Thermal Welding of Liquids

Welding of thermoplastics is a common practice in many industrial sectors, but it has yet to be realized with fluids. Here, the thermal welding of liquids by using the assembly and jamming of nanoparticle surfactants (NPSs) at liquid-liquid interfaces is reported. By fine-tuning the dynamic interaction strength within NPSs, the interfacial activity of NPSs, as well as the binding energy of NPSs to the interface can be precisely controlled, leading to a dynamic exchange of NPSs, maximizing the reduction in the interfacial energy. With NPSs jammed at the interface, the structures of liquids can be manipulated to complex geometries by applying an external force and, due to the temperature responsiveness of NPSs, when bringing liquids into contact and heating the system, welding of liquids can be achieved. This work provides a straightforward strategy for the construction of modular all-liquid fluidics, opening up numerous opportunities in fields like biotechnology, healthcare, and materials science.

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

In the process of the ultrasonic-assisted arc welding of metal materials, traditional ultrasonic application methods, such as the low-frequency impact of ultrasonic horns on a base material, can easily cause the non-fusion defect. In order to solve this problem, a rotating sonotrode with a groove and double thin ends was designed in this study. The ultrasonic vibration is transmitted into the weld pool by the rolling of the sonotrode on both sides of the weld. The resonant frequency was set at 50 kHz. Firstly, based on the Mindlin theory, a rotating sonotrode without a groove was designed by solving the frequency equation and by conducting a finite element simulation. Secondly, the effects of the groove, perforation, and transition mode on the resonant frequency, stress distribution, and amplification factor were investigated by finite element simulation. Finally, the optimum rotating sonotrode with a groove was obtained. The results show that the size of a rotating sonotrode that has a small frequency error can be obtained by using the discrete interval solver method combined with finite element simulation. The groove can significantly reduce the resonant frequency. The stress concentration can be effectively reduced by using the elliptical transition mode. The resonant frequency and amplification factor of a rotating sonotrode with a groove could be effectively adjusted by a method of double-position joint perforation. The final resonant frequency was 49.721 kHz and the amplification factor was 3.02. This study provides an effective design method for a sonotrode with double thin ends and a groove structure.

Effect of E-waste copper alloy additions on the microstructure and organization of Cu90PSn brazing joints

The effects of different contents of e-waste alloy on the microstructure and joint properties of Cu90PSn brazing filler metal was investigated during copper and copper brazing. Microstructure of base metal and brazing filler metal was studied with scanning electronic microscopy (SEM). The properties of brazing joint obtained by adding different electronic waste filler metal for smelting copper alloy were compared together. The results indicated that the fluidity of Cu90PSn brazing filler metal was weakened and the spreading property of Cu90PSn brazing filler metal was damaged after the addition of e-waste copper alloy. The structure of Cu90PSn brazing filler metal is mainly composed of (Cu), Cu3P and (Cu,Sn) compounds. When a small amount of electronic waste copper alloy is added, a trace amount of Fe in the brazing filler metal is distributed in the matrix structure of the filler metal in the form of solid solution. With the increase of copper alloys contents by smelting e-waste, Fe content in Cu90PSn brazing filler metal increases; the granular Fe3P phosphide changes into lamellar form. The Cu3P compound phase changes from continuous large orderly arrangement to discontinuous small block structure. Therefore, adding a trace amount of electronic waste copper alloy to the solder induction brazing copper/copper can obtain a uniform composition of the brazing structure. And the welding performance is not affected. However, As the content of e-waste smelted copper alloy continues to increase, the tensile strength shows a downward trend, which is attributed to the presence of brittle compound Fe3P in the joint.

The Influence of the Shielding-Gas Flow Rate on the Mechanical Properties of TIG-Welded Butt Joints of Commercially Pure Grade 1 Titanium

This article proposes as a novelty the differentiation of shielding-gas flow rates from both sides of the tungsten inert gas (TIG)-welded butt joints of commercially pure (CP) grade 1 titanium tubes. Such an approach is aimed at economically reducing the amount of protective gas used in TIG closed butt welding. The effect of the shielding-gas flow rate on the properties of CP grade 1 titanium butt-welded joints made using the tungsten inert gas (TIG)-welding method. Butt-welded joints were made for different values of the shielding-gas flow from the side of the root of the weld. Argon 5.0 was used as the shielding gas in the welding process. As part of the research, the welded joints obtained were analysed using optical and scanning electron microscopy. The microstructural characteristics of the joints were examined using an optical microscope, and the mechanical properties were determined using hardness and tensile tests. It was observed that as the flow of the shielding gas decreases, the hardness of the weld material increases and its brittleness also increases. A similar trend related to the amount of gas flow was also noticeable for the tensile strength of the joints. The increase in the hardness of the weld and the heat-affected zone compared to the base metal is mainly related to the increase in the amount of acicular structure (α' phase). The optimal gas flow rates from the side of the root of weld were found at the values of 12 dm3/min.

Microstructure and Mechanical Properties of Ti-6Al-4V Welds Produced with Different Processes

The effect of defects and microstructure on the mechanical properties of Ti-6Al-4V welds produced by tungsten inert gas welding; plasma arc welding; electron beam welding; and laser beam welding was studied in the present work. The mechanical properties of different weld types were evaluated with respect to micro hardness; yield strength; ultimate tensile strength; ductility; and fatigue at room temperature and at elevated temperatures (200 °C and 250 °C). Metallographic investigation was carried out to characterize the microstructures of different weld types, and fractographic investigation was conducted to relate the effect of defects on fatigue performance. Electron and laser beam welding produced welds with finer microstructure, higher tensile ductility, and better fatigue performance than tungsten inert gas welding and plasma arc welding. Large pores, and pores located close to the specimen surface, were found to be most detrimental to fatigue life.

Reconfiguration, Welding, Reprogramming, and Complex Shape Transformation of An Optical Shape Memory Polymer Network Enabled by Patterned Secondary Crosslinking

Stimuli-triggered generation of complicated 3D shapes from 2D strips or plates without using sophisticated molds is desirable and achieving such 2D-to-3D shape transformation in combination with shape reconfiguration, welding, and reprogramming on a single material is very challenging. Here, a convenient and facile strategy using the solution of a disulfide-containing diamine for patterned secondary crosslinking of an optical shape-memory polymer network is developed to integrate the above performances. The dangling thiolectones attached to the backbones react with the diamine in the solution-deposited region so that the secondary crosslinking may not only weld individual strips into assembled 3D shapes but also suppress the relaxation of the deformed polymer chains to different extents for shape reconfiguration or heating-induced complex 3D deformations. In addition, as the dynamic disulfide bonds can be thermally activated to erase the initial programming information and the excessive thiolectones are available for subsequent patterned crosslinking, the material also allows shape reprogramming. Combining welding with patterning treatment, it is further demonstrated that a gripper can be assembled and photothermally controlled to readily grasp an object.

Pushing the Limits of Capillary Assembly for the Arbitrary Positioning of Sub-50nm Nanocubes in Printable Plasmonic Surfaces

The fabrication of high quality nanophotonic surfaces for integration in optoelectronic devices remains a challenge because of the complexity and cost of top-down nanofabrication strategies. Combining colloidal synthesis with templated self-assembly emerged as an appealing low-cost solution. However, it still faces several obstacles before integration in devices can become a reality. This is mostly due to the difficulty in assembling small nanoparticles (<50 nm) in complex nanopatterns with a high yield. In this study, a reliable methodology is proposed to fabricate printable nanopatterns with an aspect ratio varying from 1 to 10 and a lateral resolution of 30 nm via nanocube assembly and epitaxy. Investigating templated assembly via capillary forces, a new regime was identified that was used to assemble 30-40 nm nanocubes in a patterned polydimethylsiloxane template with a high yield for both Au and Ag with multiple particles per trap. This new method relies on the generation and control of an accumulation zone at the contact line that is thin as opposed to dense, displaying higher versatility. This is in contrast with conventional wisdom, identifying a dense accumulation zone as a requirement for high-yield assembly. In addition, different formulations are proposed that can be used for the colloidal dispersion, showing that the standard water-surfactant solutions can be replaced by surfactant-free ethanol solutions, with good assembly yield. This allows to minimize the presence of surfactants that can affect electronic properties. Finally, it is shown that the obtained nanocube arrays can be transformed into continuous monocrystalline nanopatterns via nanocube epitaxy at near ambient temperature, and transferred to different substrates via contact printing. This approach opens new doors to the templated assembly of small colloids and could find potential applications in various optoelectronic devices ranging from solar cells to light-emitting diodes and displays.

