Welding with lasers

A laser welding process has been developed that offers the advantages of conventional laser welding without the use of opaque materials or the addition of unwanted colour.

Concentrated autologous plasma protein: a biochemically neutral solder for tissue welding

BACKGROUND AND OBJECTIVE

Xenographic or allographic serum protein solders used for laser welding may have immunologic and/or pathogenic complications. The objective of these studies was to develop a safe, autologous solder.

STUDY DESIGN/MATERIALS AND METHODS

Five methods of preparing concentrated autologous plasma protein solder (CAPPS) were evaluated. Next, the CAPPS was evaluated via (1) thermal denaturation studies using differential scanning calorimetry, (2) tissue welding studies to characterize both acute and healing properties.

RESULTS

The optimal concentration method to produce CAPPS rapidly was a dialysis method using chemical (osmotic) forces. The CAPPS showed similar denaturation profiles to serum albumin (SA) solders. Acutely, CAPPS provided comparable breaking strengths to SA solders. At 7 days, there was no significant difference in breaking strength or histology between 50% human SA solder and CAPPS (using a porcine skin model).

CONCLUSIONS

These studies demonstrate that the CAPPS system provides acceptable acute and chronic properties for laser welding.

Control of exposure to hexavalent chromium and ozone in gas metal arc welding of stainless steels by use of a secondary shield gas

Previous work has demonstrated that the shield gas composition in gas metal arc welding can have a considerable effect on hexavalent chromium [Cr(VI)] concentration in the fume and on ozone concentrations near the arc. Normally a single shield gas is used. This paper describes a double shroud torch that allows used of concentric shield gases of different compositions. A solid stainless steel wire was used for welding. The double shroud torch used secondary shield gases containing small amounts of the reducing agents NO and C2H4. The Cr(VI) concentration in the fume and ozone concentration at a fixed point relative to the arc were measured and compared with results when using a single shield gas. Use of the reducing agents in secondary shielding using the double shroud torch was found to offer advantages for ozone concentration reduction compared with use in a conventional torch, but this was not found to be an advantage for reducing Cr(VI) concentrations.

Control of occupational exposure to hexavalent chromium and ozone in tubular wire arc-welding processes by replacement of potassium by lithium or by addition of zinc

Hexavalent chromium [Cr(VI)] and ozone are produced in many arc-welding processes. Cr(VI) is formed when welding with chromium-containing alloys and is a suspected carcinogen. Ozone is formed by the action of ultraviolet light from the arc on oxygen and can cause severe irritation to the eyes and mucous membranes. Previous work has demonstrated that reduction of sodium and potassium in manual metal arc-welding electrodes leads to substantial reductions in Cr(VI) concentrations in the fume as well as a reduction in the fume formation rate. In this paper replacement of potassium by lithium in a tubular wire welding electrode (self-shielding flux-cored) is shown to give reductions in Cr(VI) concentrations and fume formation rates. Previous work has also demonstrated that use of a tubular wire (metal cored) containing 1% zinc can, under certain conditions, result in a reduction in Cr(VI) formation rate and in ozone concentration near the arc but with a rise in the total fume formation rate. The effects of different shield gases and different levels of zinc are examined. An experimental chromium-containing tubular wire with 1% zinc was used with the following shield gases: argon, Argoshield 5, Argoshield 20, Helishield 101, Ar + 2% CO2, Ar + 5% CO2, Ar + 1% O2 and Ar + 2% O2. The wire gave > 98% reduction in Cr(VI) formation rate compared to the control wire provided the shield gas contained no oxygen. When the shield gas did contain oxygen, 1% zinc enhanced Cr(VI) formation rate, resulting in more than double the rates measured when welding with the control wire. Experiments with zinc concentrations, from 0.018 to 0.9% using Helishield 101, gave results indicating that there is an optimum zinc concentration from the point of view of Cr(VI) reduction. Implications of the use of lithium or zinc on the overall exposure risk are discussed.

