Papers by Author: Russell Steel

Abstract: Friction Stir Welding (FSW) is being investigated as a method to fabricate a partial penetration closure weld of the steel vessel of a copper-coated used fuel container. The hemi-head is made of A516 Grade 70 steel and the cylinder body is made of A106 Grade C steel. In this initial feasibility study, the objective is to use FSW to demonstrate the merits of FSW using flat steel plate in concert with a closure weld joint designed specifically for a cylindrical container. To complete this objective, there are two initial feasibility demonstrations. First, demonstrate the capability of FSW to create defect free welds in a corner joint design with specific dimensions (10 mm deep weld nugget). Subsequently, verify the weld quality by ultrasonic inspection and metallography. Further, characterize weld zone properties by establishing mechanical properties and hardness at room temperature, and impact toughness at-5°C. Second, demonstrate the ability to use FSW to repair defects that might occur in the initial friction stir weld. Weld repair was accomplished by intentionally creating tunnel defects by FSW, performing metallography and ultrasonic inspection to characterize the morphology of the defects, performing a second friction stir weld repair over the defects, and verifying the subsequent weld integrity by repeating the metallography and ultrasonic inspections. Results on these initial two phases of this program are presented herein.

Abstract: Transformation Induced Plasticity (TRIP) steels have not yet been successfully joined by any welding technique. It is desirable to search for a suitable welding technique that opens up for full usability of TRIP steels. In this study, the potential of joining TRIP steel with Friction Stir Spot Welding (FSSW) is investigated. The aim of the study is to investigate whether acceptable welds can be produced, and additionally, to obtain an understanding of the microstructural changes during welding. The microstructure was investigated with a combination of microscopical techniques with the aim of identifying the transformations occurring during welding. Reflected light microscopy, scanning electron microscopy, and electron backscatter diffraction were among the methods applied for detailed investigations. The microstructure adjacent to the welds can generally be subdivided in two thermo-mechanically affected zones (TMAZ), and two heat-affected zones (HAZ). The dual behavior of the microstructure in the zones is related to the two transition temperatures in steel: A₁ and A₃. In parts of the TMAZ the microstructure contains ultra fine-grained ferrite. This finding parallels the observation in thermo-mechanically processed steels, where severe deformation at elevated temperatures is used to produce ultra fine-grained microstructures. Several possible transformation mechanisms could in principle explain the development of ultra fine-grained ferrite, e.g. dynamic recrystallization, strain-induced ferrite transformation and dynamic recovery.

Abstract: Commercial Waspaloy plates with two different initial microstructures (annealed and aged) were joined by Friction Stir Welding (FSW). This study presents the evolution of the grain structure, and precipitation, dissolution and reprecipitation of the γ' phase during FSW using Optical Microscopy, Scanning Electron Microscopy and Transmission Electron Microscopy. The relationship between microstructure and microhardness is also discussed.