Effects of mixed metal exposures on MRI diffusion features in the medial temporal lobe

Background

Environmental exposure to metal mixtures is common and may be associated with increased risk for neurodegenerative disorders including Alzheimer's disease.

Objective

This study examined associations of mixed metal exposures with medial temporal lobe (MTL) MRI structural metrics and neuropsychological performance.

Methods

Metal exposure history, whole blood metal, and neuropsychological tests were obtained from subjects with/without a history of mixed metal exposure from welding fumes (42 exposed subjects; 31 controls). MTL structures (hippocampus, entorhinal and parahippocampal cortices) were assessed by morphologic (volume, cortical thickness) and diffusion tensor imaging [mean (MD), axial (AD), radial diffusivity (RD), and fractional anisotropy (FA)] metrics. In exposed subjects, correlation, multiple linear, Bayesian kernel machine regression, and mediation analyses were employed to examine effects of single- or mixed-metal predictor(s) and their interactions on MTL structural and neuropsychological metrics; and on the path from metal exposure to neuropsychological consequences.

Results

Compared to controls, exposed subjects had higher blood Cu, Fe, K, Mn, Pb, Se, and Zn levels (p's<0.026) and poorer performance in processing/psychomotor speed, executive, and visuospatial domains (p's<0.046). Exposed subjects displayed higher MD, AD, and RD in all MTL ROIs (p's<0.040) and lower FA in entorhinal and parahippocampal cortices (p's<0.033), but not morphological differences. Long-term mixed-metal exposure history indirectly predicted lower processing speed performance via lower parahippocampal FA (p=0.023). Higher whole blood Mn and Cu predicted higher entorhinal diffusivity (p's<0.043) and lower Delayed Story Recall performance (p=0.007) without overall metal mixture or interaction effects.

Discussion

Mixed metal exposure predicted MTL structural and neuropsychological features that are similar to Alzheimer's disease at-risk populations. These data warrant follow-up as they may illuminate the path for environmental exposure to Alzheimer's disease-related health outcomes.

Application of New Al-Si Welding Filler with High Concentration of Copper and Magnesium: High-Temperature Strength and Anti-Corrosion Mechanism

Currently, the primary commercial aluminum alloy fillers used are 4043 and 5356. However, when welded with high-strength work pieces like 6061 and 7075 aluminum alloys, the strength of weld beads significantly lags behind that of the original welded material. Both 4043 and 5356 aluminum alloys cannot be strengthened through heat treatment. The strength difference between the weld bead and base material doubles after heat treatment. In this study, an Al-Si-Cu-Mg alloy (SCM) filler modified using a heat-treatable A319 aluminum alloy was employed to investigate the post-welding microstructural and mechanical properties of specimens under room- and high-temperature conditions and after prolonged exposure in a saltwater environment (3.5 wt.% NaCl). The aim was to demonstrate that commercial aluminum alloy fillers could be substituted with a high-silicon aluminum alloy boasting excellent solidification and mechanical properties. The results revealed that, after heat treatment of the weld bead, dendrites were not eliminated, but the tensile strength increased to 310 MPa, closely matching that of commercial 6061 aluminum alloy. The strength of the weld bead remained higher than 250 MPa in high-temperature (240 °C) and saltwater environments. These findings underscore the potential application of this material.

Fused Deposition Modelling (FDM) of Thermoplastic-Based Filaments: Process and Rheological Properties-An Overview

The fused deposition modeling (FDM) process, an extrusion-based 3D printing technology, enables the manufacture of complex geometrical elements. This technology employs diverse materials, including thermoplastic polymers and composites as well as recycled resins to encourage sustainable growth. FDM is used in a variety of industrial fields, including automotive, biomedical, and textiles, as a rapid prototyping method to reduce costs and shorten production time, or to develop items with detailed designs and high precision. The main phases of this technology include the feeding of solid filament into a molten chamber, capillary flow of a non-Newtonian fluid through a nozzle, layer deposition on the support base, and layer-to-layer adhesion. The viscoelastic properties of processed materials are essential in each of the FDM steps: (i) predicting the printability of the melted material during FDM extrusion and ensuring a continuous flow across the nozzle; (ii) controlling the deposition process of the molten filament on the print bed and avoiding fast material leakage and loss of precision in the molded part; and (iii) ensuring layer adhesion in the subsequent consolidation phase. Regarding this framework, this work aimed to collect knowledge on FDM extrusion and on different types of rheological properties in order to forecast the performance of thermoplastics.

Processing of Bimetallic Inconel 625-16Mo3 Steel Tube via Supercritical Bend: Study of the Mechanical Properties and Structure

Incineration is currently the standard way of disposing of municipal waste. It uses components protected by high-temperature-resistant layers of materials, such as Inconel alloys. Therefore, the objective of the current paper is to study the mechanical properties and structure of a bimetallic Inconel 625-16Mo3 steel tube. The Inconel 625 layer was 3.5 mm thick and was applied to the surface of the tube with a wall thickness of 7 mm via the cold metal transfer method. The bimetallic tube was bent using a supercritical bend (d ≤ 0.7D). This paper is focused on the investigation of the material changes in the Inconel 625 layer areas influenced by the maximum tensile and compressive stresses after the bend. The change in layer thickness after the bend was evaluated and compared to the non-deformed tube. In addition, the local mechanical properties (nanohardness, Young modulus) across the indicated interfacial areas using quasistatic nanoindentation were investigated. Subsequently, a thorough microstructure observation was carried out in areas with maximum tensile and compressive stresses to determine changes in the morphology and size of dendrites related to the effect of tensile or compressive stresses induced by bending. It was found that the grain featured a stretched secondary dendrite axis in the area of tensile stress, but compressive stress imparted a prolongation of the primary dendrite axis.

Evaluation of the Microstructure and Mechanical Properties of the Butt-Welded Joints of Spiral Pipes Made of L485ME (X70) Steel

The expansion of the gas pipeline network makes it necessary, on the one hand, to meet the requirements of standards regarding the materials used, but on the other hand, it is necessary to weld them. In the case of natural gas as a fuel, the welding process is widely used, but in the case of replacing natural gas with a mixture of this gas and hydrogen, the requirements regarding the quality of the process must be significantly increased or the process must be completely changed. This article presents the results of testing welded joints for a newly developed welding technology for the transmission of a hydrogen mixture. Material tests were carried out on a butt-circumferential-welded joint made between two spiral pipes with an outer diameter of 711 mm and wall thickness of 11 mm in the X70 grade. The developed welding technology is distinguished by a change in the beveling method of the edges, which allows the heat input to the material to be limited. The technology was developed for use in natural on-shore and off-shore gas pipelines with the addition of hydrogen. As a result, additional requirements in terms of joint plasticity had to be met during welding. The test results obtained indicate that the joints are characterized by high strength (more than 581 MPa), higher than that of the base material (fracture in the base material) and good impact strength at reduced temperature (more than 129 J). In transverse corrosion, a hardness below 250 HV and a favorable structure of ferrite with different morphologies were obtained.

Microstructure, Mechanical Properties and Fatigue Crack Growth Behavior of Gas Tungsten Arc Welding Welded Joint of the Hastelloy N Alloy

Hastelloy N alloy is an excellent oxidation and corrosion-resistant material, which is selected as the shell material for the main vessel of molten salt reactors (MSRs). In this work, we conducted double-sided gas tungsten arc welding (GTAW) on 4 mm thick Hastelloy N alloy plates to examine the microstructure and mechanical properties of the welded joints. The S-N curve was obtained by fatigue test. The experimental results show that fatigue cracks initiate along the weld toe and propagate inward in a fan-shaped pattern. The hardness is highest in the heat-affected zone (HAZ). The fracture mode observed was trans-granular. The plastic zone in the initial stages of crack propagation remained relatively minimal. However, it gradually expanded during subsequent stages of the process. It is noteworthy that the crack propagation process often involves the development of secondary cracks, accompanied by profound plasticity-induced closure effects. The results of our investigation demonstrate that the welded joint exhibits excellent fatigue performance.