[Experimental elaboration and perspectives of application of electric welding of the live tissues]

In experiment on pigs, rabbits and white rats there was examined method of electric welding (electrothermoadhesion) of live tissues--intestine, stomach, gallbladder and bladder, peritoneum, elements of mesentery, liver, spleen. We distinguish among "welding" of the hollow organs wall with restoration of their passability and "overwelding" of masses of the tissues with production of coagulational furrow, along which resection of necessary parts is executed. According to data of morphological investigations obtained the security of the method was established. Peculiarities of welding suture of tissues were studied. The method is introducing in the clinical practice actively due to its simplicity and safety in sutureless connection of tissues.

Laser welding of thermoplastic materials

The capabilities of the three main types of laser are compared and a new technique is introduced, which laser welds plastics using an infrared absorber to create a joint that is almost invisible to the human eye.

Plastic welding techniques based on torsional and circular motion

The torsion ultrasonic welding process and the frequency decoupled circular friction process at low frequencies deliver low particle production. In addition, the even, circular movement of the circular welding process over the whole seam area and the freely selectable frequency open up applications in the medical field that cannot be achieved, or can only be achieved with difficulty, by traditional welding processes. The processes are fast and can be process controlled to a fine degree with a facility to be integrated into automation lines.

Welding and joining techniques

There is a welding solution for most applications. As products must meet more stringent requirements or require more flexible processes to aid design or reduce cost, further improvements or totally new processes are likely to be developed. Quality control aspects are also becoming more important to meet regulation, and monitoring and control of welding processes and the standardised testing of joints will meet some if not all of these requirements.

The laser welding technique applied to the non precious dental alloys procedure and results

AIM

The laser welding technique was chosen for its versatility in the repair of dental metal prosthesis. The aim of this research is to assess the accuracy, quality and reproducibility of this technique as applied to Ni-Cr-Mo and Cr-Co-Mo alloys often used to make prosthesis

METHOD

The alloy's ability to weld was evaluated with a pulsed Nd-Yag Laser equipment. In order to evaluate the joining, various cast wires with different diameters were used. The efficiency of the joining was measured with tensile tests. In order to understand this difference, metallographic examinations and X-Ray microprobe analysis were performed through the welded area and compared with the cast part.

RESULTS

It was found that a very slight change in the chemistry of the Ni-Cr alloys had a strong influence on the quality of the joining. The Co-Cr alloy presented an excellent weldability. A very important change in the microstructure due to the effect of the laser was pointed out in the welding zone, increasing its micro-hardness.

CONCLUSION

The higher level of carbon and boron in one of the two Ni-Cr was found to be responsible for its poor welding ability. However for the others, the maximum depth of welding was found to be around 2mm which is one of the usual thicknesses of the components which have to be repaired.

[Problems faced in hygiene evaluation of Welders' working conditions--analysis of chemical hazards]

Dissemination of individual welding methods, as well as assessment of welding fume and gas emissions and their physical properties, chemical composition and related difficulties in hygiene evaluation of working conditions are discussed.

A model for prediction of fume formation rate in gas metal arc welding (GMAW), globular and spray modes, DC electrode positive

Prediction of fume formation rate during metal arc welding and the composition of the fume are of interest to occupational hygienists concerned with risk assessment and to manufacturers of welding consumables. A model for GMAW (DC electrode positive) is described based on the welder determined process parameters (current, wire feed rate and wire composition), on the surface area of molten metal in the arc and on the partial vapour pressures of the component metals of the alloy wire. The model is applicable to globular and spray welding transfer modes but not to dip mode. Metal evaporation from a droplet is evaluated for short time increments and total evaporation obtained by summation over the life of the droplet. The contribution of fume derived from the weld pool and spatter (particles of metal ejected from the arc) is discussed, as are limitations of the model. Calculated droplet temperatures are similar to values determined by other workers. A degree of relationship between predicted and measured fume formation rates is demonstrated but the model does not at this stage provide a reliable predictive tool.

