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Numerical and experimental study on keyhole and melt flow dynamics during laser welding of aluminium alloys under subatmospheric pressures
摘要： Porosity defects was highly related to the keyhole and melt flow dynamic during laser welding process. In this paper, a novel 3D numerical model was developed to describe the keyhole dynamic and melt flow behaviors during laser welding of 5A06 aluminium alloy under subatmospheric pressures. The effect of ambient pressure on laser welding process was taken into consideration by optimizing the boiling point of aluminium alloy and recoil pressure of evaporated metallic vapor jets based on vapor–liquid equilibria calculation and Wilson equation. A moving hybrid heat source model was employed to describe the laser energy distribution under subatmospheric pressures. Numerical results indicated that a wider and deeper keyhole with less humps was produced under subatmospheric pressure comparing with that of atmospheric pressure. The vortices in the rear keyhole wall became unapparent or even disappeared with the decrease of ambient pressures. The melt flow velocity on the keyhole wall was larger under a lower pressure. A smaller difference between boiling point and melting point was produced and this led to the formation of a thinner keyhole wall and improved the stability of molten pool. Larger recoil pressure produced under subatmospheric pressure was responsible for the weakened vortices and enhanced melt flow velocity. Bigger keyhole opening size, larger melt flow velocity, thinner keyhole and the weakened vortices all resulted into the reduction of porosity defects during laser welding of aluminium alloys. Based on the simulation results, the plasma distribution, weld formation and porosity defects had been demonstrated. The compared results showed that the simulation results exhibited good agreements with the experimental ones.
关键词： Porosity defects,Keyhole stability,Numerical simulation,Subatmospheric pressure,Melt flow dynamic,Laser welding
更新于2025-11-28 14:24:20
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Analysis of microstructure and mechanical strength of lap joints of TZM alloy welded by a fiber laser
摘要： The application of molybdenum alloys to structural components is severely limited due to their poor weldability with serious defects of porosity and joint embrittlement after welding despite their high melting temperature, hot strength and creep resistance. A systematical experimental study has been conducted to explore the potential of laser welding of 0.5 mm-thick Titanium-zirconium-molybdenum (TZM) alloy in a lap welding configuration. Porosity was found to be the most serious problem in the TZM laser lap welding process. Introducing an interface gap of 0.09 mm had the most positive effect in reducing the porosity compared to using helium gas, different shielding gas flow rates, adding alloy element and different heat input rate. With the use of 0.09 mm-interface gap, the porosity of the weld joint was reduced to 3%. The tensile stress of the bead on plate (BOP) welded joint could achieve about 60% that of the base metal. The fracture stress of the lap welded joint obtained by using 0.09 mm-interface gap in tensile-shear test was about 142 MPa. The porosity and embrittlement were responsible for the reduction of the strength and ductility of the welded joint.
关键词： Porosity,Mechanical property,Molybdenum alloy,Laser welding
更新于2025-11-28 14:24:20
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Effect of Heat Input on Porosity Defects in a Fiber Laser Welded Socket-Joint Made of Powder Metallurgy Molybdenum Alloy
摘要： Porosity defects are still a challenging issue in the fusion welding of molybdenum and its alloys due to the pre-existing interior defects associated with the powder metallurgy process. Fiber laser welding of end plug and cladding tube made of nanostructured high-strength molybdenum (NS-Mo) alloy was performed in this work with an emphasis on the role of welding heat input. The distribution and morphology of porosity defects in the welded joints were examined by computed tomography (CT) and scanning electron microscopy (SEM). Preliminary results showed that laser welding of NS-Mo under low heat input significantly reduced the porosity defects in the fusion zone. The results of computed tomography (CT) showed that when the welding heat input decreased from 3600 J/cm (i.e., 1200 W, 0.2 m/min) to 250 J/cm (i.e., 2500 W, 6 m/min), the porosity ratio of the NS-Mo joints declined from 10.7% to 2.1%. Notable porosity defects under high heat input were related to the instability of the keyhole, expansion and the merging of bubbles in the molten pool, among which the instability of the keyhole played the dominant role. The porous defects at low heat input were generated as bubbles released from the powder metallurgy base metal (BM) did not have enough time to overflow and escape.