Influence of Additives on the Mechanical Characteristics of Hardox 450 Steel Welds

The aim is to overcome the issues of high-hardness material welding by different additives used to achieve the desired improvements. The research is focused on Hardox 450 steel welding and factors to be considered in order to maintain the required mechanical properties of the weld. The selection of best suited welding materials or additives, including filler metals and shielding gases, are within the important factors to be taken into account. During the welding of Hardox 450 steel, cobalt, nickel, tungsten and titanium additives and cobalt and tungsten mixture additives were used and their influence on the microstructure and mechanical properties of the fusion and heat-affected zones was investigated. The microstructure of the weld zone is related to certain mechanical properties of the weld and heat-affected zone, such as hardness, tensile and bending strength, yield strength, strain at ultimate tensile strength, the Young's modulus and elongation. Research has shown significant differences in the mentioned parameters depending on specific additives used in the welds. It can be concluded that tungsten, used as an additive, increased the hardness of the heat-affected and fusion zones up to 478 HV; the combined presence of cobalt and tungsten additives improves the strength of the seam up to 744 MPa during tensile; and in the case of bending, nickel, when used as an additive, increased ductility (the bending modulus reached the limit of 94 GPa) and at the same time, decreased the risk of cracking. The obtained results highlight the possibilities for strengthening the welded joint of Hardox 450 steel using different additives or their mixtures. The research conclusions and recommendations aim at improving the quality and mechanical properties of welded Hardox 450 steel joints in various applications.

Effect of Supercritical Bending on the Mechanical & Tribological Properties of Inconel 625 Welded Using the Cold Metal Transfer Method on a 16Mo3 Steel Pipe

The presented work deals with the investigation of mechanical tribological properties on Inconel 625 superalloy, which is welded on a 16Mo3 steel pipe. The wall thickness of the basic steel pipe was 7 mm, while the average thickness of the welded layer was 3.5 mm. The coating was made by the cold metal transfer (CMT) method. A supercritical bending of 180° was performed on the material welded in this way while cold. The mechanical properties evaluated were hardness, wear resistance, coefficient of friction (COF) and change in surface roughness for both materials. The UMT Tribolab laboratory equipment was used to measure COF and wear resistance by the Ball-on-flat method, which used a G40 steel pressure ball. The entire process took place at an elevated temperature of 500 °C. The measured results show that the materials after bending are reinforced by plastic deformation, which leads to an increase in hardness and also resistance to wear. Superalloy Inconel 625 shows approximately seven times higher rate of wear compared to steel 16Mo3 due to the creation of local oxidation areas that support the formation of abrasive wear and do not create a solid lubricant, as in the case of steel 16Mo3. Strain hardening leads to a reduction of possible wear on Inconel 625 superalloy as well as on 16Mo3 steel. In the case of the friction process, the places of supercritical bending of the structure showed the greatest resistance to wear compared to the non-deformed structure.

A Review of Numerical Simulation of Laser-Arc Hybrid Welding

Laser-arc hybrid welding (LAHW) is known to achieve more stable processes, better mechanical properties, and greater adaptability through the synergy of a laser and an arc. Numerical simulations play a crucial role in deepening our understanding of this interaction mechanism. In this paper, we review the current work on numerical simulations of LAHW, including heat source selection laws, temperature field, flow field, and stress field results. We also discuss the influence of laser-arc interaction on weld defects and mechanical properties and provide suggestions for the development of numerical simulations of LAHW.

Manganese Neurotoxicity as a Stroke Mimic: A Case Report

Manganese (Mn)-induced cerebral toxicity is a rare neurological condition that can present as a stroke mimic in high-risk populations. We present a case of a 40-year-old male with no known comorbidities who was brought to the emergency department with complaints of nonprogressive slurred speech and left facial weakness for eight days. Further history revealed that he had been working as a welder in a steel factory for the past seven years without using proper personal protective equipment (PPE). On physical examination, an upper motor neuron (UMN) type weakness on the left side of his face and spastic dysarthria could be appreciated. Following a brain computed tomography (CT) scan that showed ill-defined hypodensities in the basal ganglia without any signs of a hemorrhage, he was admitted to the stroke unit for conservative management and further investigations. A magnetic resonance imaging (MRI) scan of the brain done later showed features of manganese deposition and absorption in the globus pallidus and corticospinal tracts, indicating a diagnosis of manganese-induced cerebral toxicity. His serum manganese levels obtained during admission were normal. He was managed conservatively with intravenous rehydration and was discharged after symptomatic improvement. He was counseled and educated regarding the importance of wearing protective equipment while at work to reduce further exposure to the metal. During his follow-up visit, his symptoms had considerably improved with proper adherence to workplace safety measures.

The Cracking of Al-Mg Alloys Welded by MIG and FSW under Slow Strain Rating

Al-Mg alloys used in the shipbuilding industry were tested. The most commonly used alloy AW 5083 and alloy AW 5059 with higher strength properties were selected. Both native materials and their joints welded by the traditional MIG arc welding method and the friction stir welding (FSW) method were tested. Both methods are approved by classification societies which allow them to be used in construction by the shipbuilding industry. The research was carried out in two stages. The first study was an "in-situ tensile test in SEM". The surfaces of the deformed specimens' changes were observed in the vacuum chamber of a Philips XL30 scanning electron microscope. During the tests, the force and elongation of the specimen were recorded. In addition, a chemical analysis of selected precipitates was performed by energy dispersive spectrometry (EDS) using the EDAX adapter. Slip lines were observed on the surface of the tested specimens, which are arranged in bands in the native material and in a disordered manner in the joints welded by MIG and FSW methods. Cracking starts mainly through decohesion at the matrix-precipitate interfaces. In the second stage of the research, slow strain rate testing (SSRT) was carried out in accordance with ISO 7539-7:2005. The tests were carried out on a specially designed test stand, where the FT-5307 strain gauge force sensor with a measuring range of 0-16 kN was used to measure the force value. The PSz 20 transducer with a measuring range of 0-20 mm was also used. The test consisted of subjecting the specimen to increasing deformation with the strain rate έ = 1.6 × 10^-6 s^-1 until destruction. The fracture surfaces of the SSRT specimens were subjected to fractographic analysis using a Philips XL-30 scanning electron microscope. The results of fractographic studies after the SSRT test of the native materials and their joints welded by the MIG and FSW methods indicate that the trans-crystalline cracking mechanism is dominant, characterized by ductile fracture, and cracks are initiated at the interfaces of the precipitates with the matrix. The research results show that the plastic deformation increases and micro-cracks develop and merge into a main crack, which, after reaching the critical dimension, rapidly develops, causing the destruction of the material. The fracture micrographs of the specimens of base metals and their joints welded by FSW and MIG after the SSRT test allow us to conclude that the cracking mechanism was trans-crystalline ductile.

Structure and Mechanical Properties of the NiTi Wire Joined by Laser Welding

Joining wires made of NiTi alloys with shape memory effect and pseudoelasticity causes many technical and structural problems. They result from unwanted phase interactions that occur in high temperatures and negatively affect the characteristics of these materials. Such obstacles are challenging in terms of welding. Hence, an attempt was made to join NiTi wires via an economical and reliable basic laser welding technique which does not require complicated equipment and gas protection. The parameters such as spot diameter and pulse time were constant and only the laser power, calculated as a percentage of the total power, was optimized. The wires were parallelly connected with overlapping seam welds 10 mm long. The welds were examined regarding their microstructure, chemical and phase composition, reversible martensitic transformation, microhardness, and pseudoelasticity. The obtained results showed that the joint was completed at the 12-14% power. The weld revealed good quality with no voids or pores. As the laser power increased, the microhardness rose from 282 (for 4%) to 321 (for 14%). The joint withstood the stress-inducing reversible martensitic transformation. As the transformation was repeated cyclically, the stress value decreased from 587 MPa (initial wire) to 507 MPa (for the 14% power welded wire).