[Titanium joints welded with laser and infrared techniques: comparative analysis of its microstructure]

BACKGROUND

Aim of the study is to compare microstructure of Titanium joints soldered with Laser and Infrared methods by performing SEM analysis, metallography and microhardness evaluation.

METHODS

Wax specimens were separated in the middle area corresponding to the joint region, machined and then soldered. 40 Titanium samples were fused and divided in 2 groups of 20 samples each. First group was soldered by laser welding, second one by infrared brazing. SEM analysis and standard metallography were carried out at joined areas and unsoldered surfaces. Microhardness test was performed on longitudinally sectioned samples with 150 g load for 15 second up to 7 mm distance from the joined area.

RESULTS

SEM photomicrographs revealed for group 1 a homogeneous metal-joint interface, without microporosities; for group 2 exhibited a distinct demarcation of metal joint interface. Metallography evaluation showed for laser joined samples only the presence of Titanium; infrared joined samples showed in soldered regions also Ni and Cu. Microhardness values detected at the joined surfaces seem to be higher for both considered groups.

CONCLUSIONS

Laser joining method with exclusive presence of Titanium seems to be ideal for monometallism; both techniques exhibited microstructural changes in the heated surface layer.

[Study of accuracy of one-piece casted and laser welded bridges]

OBJECTIVE

To assess whether laser welded bridge be fit for the clinical usage, this study compares the accuracy of laser welded multi-unit bridges with one-piece casted bridges.

METHODS

A precise stainless mold which was 20 mm length composed of two abutments (one premolar and one molar) and one pontic (two missed teeth) was made. 5 wax patterns of four-unit FPD frame-works in one-piece casting based on the mold were made. After that, they were invested with inner (Bellavest) and outer investment (phosphate and gypsum). Then they were casted with CW-PA (Ni-Cr-Nb) alloys. The other 5 wax patterns of four-unit FPD frameworks were invested and casted in two halves. Each couple of frameworks were ultra-sonic washed in distilled water and inserted to the standard metal FPD mold accurately. Laser welding machine (DL-2002) was used to weld each couple of frameworks at 305V, 20 ms. Both groups of specimens were tested on their mesiodistal span dimensions and the diameters of alloy crowns. Then they were inserted to their original stainless mold, where the marginal fitness was examined.

RESULTS

1. The one-piece casted fixed multi-unit bridge couldn't be inserted to abutments completely because of distortion, while the laser welded bridge could be inserted to abutments completely. The average marginal opening of laser welded bridges was about 74 microns and conformed to clinical standard of fitness. 2. Mesiodistal dimensions of one-piece casted bridges at the inner, bottom and top margins were 19.5600 +/- 0.3877 mm, 41.2206 +/- 0.4140 mm, 41.0598 +/- 0.3379 mm respectively; while those of laser welded bridges were 20.2950 +/- 0.1191 mm, 41.9625 +/- 0.0788 mm, 42.0584 +/- 0.1089 mm, which were obviously close to metal abutments (P < 0.05). 3. The alloy crowns' diameters of one-piece casted bridges were examined as following, the premolar: phi IJ = 9.8386 +/- 0.0567 mm, phi LK = 9.9596 +/- 0.0548 mm, the molar: phi EF = 11.7948 +/- 0.0252 mm, phi HG = 11.9412 +/- 0.0763 mm; The alloy crowns' diameters of laser bridges were as following, the premolar: phi IJ = 9.7927 +/- 0.0636 mm, phi LK = 9.9438 +/- 0.0726 mm, the molar: phi EF = 11.8287 +/- 0.0863 mm, phi HG = 11.8893 +/- 0.1049 mm. There was no significant difference between the two groups (P < 0.05).

CONCLUSION

Laser welding greatly improve the fitness of multi-unit fixed bridges.