关键词： fiber laser welding,molybdenum alloy,porosity defects,heat input
更新于2025-11-28 14:24:20
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Effects of Power Modulation, Multipass Remelting and Zr Addition Upon Porosity Defects in Laser Seal Welding of End Plug to Thin-Walled Molybdenum Alloy
摘要： Aiming to solve the serious porosity defects in laser welded girth joints of thin-walled tube and end plug made of nano-sized Ce2O3 doped Mo alloy (NC-Mo), the influences of laser power modulation, multipass remelting and zirconium (Zr) addition on the number, size and distribution of porosity defects were experimentally studied. By utilizing X-ray computed tomography (XCT), scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) analysis, transmission electron microscope (TEM) and Raman spectrum (RS), the porosity feature of welded joints achieved under various conditions was analyzed. The results showed that welding cycles had a significant influence on the porosity ratio of fusion zone (FZ) while the amplitude and frequency of laser power waveform slightly influenced the porosity. When the welding cycles increased from 2 to 8, the porosity ratio of FZ decreased from about 1.00% to about 0.48% and the maximum and average pore diameters reduced by about 53% and 27%, respectively. Adding minor Zr in molten pool can further reduce the RP of FZ to about 0.35%. Through analysis, it can be seen that the pores in FZ can be divided into irregularly-shaped keyhole-induced pores and spherical metallurgy-induced pores. The latter was generated possibly because some impurity elements (including O and H) pre-existing in base metal (BM). Increasing welding cycles can promote the gas in molten pool to float and outflow, thus significantly decreasing the porosity. Moreover, Zr added in molten pool can be preferentially reacted with O to generate ZrO2, which can inhibit the precipitation of volatile MoO2 to thus suppress the generation of metallurgy-induced pores.
关键词： Molybdenum alloy,Multipass remelting,Power-Modulated laser welding,Zirconium addition,Porosity
更新于2025-11-28 14:24:20
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Controlling porosity and ultraviolet photoresponse of crystallographically oriented ZnO nanostructures grown by pulsed laser deposition
摘要： We have synthesized a series of porous nanostructures of c-axis oriented wurtzite ZnO using glancing angle pulsed laser deposition. During deposition, the oxygen partial pressure (PO2) was varied to study the effects on growth, porosity and optical properties. With varied PO2 the growth of nanostructure changes gradually without losing its crystallographic orientation. The variation in PO2 causes systematic change in porosity of these nanostructures, which strongly influences ultraviolet photoresponse. These results show that the parameters such as surface morphology, growth and porosity as well as the optoelectronic properties can be controlled by variation in PO2 without compromising the crystalline structure.
关键词： Crystalline nanostructures,Photoresponse,Porosity,Ultraviolet,Glancing angle pulsed laser deposition
更新于2025-11-19 16:56:42
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Three-dimensional Nanoscale Mapping of Porosity in Solution-Processed ITO Multilayer Thin Films for Patternable Transparent Electrodes
摘要： Indium tin oxide (ITO) films constitute components of many layered heterostructures used for emergent technologies beyond conventional optoelectronics. Compositional and morphological changes have a direct impact on the device’s performance. Hence control over the morphology with advanced multimodal characterization approaches are required to evaluate the devices. Herein multilayer ITO films deposited by spin coating were quantified in nanoscale detail in three dimensions by combining results from depth-sensitive neutron reflectometry (NR), non-contact topographic AFM images and cross-sectional SEM images. Films with different number of deposited layers were visually transparent even though the topmost layer was as high as 60% porous, with porosity gradually decreasing as the number of the underneath sublayers increased. Surface and interfacial roughness through the total film and individual layer thickness were obtained. NR data also furnished quantitative depth information on the films chemical composition and layer-by-layer bulk density, which has never been obtained before, providing a way to monitor and ultimately control the sheet resistivity via the pore network. When the same formulation is used for inkjet printing patterns, the larger pores disappear and the optical properties are improved to >90% transmittance at all visible wavelengths. All 5L films achieved sheet resistivities as low as 10-2 ?-cm and can therefore be used as patternable transparent electrodes for many devices including liquid crystal displays.