Microstructure and Mechanical Properties of Solid-State Rotary Friction Welded Inconel 713C and 32CrMo4 Steel Joints Used in a Turbocharger Rotor

The aim of this work was to determine the effect of selected parameters of friction welding, such as friction pressure and welding speed, on the mechanical properties and microstructure of friction-welded Inconel 713C-32CrMo4 joints. Tensile strength and hardness tests were carried out to determine the mechanical properties of the resulting welded joints. The results of the ultimate tensile strength, hardness, and microstructure were linked to the parameters of the welding process. It was found that the highest tensile strength was 1222 N/mm². There was a significant increase in the hardness value in the thermo-mechanically affected zone for all samples. However, as the friction pressure increased, the zone with the higher hardness value migrated towards the 32CrMo4 material. In all weld tests, the fracture was found on the 32CrMo4 steel side. A distinct band of carbide formation was observed between the thermo-mechanically affected zone and the Inconel 713C base material.

Experimental and Numerical Analysis of the Residual Stresses in Seamed Pipe in Dependence on Welding and Metal Forming

Concerning the increasingly widespread utilization of the finite element method (FEM), the concept of the so-called virtual factory is also gaining ground, and not only in the engineering industry. This approach does not use numerical simulations of individual production technologies separately but treats the entire production process as a chain of interrelated technologies. Thus, the output data from one technology is taken as input data for the following technology. The resulting thermal and mechanical effects are then not only dealt with within one technology but always comprehensively within the production process. In the consideration of the loading and subsequent service lives of manufactured components, values of residual stresses are one of the very important characteristics. For these reasons, this paper deals with the effect of residual stresses' magnitude and distribution during the formation and the final springback of the seamed pipe end section with and without respect to the influence of the preceding welding. The resulting residual stress values from numerical simulations are subsequently compared with the actual values of residual stresses experimentally measured using X-ray diffraction.

Experimental Studies of Welded Joints in Structures Subject to High Impact Vibrations Using Destructive and Non-Destructive Methods

This article presents the issues of control and quality assurance of high-strength railway rail joints. Selected test results and requirements for rail joints made by welding with stationary welders on the basis of the requirements included in the PN-EN standards have been described. In addition, destructive and non-destructive tests of weld quality were performed, including visual tests, geometrical measurements of irregularities, magnetic particle and penetration tests, fracture tests, observations of micro- and macro-structure and hardness measurements. The scope of these studies included conducting tests, monitoring the process and evaluating the results obtained. Laboratory tests on the rail joints confirmed the good quality of the rail joints from the welding shop. Increasingly less damage to the track in places of new welded joints is proof that the methodology of laboratory qualification tests is correct and fulfils its task. The presented research will help educate engineers on the welding mechanism and the importance of quality control of rail joints during their design. The results of this study are of key importance for public safety and will improve knowledge on the correct implementation of the rail joint and how to conduct quality control tests in accordance with the requirements of the currently applicable standards. It will help engineers choose the right welding technique and choose solutions to minimize cracks.

3D Scanner-Based Identification of Welding Defects-Clustering the Results of Point Cloud Alignment

This paper describes a framework for detecting welding errors using 3D scanner data. The proposed approach employs density-based clustering to compare point clouds and identify deviations. The discovered clusters are then classified according to standard welding fault classes. Six welding deviations defined in the ISO 5817:2014 standard were evaluated. All defects were represented through CAD models, and the method was able to detect five of these deviations. The results demonstrate that the errors can be effectively identified and grouped according to the location of the different points in the error clusters. However, the method cannot separate crack-related defects as a distinct cluster.

Dynamic Range Compression of Thermograms for Assessment of Welded Joint Face Quality

Temperature is one of the essential parameters in fusion welding. Typically, an uncooled infrared detector acquires 14-bit data, while a human observer can only distinguish about 128 levels of grey. For IR HDR (high dynamic range) images, one of the main goals of dynamic range compression is to enhance the visibility of low-contrast details. It is an important issue because the temperature span in the cross-section of a welded joint and its length are large. In the paper, global approaches for range compression are investigated, such as algorithms that include pixel transformations, histogram equalization ('he') and some of its variants. Additionally, multiscale decomposition methods were investigated. All results are obtained for the sequences of thermograms acquired during the TIG welding of plates made of Inconel 625 superalloy. The process was observed with an uncooled IR camera. The application of compression methods led to the generation of low-dynamic-range (LDR) IR images. The algorithms allowed the preservation of global contrast and enhancement of the visibility of hot details in dark and low-contrast areas. All IR representations of the welded samples were evaluated, and relationships between apparent temperature counted in the pixel-level value and weld-face geometry were revealed. Methods based on wavelet transforms were found to be the most suitable for this type of image; nevertheless, a relatively large local noise was generated.

Effect of Post-Weld Heat Treatment on Microstructure and Hardness of Laser Beam Welded 17-4 PH Stainless Steel

This article presents the results of research on the development of the technology of laser beam butt welding of 17-4 PH stainless steel sheets and the technology of post-weld heat treatment (PWHT). The developed technology allows for favorable conditions to be obtained and for the appropriate microstructure and hardness to exist in the weld area. Moreover, it enables the fulfillment of a number of specific requirements beyond the possibilities of manual welding and other methods. The tests performed include the analysis of the microstructure with the use of light microscopy (LM) for the materials after welding and PWHT. The applied PWHT showed changes in the microstructure and mechanical properties. In all weld areas the martensitic microstructure was observed. The homogeneity of the microstructure in the area of the welded joint after PWTH was revealed. In the as-welded condition and after the PWHT with aging at 481 °C, the hardness was 440 HV5, but after aging at 621 °C, it decreased to 330-340 HV5.

Characterization of Microstructural Evolution in Heat-Affected Zone of Cu-Bearing Ultra-High-Strength Steel with Lamellar Microstructure

The advanced lamellar microstructure significantly improves the toughness of Cu-bearing ultra-high strength steel by delamination toughening (yield strength: 1370 MPa, impact toughness at -40 °C: 60 J). The lamellar microstructure affects the microstructure evolution of heat-affected zone (HAZ), resulting in separate distributions of lath martensite and granular bainite in the complete austenitizing zone and the formation of cluster fresh martensite in the partial austenitizing zone. The grain refinement and decrease in dislocation density are predominant features, especially for the complete austenitizing zone, where the grain is refined to 4.33 μm, and dislocation density is decreased by 27%. With the degree of austenitizing increase, the dissolution of Cu-rich precipitates (CRPs) aggravates during welding. A small fraction of CRPs in the complete austenitizing zone implies the onset of reprecipitation of CRPs. The reason for softening in HAZ is attributed to a combined effect of granular bainite forming, dislocation density decreasing, and CRPs dissolving. After PWTH, large numbered reprecipitation of coherent CRPs occurs, contributing to the hardness recovery of HAZ. Meanwhile, due to the high density of dislocation of lamellar microstructure inherited by partial austenitizing zone, coarsening of coherent CRPs is easy to occur, and various incoherent structures are observed.

Residual Stress Measurement Techniques for Metal Joints, Metallic Coatings and Components in the Railway Industry: A Review

Manufacturing and maintenance procedures in the railway industry regularly implement welding and metal deposition operations to produce joints, coatings and repair structures. During these processes, residual stresses arise through the generation of heat affected zones and plastic deformation. This makes accurate measurements of the internal stresses a critical aspect of manufacturing, monitoring, repair and model validation in the develop new metallic coating and joining technologies. Selection of an appropriate residual stress measurement method has many important factors including component size, resolution and the magnitude and location of internal stresses, often resulting in a combination of techniques required to obtain complete assessment of the stress state. This paper offers a review of residual stress measurement techniques for railway components including rail joints and coatings through comparison of destructive and non-destructive approaches, their measurement capabilities, benefits and limitations. A comprehensive discussion of different applications is provided with a summary of facilities available to both research and industry.