[Stress-corrosion test of laser welded ceramic alloys]

OBJECTIVE

The corrosion properties of dental material are very critical. This study is to investigate the corrosion properties of laser welded basemetalalloys.

METHODS

The precise stainless rod molds had been made in size of phi 3 mm x 4 mm, with which 20 wax patterns were made. They were invested with inner investment (Bellavest) and outer investment (phosphate and gypsum). Then they were casted with CW-PA (Ni-Cr-Nb) alloys. All casted alloy rods were ultra-sonic washed in distilled water. Every two rods were contacted longitudinally by a special welding jig. Laser welding machine (DL-2002) was used to weld them at 305 V, 20 ms. The specimens were divided into 2 groups as following: 1. The group of stress-corrosion: 5 laser welded samples were subjected to the stress-corrosion test under 261.44 MPa in the 37 degrees C artificial saliva for 3 months in a special stress-corrosion test jig. After that, the ultimate tensile strength (UTS) was tested, the surface microcrack at the fusion zone (FZ), the heat affecting zone (HAZ) and the interface zone was observed with SEM (ARMY-1845, USA), the elements were also analyzed with EPMA (ARMY-1845, USA) at the fusion zone (FZ), the parent metal zone and the interface zone. 2. The other 5 laser welded samples were made as the controlled group. No special treatment were done to them, and the UTS was also tested, the surface of the micro crack and the elements at the FZ, the HAZ, parent metal zone and the interface zone were observed and analyzed with SEM, EPMA as well.

RESULTS

The study showed us that the UTS of the stress-corrosion group was 502.48 +/- 12.49 MPa, while that of the controlled group was 446.05 +/- 82.50 MPa, there was no significant difference (P > 0.05). There was no microcrack on any sample's surface at the FZ, the HAZ and the interface zone. The main elements of the FZ were Ni(56.63%), Cr(19.36%), Nb (6.57%), Si(6.01%), Al(0.32%) and Mo(11.11%), while the elements of the parent metal zone were Ni(60.77%), Cr (20.59%), Nb(5.03%), Si(3.95%), Al(0.37%) and Mo(9.29%) respectively.

CONCLUSION

The results suggest that the corrosion properties of laser welded alloys are excellent.

[Laser technologies for the making of dentures, orthodontic appliances, metallic and sapphire implants and root pins]

The authors analyze 10-year experience gained in the use of patented laser technologies for making metal dentures, orthodontic devices, metal and sapphire implants, radical pins, and other structures from various metal dental alloys (steel IXI8H9T, cobalt-chromium, silver-palladium, gold, titanium, etc.). Kvant-155, a new-generation Russian laser device, is described.

Effects of joint configuration for the arc welding of cast Ti-6Al-4V alloy rods in argon

STATEMENT OF PROBLEM

Titanium and its alloys are more commonly used in prosthodontics and welding has become the most common modality for their joining. Studies on the welding of titanium and its alloys have not quantified this value, though its importance has been suggested.

PURPOSE

This study compared the strength and properties of the joint achieved at various butt joint gaps by the arc-welding of cast Ti-6Al-4V alloy tensile bars in an argon atmosphere.

MATERIAL AND METHODS

Forty of 50 specimens were sectioned and welded at four gaps. All specimens underwent tensile testing to determine ultimate tensile strength and percentage elongation, then oxygen analysis and scanning electron microscopy.

RESULTS

As no more than 3 samples in any group of 10 actually fractured in the weld itself, a secondary analysis that involved fracture location was initiated. There were no differences in ultimate tensile strength or percentage elongation between specimens with weld gaps of 0.25, 0.50, 0.75, and 1.00 mm and the as-cast specimens. There were no differences in ultimate tensile strength between specimens fracturing in the weld and those fracturing in the gauge in welded specimens; however, as-cast specimens demonstrated a higher ultimate tensile strength than welded specimens that fractured in the weld. Specimens that fractured in the weld site demonstrated less ductility than those that fractured in the gauge in both welded and as-cast specimens, as confirmed by scanning electron microscopy examination. The weld wire showed an oxygen scavenging effect from the as-cast parent alloy.