关键词： thin multilayer film,neutron reflectometry,depth density distribution,neutron absorption reflectometry,Indium tin oxide,porosity,structure chemical depth profile,off-specular neutron scattering,layer by layer deposition
更新于2025-11-19 16:56:35
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Porosity Determination of Carbon and Glass Fibre Reinforced Polymers Using Phase-Contrast Imaging
摘要： This paper presents multi-modal image data of different fibre reinforced polymer samples acquired with a desktop Talbot-Lau grating interferometer (TLGI) X-ray computed tomography (XCT) system and compare the results with images acquired using conventional absorption-based XCT. Two different fibre reinforced polymer samples are investigated: (i) a carbon fibre reinforced polymer (CFRP) featuring a copper mesh embedded near the surface for lightning conduction and (ii) a short glass fibre reinforced polymer (GFRP) sample. The primary goal is the non-destructive detection of internal defects such as pores and the quantification of porosity. TLGI provides three imaging modalities including attenuation contrast (AC) due to absorption, differential phase contrast (DPC) due to refraction and dark-field contrast (DFC) due to scattering. In the case of the CFRP sample, DPC is less prone to metal streak artefacts improving the detection of pores that are located close to metal components. In addition, results of a metal artefact reduction (MAR) method, based on sinogram inpainting and an image fusion concept for AC, DPC and DPC, are presented. In the case of the GFRP sample, DPC between glass fibres and matrix is lower compared to AC while DPC shows an increased contrast between pores and its matrix. Porosity for the CFRP sample is determined by applying an appropriate global thresholding technique while an additional background removal is necessary for the GFRP sample.
关键词： Porosity,Carbon and glass fibre reinforced polymers,Talbot-Lau grating interferometer,X-ray computed tomography,Differential phase contrast
更新于2025-09-23 15:22:29
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Silica aerogel membranes fabricated using removable nitrocellulose scaffolds
摘要： Two different methods were developed to generate silica-based aerogel membranes using nitrocellulose scaffolds. The first method involved incorporating fibers of nitrocellulose (NC) into the sol prior to gelation. NC fibers were either removed using a solvent during aging or calcining after aerogel formation to produce reticulated micron-sized channels in the aerogels. In the second method, an NC lacquer was mixed with the sol, and the mixture separated into a NC-rich phase and a sol-rich phase. The NC phase was subsequently removed from the aerogel using a solvent, creating aerogels with interconnected porosity. Aerogels were prepared from tetraethyloxysilane (TEOS) as a precursor and methyltriethoxysilane (MTES) as a co-precursor. Replacing TEOS with 25 vol% MTES increased the mechanical stability, allowing for greater ease of handling. Additionally, the more open network of the MTES gels led to higher helium gas permeability than that for the pure TEOS gels.
关键词： Silica membrane,Interconnected porosity,Nitrocellulose template,Cellulose nitrate,Silica aerogel
更新于2025-09-23 15:22:29
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Selected aspects of graphene exfoliation as an introductory step towards 3D structuring of graphene nano-sheets
摘要： The paper reviews the advantages of the synthesis of porous three-dimensional (3D) graphene obtained by various exfoliation methods, with a focus on their recent progress and remaining challenges. The manufacturing procedure influences some crucial properties of obtained carbon materials, such as pore structure and the chemical composition of the surface.
关键词： extended surface,graphene,exfoliation,hard template method,3D structuring,porosity
更新于2025-09-23 15:22:29
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The influence on sample preparation on spectral induced polarization of unconsolidated sediments
摘要： Spectral induced polarization (SIP) measurements in the laboratory are in many cases intended to provide representative and comparable results of complex electrical conductivity. This is not invariably the case when using unconsolidated sediments, as the sample preparation influences several SIP-relevant properties of the samples, including the pore geometry. The pore space is supposed to control the polarization effect and therefore a change in the pore space will change the measured parameters. We analysed the influence of the sample preparation on SIP measurements by testing various filling methods, each defined by a sequence of particular steps, with regard to the reproducibility of the spectra. The measurements were performed on three different sample materials. Variations of the spectra due to different filling methods were obtained, indicating the importance of considering the sample preparation. Methods that improved the reproducibility compared to loose packing of the samples were found, but the most suitable packing procedure depended on the material properties. The mean relaxation times and normalized chargeabilities were obtained from a Debye decomposition. Although unidentified processes caused scattering of the measured parameters, a relation of the IP-parameters to the porosities was present. A decrease of the porosity reduced both the relaxation times and the normalized chargeabilities.
关键词： Debye decomposition,sample preparation,unconsolidated sediments,reproducibility,spectral induced polarization,porosity
更新于2025-09-23 15:22:29