Numerical Simulations Based on a Meshfree Method for Nickel-Steel Welded Joint Manufactured by Micro-Jet Cooling

The article presents a numerical-experimental approach to the weldability and mechanical resistance of the joint of Alloy 59 (2.4605, nickel-chromium-molybdenum) and S355J2W (1.8965) structural steel manufactured by the MIG process with the use of micro-jet cooling. This research was considered because the standard MIG process does not guarantee the procurement of a mixed hard-rusting structural steel superalloy weld of a repeatable and acceptable quality. Welds made through the classic MIG process express cracks that result from their unfavorable metallographic microstructure, while the joint supported by micro-jet cooling does not reflect any cracks and has a high strength with good flexibility. This was achieved by the application of helium for cooling. The joining technology was also considered in the numerical stage, represented by calculations in situ. For this purpose, the fundamental solution method (FSM) for the simulation of heat transfer during the process of welding with micro-jet cooling was implemented according to the initial boundary value problem (IBVP). The problem was solved employing the method of combining the finite difference method, Picard iterations, approximation by the radial basis function, and the fundamental solution method so as to solve the IVBP. The proposed method was validated by the data and results obtained during in situ experiments. The numerical approach enabled us to obtain variations in the temperature distribution values in HAZ with its different dimensional variants, ranging between 600 °C and 1400 °C.

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

Joining immiscible materials such as copper and stainless steel together is a significant concern due to distinct mechanical and metallurgical properties across the joint line, such as melting points, the coefficient of linear thermal expansion, and thermal conductivity. The joint properties of copper to stainless steel welds are in great demand for various mechanical components of the international thermonuclear experimental reactor, ultra-high vacuum system, plan wave linear-accelerator or linac structure, and heat exchanger. These dissimilar-metals joints offer excellent flexibility in design and production, leading to a robust structure for many cutting-edge applications. Hence, the present article reviews the copper to stainless steel joining mechanism under different solid-state processing conditions. The present understanding says that defect-free strong joints between the dissimilar metals are systematically possible. Apart from this understanding, the authors have identified and highlighted the gaps in the research exploration to date. Moreover, a sustainable methodology to achieve a desirable weld of copper to stainless steel depends on favorable processing conditions.

Welder's Anthrax: A Tale of 2 Cases

Bacillus anthracis has traditionally been considered the etiologic agent of anthrax. However, anthrax-like illness has been documented in welders and other metal workers infected with Bacillus cereus group spp. harboring pXO1 virulence genes that produce anthrax toxins. We present 2 recent cases of severe pneumonia in welders with B. cereus group infections and discuss potential risk factors for infection and treatment options, including antitoxin.

Hardox 450 Weld in Microstructural and Mechanical Approaches after Welding at Micro-Jet Cooling

The demand for high-strength steel welds, as observed in civil and transport engineering, is related to a mass reduction in vehicles. Container-type trucks are examples of this kind of transport means because their boxes are able to be produced using Hardox grade steels. Therefore, this study reflects on the properties of welds in the MAG welding of Hardox 450, obtained through an innovative micro-jet cooling process with helium. This joining technology aims to reduce the formation of defects and to obtain a joint with very good assumed mechanical properties. Structural components of grade steel require welds with acceptable mechanical parameters with respect to operational loading conditions. That is, this study focuses on selecting welding parameters for the Hardox 450 steel and determining the weld quality with respect to microstructural observations and mechanical tests, such as the Charpy, tensile and fatigue tests. Weld fracturing under increasing monotonic force was examined and was strongly related to both stress components, i.e., axial and shear. The joint response under fatigue was expressed through differences in the fracture zones, i.e., at a stress value lower than the proportional limit, and weld degradation occurred in the shear and axial stress components. The data indicate that the hourglass specimen, with the weld in the centre zone of the measurement section, can be directly used to determine a weld response under cyclic loading. The impact test results showed attractive behaviour in the tested joint, as represented by 47 J at -20 °C. The recommended MAG welding parameters for Hardox 450 steel are low-oxygen when using an Ar + 18% CO₂ shielding mixture. The collected results can be directly used as a guide to weld thin-walled structures (6 mm) made of Hardox grade steel, while the data from mechanical tests can support the modelling, designing and manufacturing of components made from this kind of steel grade.

Effect of Metal-Cored Filler Wire on Surface Morphology and Micro-Hardness of Regulated Metal Deposition Welded ASTM A387-Gr.11-Cl.2 Steel Plates

Environmental and human-friendly welding is the need of the hour. In this context, this study explores the application of the regulated metal deposition (RMD) technique for ASTM A387-Gr.11-Cl.2 steel plates. To examine the effect of metal-cored filler wire (MCFW), MEGAFIL 237 M was employed during regulated metal deposition (RMD) welding of 6 mm thick ASTM A387-Gr.11-Cl.2 steel plates. The welding was carried out at an optimized current (A) of 100 A, voltage (V) of 13 V, and gas flow rate (GFR) of 21 L/min. Thereafter, the as-welded plates were examined for morphological changes using optical microscopy. Additionally, the micro-hardness of the as-welded plates was measured to make corroboration with the obtained surface morphologies. In addition to this, the as-welded plates were subjected to heat treatment followed by surface morphology and micro-hardness examination. A comparison was made between the as-welded and heat-treated plates for their obtained surface morphologies and microhardness values. During this, it was observed that the weld zone of as-welded plates has a dendritic surface morphology which is very common in fusion-based welding. Similarly, the weld zone of heat-treated plates has a finer and erratic arrangement of martensite. Moreover, the obtained surface morphologies in the weld zone of as-welded and heat-treated plates have been justified by their respective hardness values of 1588.6 HV and 227.3 HV.

Analysis of the Influence of GMAW Process Parameters on the Properties and Microstructure of S32001 Steel

The properties of duplex steels can be seriously affected when welding processes are performed on them. Duplex S32001 is a recent development, so there is very little published information on its behavior after a welding process. For this reason, the present article determines how the main welding parameters of the GMAW process influence its mechanical and microstructural properties. From this study, it was determined that the parameter W/m³ best defines the phase balance in the bead due to the values involved. In the HAZ, this parameter is the t_12/8. The welding parameters that are used determine the bead dimensions and geometry. These dimensions induce differences in the distribution of heat in the material. For this reason, the thermal cycles undergone by the material vary and, consequently, in the phase balance obtained. A theoretical study of the chemical composition in the bead, through dilution, and in the HAZ, through diffusion, was carried out. A mathematical model was developed that allows the variation of the composition in the HAZ that induces diffusion to be determined.

Effect of B on Microstructure and Properties of Surfacing Layer of Austenitic Stainless Steel Flux Cored Wire

In order to study the effect of element B on the corrosion resistance of stainless steel-based flux cored wire surfacing alloy, a stainless steel surfacing layer was prepared on the surface of carbon steel plate by melt electrode gas shielded welding, and then the microstructure, electrochemical corrosion resistance, and wear resistance of the surfacing layer were analyzed. The results show that the surfacing layer of surfacing alloy presents M₂B and Fe₃(C, B) phases based on austenite. Boride formed in deposited metal has good corrosion resistance. Therefore, adding the proper amount of B can significantly improve the corrosion resistance of the surfacing layer. When the boron content is 2%, the corrosion resistance is the best. The minimum self-corrosion current density is 1.75766 × 10^-11 mA·cm², and the maximum self-corrosion potential is -0.254438 V. Maximum impedance curve radius. At this time, the wear resistance of the surfacing layer is also the best.

Performance Enhancement of Silver Nanowire-Based Transparent Electrodes by Ultraviolet Irradiation

Silver nanowires (AgNWs) are used as transparent electrodes (TE) in many devices. However, the contact mode between the nanowires is the biggest reason why the sheet resistance of silver nanowires is limited. Here, simple and effective ultraviolet (UV) irradiation welding is chosen to solve this problem. The influence of the power density of the UV irradiation on welding of the silver nanowires is studied and the fixed irradiation time is chosen as one minute. The range of the UV (380 nm) irradiation power is chosen from 30 mW/cm² to 150 mW/cm². First of all, the transmittance of the silver nanowire film is not found to be affected by the UV welding (400-11,000 nm). The sheet resistance of the silver nanowires decreases to 73.9% at 60 mW/cm² and increases to 127.6% at 120 mW/cm². The investigations on the UV irradiation time reveal that the sheet resistance of the AgNWs decreases continuously when the UV irradiation time is varied from 0 to 3 min, and drops to 57.3% of the initial value at 3 min. From 3-6 min of the continuous irradiation time, the change of the sheet resistance is not obvious, which reflects the self-limiting and self-termination of AgNWs welding. By changing the wavelength of the UV irradiation from 350-400 nm, it is found that the welding effect is best when the UV wavelength is 380 nm. The average transmittance, square resistance, and the figure of merit of the welded AgNWs at 400-780 nm are 95.98%, 56.5 Ω/sq, and 117.42 × 10^-4 Ω^-1, respectively. The UV-welded AgNWs are also used in silicon-based photodetectors, and the quantum efficiency of the device is improved obviously.