CONCLUSIONS

The effects of the joint gap were not significant, whereas the characteristics of the joint itself were, which displayed slightly lower strength and significantly lower ductility (and thus decreased toughness). The arc-welding of cast titanium alloy in argon atmosphere appears to be a reliable and efficient prosthodontic laboratory modality producing predictable results, although titanium casting and joining procedures must be closely controlled to minimize heat effects and oxygen contamination.

Looking into the future: materials and joining technology

To improve existing products and create new ones manufacturers of medical devices need to consider the latest technology and materials. This review of recent developments in joining techniques describes alternative joining processes and how to establish best practice when working with adhesives and welding.

Fatigue life of a Nd:YAG laser-welded metal ceramic alloy

Fifteen laser-welded Olympia alloy samples were divided into three groups of five samples each, with different gap distances between the welded halves. The first group was welded with a 0.0-mm gap distance. The second and third groups had Olympia shims placed in 0.3- and 1.0-mm gaps, respectively, prior to laser welding. Each of the samples was tested to failure in load fatigue at 30 Hz in a fatigue testing device using an applied stress of 35,000 psi (241.4 MPa). The means and standard deviations for the number of cycles required to produce fatigue failure for each group was 494,618 +/- 118,311 cycles for the group welded with 0.0-mm gap distance, and 242,741 +/- 44,623 and 232,021 +/- 55,877 cycles for the 0.3- and 1.0-mm specimens, respectively. A one-way analysis of variance showed that the 0.0-mm gap specimens had the greatest number of cycles to failure (P < or = 0.05). There was no significant difference between the other two groups. With the exception of two specimens that failed at the weld center, all failures occurred at the edge of the weld.

Multiple exposure to metals in eight types of welding

This article evaluates multiple exposures to metals in different types of metal welding such as manual metal arc for mild and stainless steel, continuous wire, submerged arc, laser and brazing. Environmental monitoring was carried out in eight different occupational situations and the inductively coupled plasma mass spectrometry technique was adopted in order to characterize exposure to several elements simultaneously and with high accuracy. The results showed that up to 23 elements could be measured. The highest concentrations were found for Al, Mn, Fr, Ni, Cr, Cu and Zn. For some elements such as In, Nd, I, Rb the concentrations were very low. A qualitative and quantitative variation in fume composition was observed at a certain distance from the welding point, which should be to taken into account when evaluating indirect exposures. It would also be possible, with this technique, to identify specific elements in the mixture which could also be measured in biological fluids.

In vitro study of intraoral welding procedures for pure titanium

This in vitro study investigated the temperature changes experienced during electric welding of titanium to determine if the welding heat presented a potential danger to pulpal vitality. Welds were applied to cast titanium simulations of a three-unit fixed partial denture containing two thermocouples measuring temperature changes. Mean maximal temperature changes were 127.4 degrees F near the weld and 68.6 F degrees at the axial wall. The mean times for the temperature to drop to within 10.0 degrees F of the starting temperature ranged from 84.1 to 133.7 seconds. The relatively low temperatures recorded in this study suggest that further investigation is warranted into the use of the welder intraorally.

Mechanical properties of titanium connectors

The tensile mechanical properties of welded titanium joints were studied, and intact titanium was used as controls. Welded joints were fabricated with either a stereographic laser-welding technique or a gas tungsten arc welding technique. The effect of heat treatment following a simulated porcelain application was also investigated. Heat-treated laser welds had significantly lower ultimate tensile strengths. Heat treatment had no effect on the modulus of elasticity or elongation, but generally significantly decreased the yield strength of the titanium specimens. The gas tungsten are welding specimens had significantly higher yield strengths and elastic moduli than the other two groups. The elongation of the control specimens was significantly greater than the elongation of the gas tungsten arc welding specimens, which was in turn significantly higher than that of the laser-welded specimens.

