements and analysis of both butt and fillet welded samples. A detailed technology transfer study of Thermal Tensioning by Cooling was carried out in which different aspects of the application of TTC to arc welding (Gas Metal Arc Welding and Gas Tungsten Arc Welding) was examined. This study focused on the influence of both the liquid CO2 delivery system installation and welding tooling and jigging on the effectiveness of Thermal Tensioning by Cooling in reducing buckling distortion. Experimental and numerical cooling source characterisation was also carried out in the Thermal Tensioning by Cooling work to investigate the characteristics of the cooling source under different cooling conditions. The Thermal Tensioning by Cooling work was then concluded with welding trials and residual stress measurement and analysis. The results of the Thermal Tensioning by Cooling study show that the installation of the liquid CO2 delivery system as well as the welding tooling and jigging has a major influence on the effectiveness of Thermal Tensioning by Cooling in reducing buckling distortion. The cooling source characterisation work reveals that the most important parameter of the cryogenic nozzle delivery system used in this work is the Air Entrainment Gap. A description of a control system of Thermal Tensioning by Cooling is suggested based on controlling the Air Entrainment Gap. The residual stress analysis shows a reduction in the Applied Weld Load and minor changes in the tensile peak of the residual stress distribution of both butt and fillet welded panels. The Thermal Tensioning by Heating investigation includes heat source characterisation, application of Thermal Tensioning by Heating on butt and fillet welds, utilisation of alternative heat sources and residual stress analysis. The results of these investigation show that Thermal Tensioning by Heating is also highly effective in eliminating buckling distortion in butt, fillet and overlapped panels. The applied heating temperature in this work is typically in the range of 160-250 °C but not greater than 330 °C. The residual stress measurements reveal that the additional heating of Thermal Tensioning by Heating generates a positive stress gradient at the location of heating

A novel application of Fiber Bragg Grating (FBG) sensors in MPGD

We present a novel application of Fiber Bragg Grating (FBG) sensors in the construction and characterisation of Micro Pattern Gaseous Detector (MPGD), with particular attention to the realisation of the largest triple (Gas electron Multiplier) GEM chambers so far operated, the GE1/1 chambers of the CMS experiment at LHC. The GE1/1 CMS project consists of 144 GEM chambers of about 0.5 m2 active area each, employing three GEM foils per chamber, to be installed in the forward region of the CMS endcap during the long shutdown of LHC in 2108-2019. The large active area of each GE1/1 chamber consists of GEM foils that are mechanically stretched in order to secure their flatness and the consequent uniform performance of the GE1/1 chamber across its whole active surface. So far FBGs have been used in high energy physics mainly as high precision positioning and re-positioning sensors and as low cost, easy to mount, low space consuming temperature sensors. FBGs are also commonly used for very precise strain measurements in material studies. In this work we present a novel use of FBGs as flatness and mechanical tensioning sensors applied to the wide GEM foils of the GE1/1 chambers. A network of FBG sensors have been used to determine the optimal mechanical tension applied and to characterise the mechanical tension that should be applied to the foils. We discuss the results of the test done on a full-sized GE1/1 final prototype, the studies done to fully characterise the GEM material, how this information was used to define a standard assembly procedure and possible future developments.Comment: 4 pages, 4 figures, presented by Luigi Benussi at MPGD 2015 (Trieste, Italy). arXiv admin note: text overlap with arXiv:1512.0848

Onset of dissipation in ballistic atomic wires

Electronic transport at finite voltages in free-standing gold atomic chains of up to 7 atoms in length is studied at low temperatures using a scanning tunneling microscope (STM). The conductance vs voltage curves show that transport in these single-mode ballistic atomic wires is non-dissipative up to a finite voltage threshold of the order of several mV. The onset of dissipation and resistance within the wire corresponds to the excitation of the atomic vibrations by the electrons traversing the wire and is very sensitive to strain.Comment: Revtex4, 4 pages, 3 fig