Hybrid Carbon Nanotubes-Graphene Nanostructures: Modeling, Formation, Characterization

A technology for the formation and bonding with a substrate of hybrid carbon nanostructures from single-walled carbon nanotubes (SWCNT) and reduced graphene oxide (rGO) by laser radiation is proposed. Molecular dynamics modeling by the real-time time-dependent density functional tight-binding (TD-DFTB) method made it possible to reveal the mechanism of field emission centers formation in carbon nanostructures layers. Laser radiation stimulates the formation of graphene-nanotube covalent contacts and also induces a dipole moment of hybrid nanostructures, which ensures their orientation along the force lines of the radiation field. The main mechanical and emission characteristics of the formed hybrid nanostructures were determined. By Raman spectroscopy, the effect of laser radiation energy on the defectiveness of all types of layers formed from nanostructures was determined. Laser exposure increased the hardness of all samples more than twice. Maximum hardness was obtained for hybrid nanostructure with a buffer layer (bl) of rGO and the main layer of SWCNT-rGO(bl)-SWCNT and was 54.4 GPa. In addition, the adhesion of rGO to the substrate and electron transport between the substrate and rGO(bl)-SWCNT increased. The rGO(bl)-SWCNT cathode with an area of ~1 mm² showed a field emission current density of 562 mA/cm² and stability for 9 h at a current of 1 mA. The developed technology for the formation of hybrid nanostructures can be used both to create high-performance and stable field emission cathodes and in other applications where nanomaterials coating with good adhesion, strength, and electrical conductivity is required.

Pneumococcal pneumonia on the job: Uncovering the past story of occupational exposure to metal fumes and dust

The objectives of this study are to elucidate the early history of risk for pneumococcal pneumonia from occupational exposure to metal fumes and dusts, and to demonstrate the importance of searching older literature when performing reviews. We performed manual searching for articles in the Library of the Surgeon General's Office (the precursor to Index Medicus), in the Hathi Trust database, in PubMed, andby screening reference lists in literature appearing before the introduction of PubMed. An early body of literature, from the 1890s onward, recognized that pneumonia was linked to "Thomas slag," a steel industry byproduct containing iron, manganese, and lime. Researchers, mainly in Germany, showed that workers in metal-dust-exposed occupations, especially using manganese, manifested an increased incidence of pneumococcal pneumonia. An outbreak of pneumococcal pneumonia in the 1930s implicated manganese fume in its etiology. In the immediate post-World War II period, there was a brief flurry of interest in pneumonia from exposure to potassium permanganate that was soon dismissed as a chemical pneumonitis. After a hiatus of two decades, epidemiologic investigations drew attention to the pneumonia risks of welding and related metal fume exposure, bringing renewed interest to the forgotten role of pneumococcal pneumonia as an occupational disease. Occupational or environmental inhalation of manganese, iron, or irritants may be causally related to increased pneumococcal pneumonia risk. In particular, the risk associated with manganese seems to be overlooked in recent literature. An important conclusion is the importance of obtaining additional evidence through a deeper assessment of the literature in a broad historical context.

Investigating the field effectiveness of respirators against metal particle exposure in various workplaces: a systematic review

Welders are exposed to high levels of metal fumes, which could be resulting in various health impairments. Respirators became a practical protective option in workplaces, as they are lightweight and easy to use. This systematic review attempts to explore the field effectiveness of using respirators to reduce metal particle exposure in workplaces. We reviewed papers published from 1900 to April 2019 in five major bibliographic databases, including Embase, Web of Science, Medline, Scopus, and CINAHL, along with organizational websites to cover gray literature. In total, 983 references were identified from the databases, out of which, 520 duplicates were removed from the EndNote database. The remaining 463 references were screened for their title and abstract. Out of 463, 70 references went through the full-text screening. Finally, eight papers, including 19 workplace respirator studies, satisfied all the inclusion criteria and were reviewed in this report. The geometric means for metal levels in workers' breathing zone with and without respirators were 9.4 and 1,777 µg/m³ for iron, 1.1 and 139 µg/m³ for lead, 2.1 and 242 µg/m³ for zinc, and 27 and 1,398 µg/m³ for manganese oxide, respectively. Most reviewed studies reported significant differences between measured metal particle levels among workers who worn respirators and who did not. In addition, results showed that N95 provided significantly less protection than elastomeric half facepieces, full-face respirators, and powered air-purifying respirators (p<0.001). More field studies are recommended to investigate Workplace Protection Factor (WPF) and fit factor (FF) of different respirators to understand the actual protection levels that they could be provided to control welding fume exposure among welders in various workplaces.

Casting Welding from Magnesium Alloy Using Filler Materials That Contain Scandium

Based on the results achieved in systematic studies of structure formation and the formation of multicomponent phases, a scandium-containing filler metal from system alloy Mg-Zr-Nd for welding of aircraft casting was developed. The influence of scandium in magnesium filler alloy on its mechanical and special properties, such as long-term strength at elevated temperatures, was studied by the authors. It is established that modification of the magnesium alloy with scandium in an amount between 0.05 and 0.07% allows a fine-grained structure to be obtained, which increases its plasticity up to 70% and heat resistance up to 1.8 times due to the formation of complex intermetallic phases and the microalloying of the solid solution. Welding of the aircraft castings made of magnesium alloy with scandium-containing filler material allows obtaining a weld with a dense homogeneous fusion zone and the surrounding area without any defects. The developed filler material for welding surface defects (cracks, chips, etc.) formed during operation on aircraft engine bodies makes it possible to restore cast body parts and reuse them. The proposed filler material composition with an improved set of properties for the welding of body castings from Mg-Zr-Nd system alloy for aircraft engines makes it possible to increase their reliability and durability in general, extend the service life of aircraft engines, and obtain a significant economic effect.

Effect of Laser Peening on Microstructural Changes in GTA-Welded 304L Stainless Steel

The introduction of tensile residual stress has led to the induction of damage such as fatigue, corrosion fatigue, and stress corrosion cracking (SCC) in stainless steel in association with the influence of environments, components, surface defects, and corrosive factors during its use. Compressive residual stress can be achieved through various techniques. Among several methods, laser peening can be more attractive as it creates regularity on the surface with a high-quality surface finish. However, there is very little research on heavily peened surface and cross-section of stainless steel with very deep compressive residual stress. This work focused on welding and laser peening and the influence of Al coating on the microstructural changes in 304L stainless steel. The specimen obtained by laser peening had a very deep compressive residual stress of over 1 mm and was evaluated based on microstructural and hardness analysis. Therefore, a model for microstructural change by laser peening on welded 304L stainless steel was proposed.

Pregnancy Outcome in Women Exposed to Metal Fume in Welding: A Canadian Cohort Study

OBJECTIVES

Welding is a physically demanding job that entails exposure to metal fume and particles. There is little information on the effect of welding exposures on the outcome of a pregnancy conceived during a period when a woman was employed as a welder.

METHODS

Women welders recruited to the Workers Health in Apprenticeship Trades-Metal and Electrical (WHAT-ME) study were followed-up every 6 months for up to 5 years (January 2011-August 2018), and every pregnancy recorded. At the first 6-month follow-up, a detailed questionnaire was completed for the most recent day in welding, and this information was collected again at each follow-up and also from questionnaires completed during pregnancy. The date of conception was estimated for each pregnancy and the job at that date identified. Exposures to ergonomic factors, work schedule and perceptions of noise, heat and cold were extracted for the job at conception. Exposures to metals (aluminum, chromium, manganese, and nickel) and particles in welding fume were estimated from previously validated exposure algorithms reflecting the welding process, base metal and consumables of the job at the conception date. The effects of exposures were estimated in multilevel multivariable models allowing for confounding.