Laser welding in the dental laboratory: an alternative to soldering

Only recently has laser welding been applied to dental technology, primarily as an alternative to soldering. This article addresses how the laser is used for welding, the effect welding has on metals as the energy is converted into heat and reacts with the alloy's surface and the practicality of laser welding in the dental laboratory. A step-by-step procedure for accomplishing laser-welded connections in a fixed partial denture is included. A laser-welded clasp repair using wrought wire and the addition of custom cast parts welded to an existing removable partial denture framework on the master model are also shown.

Joining titanium materials with tungsten inert gas welding, laser welding, and infrared brazing

Titanium has a number of desirable properties for dental applications that include low density, excellent biocompatibility, and corrosion resistance. However, joining titanium is one of the practical problems with the use of titanium prostheses. Dissolved oxygen and hydrogen may cause severe embrittlement in titanium materials. Therefore the conventional dental soldering methods that use oxygen flame or air torch are not indicated for joining titanium materials. This study compared laser, tungsten inert gas, and infrared radiation heating methods for joining both pure titanium and Ti-6Al-4V alloy. Original rods that were not subjected to joining procedures were used as a control method. Mechanical tests and microstructure analysis were used to evaluate joined samples. Mechanical tests included Vickers microhardness and uniaxial tensile testing of the strength of the joints and percentage elongation. Two-way analysis of variance and Duncan's multiple range test were used to compare mean values of tensile strength and elongation for significant differences (p < or = 0.05). Tensile rupture occurred in the joint region of all specimens by cohesive failure. Ti-6Al-4V samples exhibited significantly greater tensile strength than pure titanium samples. Samples prepared by the three joining methods had markedly lower tensile elongation than the control titanium and Ti-6Al-4V rods. The changes in microstructure and microhardness were studied in the heat-affected and unaffected zones. Microhardness values increased in the heat-affected zone for all the specimens tested.

Consolidation conditions for a cold-welded mercury-free alloy

Alloys being investigated as possible direct-filling materials rely upon a cold-welded, deformable silver matrix phase for cohesion and strength. The silver matrix is formed by direct consolidation of comminuted silver under an oxide-removing acid. The object of this study was to determine the effect of conditions such as load, increment thickness, and concentration of oxide-removing acid on the properties of the silver matrix. Results indicate that the addition of higher impact loads significantly improved yield strength and specimens built up by using thinner increments were significantly stronger and denser.

A new technology for direct restorative alloys

OBJECTIVES

The purpose of this study was to develop a new technology for preparing mercury-free metallic dental restorative materials.

METHODS

The novel approach relies on the cold welding of surface treated silver particles. At ambient temperature, intermetallic compound formation takes place spontaneously at the silver-tin interface. The ability of a loose powder to consolidate at ambient temperature under moderate pressure and within a short time duration was investigated for various mixtures of elemental silver, tin, and pre-alloyed silver-coated powders. Surface treatment aimed at removing silver surface oxide layers is done with a dilute acid. The compressive and the transverse rupture strengths of several of the consolidated powder mixtures were determined.

RESULTS

Cold-welding of surface-treated powder particles takes place across the silver-silver interface and is promoted by exposure to a mild acid. Powder mixtures containing approximately 50% silver powder, 40% silver-coated silver-tin intermetallic compound particles, and a small silver-tin fraction deposited from an aqueous solution display very good condensability, depending on the amount of silver-silver interface area available. The attained rupture strength values (200 Mpa) were higher than those of amalgams; the compressive strengths (120 MPa) and hardness values (100 KHN), however, were lower than those found for amalgams.

SIGNIFICANCE

Mercury-free silver-tin powder mixtures can be processed for use as metallic composite dental restorative materials.