RESULTS

There were 242 pregnancies conceived by a welder working in her trade, 87 were before the first follow-up, 3 were after first follow-up but detailed information was not collected, 22 of those potentially included in the assessment group were in-trade but not welding leaving 122 pregnancies in 90 welders for analysis. Of these 91 resulted in a live birth and 31 in a fetal loss (27 miscarriages and 4 stillbirths). Mean birth weight for live births was 3365 g and gestation 39.4 weeks. Final models showed that risk of fetal loss increased with manipulating heavy objects [odds ratio (OR) = 5.13, 95% confidence interval (CI) 2.04-12.92], whole-body vibration (OR = 5.86, 95% CI 1.81-18.92), a higher rating for noise exposure intensity (OR = 1.52, 95% CI 1.24-1.85), and decreased with use of local exhaust ventilation (OR = 0.20, 95% CI 0.03-1.18). Gestation decreased with perceived heat intensity (β = -0.15, 95% CI -0.29 to -0.02) and number of previous pregnancies (β = -0.35, 95% CI -0.65 to -0.05). Birth weight was lower in those reporting whole-body vibration (β = -596 g, 95% CI -924 to -267) and increased with the welder's body mass index (β = 36 g, 95% CI 12-61). Estimates of exposure to metals and particles were unrelated to gestation or birth weight. In a bivariate analysis, allowing for the same welder reporting >1 pregnancy, estimated airborne aluminum exposure (and to a lesser degree exposure to nickel and particles) was related to greater risk of fetal loss (OR = 1.52, 95% CI 1.04-2.24) but neither aluminum nor the other estimated elements of welding fume added to the final model.

CONCLUSIONS

In this group of women actively engaged in welding during the time surrounding conception, the outcome of pregnancy was strongly related to work exposures, particularly vibration (reported in grinding tasks), manipulation of heavy objects, and perceived intensity of noise and heat. The study was unable to show an independent effect of exposure to metal fume constituents.

Urinary Metals as a Marker of Exposure in Men and Women in the Welding and Electrical Trades: A Canadian Cohort Study

OBJECTIVES

Men and women working in the welding trades undergo the same apprenticeship training but it is unknown whether, once in the trade, their exposures differ. Comparison of urinary metal concentrations, having adjusted for estimated airborne exposure, may provide an answer.

METHODS

Men and women were recruited to a cohort study of workers in the welding and electrical trades (the Workers Health in Apprenticeship Trades-Metal working and Electrical [WHAT-ME study]). They completed a recruitment questionnaire and further questionnaires every 6 months for up to 5 years. At each follow-up, they gave details on employment and, if welding, answered trade-specific questionnaires. Urine samples were collected by mail. Welding exposure matrices were developed to estimate metal exposures from welding process, base metal, and consumables. Urinary metal concentrations, determined by ICP-MS, were compared by trade (welding or electrical). Within welding, the relation of urinary concentrations to estimated airborne exposure was examined, with adjustment for potential confounders including sex, use of respiratory protective equipment (RPE), and time spent outdoors. Natural logarithms were taken of exposure estimates and urinary concentrations, to reduce skew. All regression analyses included creatinine concentration.

RESULTS

Urinary metal concentrations were analysed for 12 metals in 794 samples. Antimony, arsenic, lead, and mercury had a high proportion of samples with no metal detected and were not considered further. The urinary concentrations of aluminum, cadmium, chromium, cobalt, copper, manganese, nickel, and zinc were compared for welders (434 samples) and electrical workers (360). After adjustment for potential confounders, welders had higher urinary concentrations for aluminum (β = 0.13 95%CI 0.03-0.24) and chromium (β = 0.66 95%CI 0.55-0.77). Of 434 welder urines, 334 could be matched securely to detailed information about the most recent day welding. For these, an estimate of airborne exposure was made for aluminum, chromium, manganese, and nickel. Male welders were estimated to have higher airborne exposure to chromium and nickel than women welders. No difference was seen in the estimated exposures for aluminum or manganese (or total dust). Regression analyses of the relation of urinary metals to estimated exposure showed a good concordance for aluminum (β = 0.09 95%CI 0.04-0.15 (P < 0.001) and chromium (β = 0.11 95%CI 0.05-0.17 P < 0.001). The concordance for manganese and nickel was positive, but much weaker. Urinary concentrations of aluminum and nickel were somewhat lower with increasing time wearing RPE and, for chromium and nickel, with time working outdoors. Having adjusted for estimated exposure, creatinine and other confounders, male welders had lower urine concentrations of aluminum (β = -0.35 95%CI -0.51 to -0.19 P < 0.001) chromium (β = -0.38 95%CI -0.57 to -0.19 P < 0.001) and manganese (β = -0.36 95%CI -0.49 to -0.23 P < 0.001) than female welders.

CONCLUSION

Welders had higher urinary concentrations of aluminum and chromium than electrical workers. Exposure estimates of aluminum and chromium for welders were a valid representation of the airborne exposures to these metals. Although male welders were estimated to have higher exposures of chrome and nickel than female welders, the higher urinary metal concentrations in women welders is of concern, particularly for women who may conceive while in the trade.

Lung toxicity profile of inhaled copper-nickel welding fume in A/J mice

Objective: Stainless steel welding creates fumes rich in carcinogenic metals such as chromium (Cr). Welding consumables devoid of Cr are being produced in an attempt to limit worker exposures to toxic and carcinogenic metals. The study objective was to characterize a copper-nickel (Cu-Ni) fume generated using gas metal arc welding (GMAW) and determine the pulmonary deposition and toxicity of the fume in mice exposed by inhalation. Materials and Methods: Male A/J mice (6-8 weeks of age) were exposed to air or Cu-Ni welding fumes for 2 (low deposition) or 4 (high deposition) hours/day for 10 days. Mice were sacrificed, and bronchoalveolar lavage (BAL), macrophage function, and histopathological analyses were performed at different timepoints post-exposure to evaluate resolution. Results and Discussion: Characterization of the fume indicated that most of the particles were between 0.1 and 1 µm in diameter, with a mass median aerodynamic diameter of 0.43 µm. Metal content of the fume was Cu (∼76%) and Ni (∼12%). Post-exposure, BAL macrophages had a reduced ability to phagocytose E. coli, and lung cytotoxicity was evident and significant (>12%-19% fold change). Loss of body weight was also significant at the early timepoints. Lung inflammation, the predominant finding identified by histopathology, was observed as a subacute response early that progressively resolved by 28 days with only macrophage aggregates remaining late (84 days). Conclusions: Overall, there was high acute lung toxicity with a resolution of the response in mice which suggests that the Cu-Ni fume may not be ideal for reducing toxic and inflammatory lung effects.

An ergonomic welding torch reduces physical load response and improves welding quality in novices: a pilot study

Objectives. This crossover pilot study aimed to compare the physical load response of an ergonomically improved welding torch versus a conventional torch. Methods. Ten inexperienced volunteers performed an experimental augmented virtual welding trial at chest height (ASME code 1G) and overhead (ASME code 4G) with both welding torches in random order. Skeletal muscle load and fatigue were assessed by surface electromyography and changes in isometric peak force. The sensation of pain, perceived exertion and welding execution quality were defined as further outcome parameters. Results. The muscle load response in three out of eight muscles was lower in favour of the ergonomic welding torch, which went along with a lower sensation of pain and a higher working accuracy. Conclusions. An ergonomically improved welding torch reduces the acute physical load response and sensation of pain, which ultimately allows performing better, and might contribute to prevention of musculoskeletal diseases in the long term.

Elucidating the Effect of Step Cooling Heat Treatment on the Properties of 2.25 Cr-1.0 Mo Steel Welded with a Combination of GMAW Techniques Incorporating Metal-Cored Wires

The prospect of using metal-cored wires instead of solid wires during gas metal arc welding (GMAW) of 2.25 Cr–1.0 Mo steels embraces several challenges. The in-service requirements for the equipment made up of these steels are stringent. The major challenge faced by the manufacturers is temper embrittlement. In the current study, the temper embrittlement susceptibility of the welded joint was ascertained by subjecting it to step cooling heat treatment. A 25 mm thick 2.25 Cr–1.0 Mo weld joint was prepared using a combination of the regulated metal deposition (RMD) and GMAW processes incorporating metal-cored wires. After welding the plates were exposed to post-weld heat treatment followed by a rigorous step cooling heat treatment prescribed by API standards. The temper embrittlement susceptibility of the weld joint was ascertained by Bruscato X-factor as well as by formulating ductile-to-brittle transition temperature (DBTT) curves by carrying out the impact toughness testing at various temperatures. Detailed microscopy and hardness studies were also carried out. It was established from the study that the X-factor value for the welded joint was 15.4. The DBTT for the weld joint was found to occur at −37 °C which was well below 10 °C. Optical microscopy and scanning electron microscopy indicated the presence of carbides and the energy dispersive X-ray spectrometry studies indicated the presence of chromium and manganese-rich carbides along with the presence of sulfur near the grain boundaries. This study establishes a base for the usage of metal-cored wires particularly in high temperature and pressure application of Cr–Mo steels.

Assessment of the Oxidative Potential and Oxidative Burden from Occupational Exposures to Particulate Matter

Oxidative potential (OP) is a toxicologically relevant metric that integrates features like mass concentration and chemical composition of particulate matter (PM). Although it has been extensively explored as a metric for the characterization of environmental particles, this is still an underexplored application in the occupational field. This study aimed to estimate the OP of particles in two occupational settings from a construction trades school. This characterization also includes the comparison between activities, sampling strategies, and size fractions. Particulate mass concentrations (PM4-Personal, PM4-Area, and PM2.5-Area) and number concentrations were measured during three weeks of welding and construction/bricklaying activities. The OP was assessed by the ascorbate assay (OPAA) using a synthetic respiratory tract lining fluid (RTLF), while the oxidative burden (OBAA) was determined by multiplying the OPAA values with PM concentrations. Median (25th-75th percentiles) of PM mass and number concentrations were 900 (672-1730) µg m-3 and 128 000 (78 000-169 000) particles cm-3 for welding, and 432 (345-530) µg m-3 and 2800 (1700-4400) particles cm-3 for construction. Welding particles, especially from the first week of activities, were also associated with higher redox activity (OPAA: 3.3 (2.3-4.6) ρmol min-1 µg-1; OBAA: 1750 (893-4560) ρmol min-1 m-3) compared to the construction site (OPAA: 1.4 (1.0-1.8) ρmol min-1 µg-1; OBAA: 486 (341-695) ρmol min-1 m-3). The OPAA was independent of the sampling strategy or size fraction. However, driven by the higher PM concentrations, the OBAA from personal samples was higher compared to area samples in the welding shop, suggesting an influence of the sampling strategy on PM concentrations and OBAA. These results demonstrate that important levels of OPAA can be found in occupational settings, especially during welding activities. Furthermore, the OBAA found in both workplaces largely exceeded the levels found in environmental studies. Therefore, measures of OP and OB could be further explored as metrics for exposure assessment to occupational PM, as well as for associations with cardiorespiratory outcomes in future occupational epidemiological studies.

Characterization of a PCB Based Pressure Sensor and Its Joining Methods for the Metal Membrane

Essential quality features of pressure sensors are, among other accuracy-related factors, measurement range, operating temperature, and long-term stability. In this work, these features are optimized for a capacitive pressure sensor with a measurement range of 10 bars. The sensor consists of a metal membrane, which is connected to a PCB and a digital capacitive readout. To optimize the performance, different methods for the joining process are studied. Transient liquid phase bonding (TLP bonding), reactive joining, silver sintering, and electric resistance welding are compared by measurements of the characteristic curves and long-term measurements at maximum pressure. A scanning electron microscope (SEM) with energy-dispersive X-ray spectroscopy (EDX) analysis was used to examine the quality of the joints. The evaluation of the characteristic curves shows the smallest measurement errors for TLP bonding and sintering. For welding and sintering, no statistically significant long-term drift was measured. In terms of equipment costs, reactive joining and sintering are most favorable. With low material costs and short process times, electric resistance welding offers ideal conditions for mass production.

Effect of Imidazole as Corrosion Inhibitor on Carbon Steel Weldment in District Heating Water

Many research studies have been conducted on the corrosion inhibition performance of imidazole in acidic environments such as in the piping of a petrochemical plant. However, there has been no study on the effect of imidazole in alkaline conditions such as a local district water heating environment. Therefore, in this study, the effect of imidazole as a corrosion inhibitor on carbon steel weldment was investigated in alkaline district heating water. Inhibition efficiency and electrochemical properties were investigated by potentiodynamic polarization test and electrochemical impedance spectroscopy. As the concentration of imidazole increased up to 500 ppm, inhibition efficiency increased up to 91.7%. At 1000 ppm, inhibition efficiency decreased. Atomic force microscopy showed that surface coverage of imidazole at 1000 ppm is lower than that of imidazole at 500 ppm. X-ray photoelectron spectroscopy showed that with 500 ppm of imidazole, the amount of pyrrole type interaction is 4.8 times larger than pyridine type interaction. At 1000 ppm of imidazole, the amount of pyridine type interaction is 3.49 times larger than pyrrole type interaction. Depending on the concentration of imidazole, the ratio of interaction between carbon steel and imidazole affected inhibition efficiency.

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

The aim of the investigations was to determine the effect of parameters of refill friction stir spot welding (RFSSW) on the fracture load and failure mechanisms of the resulting joint. RFSSW joints were made in 7075-T6 Alclad aluminium alloy sheets using different welding parameters. The load capacity of joints was determined under tensile/shear loadings. Finite element-based numerical simulations of the joint-loading process were carried out, taking into account the variability of elasto-plastic properties of weld material through the joint cross-section. The influence of welding parameters on selected phenomena occurring during the destruction of the joint is presented. The considerations were supported by a fractographic analysis based on SEM images of fractures. It was found that there is a certain optimal amount of heat generated, which is necessary to produce the correct joint in terms of its load capacity. This value should not be exceeded, because it leads to weakening of the base material and thus to a reduction in the strength of the joint. Samples subjected to uniaxial tensile shear load showed three types of failure mode (tensile fracture, shear fracture, plug type fracture) depending on the tool rotational speed and duration of welding. Prediction of the fracture mode using FE-based numerical modelling was consistent with the experimental results. The samples that were damaged due to the tensile fracture of the lower sheet revealed a load capacity (LC) of 5.76 KN. The average value of LC for the shear fracture failure mechanism was 5.24 kN. The average value of the LC for plug-type fracture mode was 5.02 kN. It was found that there is an optimal amount of heat generated, which is necessary to produce the correct joint in terms of its LC. Excessive overheating of the joint leads to a weakening of the base metal and thus a reduction in the strength of the joint. Measurements of residual stresses along the axis specimens showed the presence of stresses with a certain constant value for the welded area on the side of the 1.6 mm thick plate.

Evaluation of a Filtering Facepiece Respirator and a Pleated Particulate Respirator in Filtering Ultrafine Particles and Submicron Particles in Welding and Asphalt Plant Work Environments

Manufacturing sites, such as welding, casting, and asphalt production (fumes), generate vast numbers of ultrafine particles of <0.1 µm in size and submicron particles close to the ultrafine range (0.1-0.5 µm). Although cumulative masses of these particles are negligible in comparison to the larger particles, the health effects are more severe due to the higher penetration in the human lower respiratory tract, other body parts crossing the respiratory epithelial layers, and the larger surface area. This research investigates the effectiveness of two common commercially available N95 filtering facepieces and N95 pleated particulate respirator models against ultrafine and submicron particles. Two specific types of respirators, the N95 filtering facepiece and the N95 pleated particulate models, in both sealed and unsealed conditions to the manikin face, were tested at various commercial and academic manufacturing sites, a welding and foundry site, and an asphalt production plant. Two TSI Nanoscan SMPS nanoparticle counters were used simultaneously to collect data for particles of 10-420 nm in size from inside and outside of the respirators. While one of them represented the workplace exposure levels, the other one accounted for the exposure upon filtration through the respiratory surfaces. The results showed the particles generated by these manufacturing operations were mostly within the range of from 40 to 200 nm. Results also indicated that while the percentage of filtration levels varied based on the particle size, it remained mostly within the desired protection level of 95% for both of the N95 respirator models in sealed conditions and even for the N95 pleated particulate model in the unsealed condition. However, in the case of the N95 filtering facepiece model, unsealed respirators showed that the percentage of penetration was very high, decreasing the protection levels to 60% in some cases. Although the number of workplace airborne particle levels varied considerably, the filtration percentages were relatively consistent.