Nd:YAG Laser Welding of 5083 Aluminium Alloy using Filler Wire

High reflectivity and high thermal conductivity, high vapour pressure of alloyingelements as well as low liquid surface tension and low ionisation potential, make laser welding of aluminium and its alloys a demanding task.Problems that occur during welding are mainly process instabilities of the keyhole and the melt pool, increased plasma formation above the melt pool and loss of alloying elements. These problems lead to unwanted metallurgical defects like hot cracks and porosity in the weld bead andother problems concerning the shape and appearance of the weld bead. In order to minimise the defects and improve the weld quality, the process and beam parameters need to be carefully adjusted along with a consideration concerning the use of filler wire for the welding process. In this work the welding of 3,0 mm thick grade 5083 aluminium alloy plates using a 3,0 kW Nd:YAG laser with grade 5183 filler wire addition is investigated. The plates were welded as butt joints with air gap sizes 0,5 mm, 0,7mm and 1,0 mm. The analysis of the weld beads obtained from the weldedsamples showed that the least imperfections were produced with 0,7 mm air gaps at moderate welding speeds. The analysis also covered the calculation of the melting efficiency and the study of the shape of the weld bead. The melting efficiency was on average around 20 % for the melting process of the welded plates. The weld beads showed the characteristic V-shape of a laser weld and retained this shape during the whole series of experiments.

Effect of Shielding Gases in Laser Welding of Aluminium Alloys

High reflectivity to laser light, alloying element evaporation during high power laser welding makes aluminium alloys highly susceptibility to weld defects such as porosity, cracking and undercutting. The dynamic behaviour of the keyhole, due to fluctuating plasma above the keyhole and the vaporization ofthe alloying elements with in the keyhole, is the key problem to be solved for the improvement of the weld quality and stabilization of the keyhole dynamics isperhaps the single most important development that can broaden the application of laser welding of aluminium alloys. In laser welding, the shielding gas is commonly used to stabilize the welding process, to improve the welded joint features and to protect the welded seam from oxidation. The chemicalcomposition of the shielding gas is a key factor in achieving the final qualityof the welded joints. Wide range of shielding gases varying from the pure gasesto complex mixtures based on helium, argon, nitrogen and carbon dioxide are commercially available. These gas mixtures should be considered in terms of their suitability during laser welding of aluminium alloys to produce quality welds. The main objective of the present work is to study the effect of the shielding gascomposition during laser welding of aluminium alloys. Aluminium alloy A15754 was welded using 3kW Nd-YAG laser (continuous wave mode). The alloy samples were butt welded with different shielding gases (pure and mixture of gases) so that high quality welds with high joint efficiencies could be produced. It was observed that the chemical composition of the gases influenced the final weld quality and properties. In general, the mixture gases, in correct proportions, enabled better utilisation of the properties of the mixing gases, stabilized the welding process and produced better weld quality compared to the pure shielding gases.

Diodilaserin käytön edellytykset ohutlevyjen hitsauksessa

Diplomityössä tutkitaan diodilaserhitsausta mahdollisena teollisuuden menetelmänä ja menetelmän vaatimuksia hitsattaessa ohutlevyjä. Työssä tutkittavat materiaalit ovat kylmävalssattu teräs ja ruostumaton teräs sekä liitosmuotoina päittäis-, laippa- ja päällekkäisliitos. Materiaalivahvuudet ovat 0,50 mm:stä 1,50 mm:iin. Työn tavoitteena on määrittää näille kyseisille materiaaleille ja liitosmuodoille hitsausnopeus levynvahvuuden funktiona. Lisäksi käsitellään diodilaserin rakennetta, säteen muodostusta, säteen muokkaamista, säteen analysointia ja säteen turvallisuuteen liittyviä asioita. Suoritetaan vertailua käytössä oleviin muihin lasertyöstömenetelmiin konepajoissa ja tehdään arvio mahdollisen diodilaserinvestoinnin kannattavuudesta. Diodilaserhitsauskokeissa käytettiin Hämeen ammattikorkeakoulun Riihimäen yksikön 1 kW:n tehoista diodilaseria. Koekappaleet leikattiin suuntaisleikkurilla. Osalle hitsatuista kappaleista tehtiin poikittaiset vetokokeet ja mitattiin mikrokovuudet. Virheitä tutkittiin silmämääräisesti sekä radiografisella kuvauksella. Kaikille tutkituille liitoksille, materiaaleille ja vahvuuksille saatiin määriteltyä hitsausnopeudet. Tehtyjen testien perusteella suuntaisleikkurin käyttö on mahdollista. Lisäksi havaittiin suojakaasun käytön myötä, että kirkkaan sulan aiheuttama heijastavuuden kasvu edellyttää hitsausnopeuden pienentämistä.

Neutronisäteilylle altistuminen käytetyn polttoaineen siirrossa Olkiluodon voimalaitoksella

Tässä työssä on tutkittu OL1/OL2-ydinvoimalaitosten käytetyn polttoaineen siirrossa aiheutuvaa altistusta neutronisäteilylle. Käytetty polttoaine siirretään vedellä täytetyssä käytetyn polttoaineen siirtosäiliössä Castor TVO:ssa OL1/OL2-laitoksilta käytetyn polttoaineen varastolle. Siirtotyön aikana useat eri ammattiryhmiin kuuluvat henkilöt työskentelevät siirtosäiliön välittömässä läheisyydessä, altistuen käytetystä polttoaineesta emittoituvalle fotoni- ja neutronisäteilylle. Aikaisemmista neutronisäteilyannosten mittauksista on todettu, ettei jatkuvalle altistuksen seurannalle ole ollut tarvetta. Tämän työn tarkoitus on selvittää teoreettisilla laskelmilla siirtotyöhön osallistuvan henkilön mahdollisuus saada kirjausrajan ylittävä annos neutronisäteilyä. Neutronisäteilyn annosnopeudet siirtosäiliötä ympäröivässä tilassa on laskettu yhdysvaltalaisella Monte Carlo-menetelmään perustuvalla MCNP-ohjelmalla. MCNP:llä mallinnettiin siirtosäiliö, siirtosäiliön sisältämä polttoaine ja ympäröivä tila kolmella jäähtymisajalla ja kolmella keskimääräisellä maksimipoistopalamalla. Polttoainenippujen isotooppikonsentraatiot ja säteilylähteiden voimakkuudet on laskettu Studsvik SNF-ohjelmalla. Simuloinnin perusteella voidaan todeta, ettei neutronisäteilyannosten jatkuvalle seurannalle ole tarvetta käytetyn polttoaineen siirrossa. Vaikka neutronisäteilyn annosnopeudet voivat nousta siirtosäiliön läheisyydessä suhteellisen suuriksi, ovat siirtosäiliön lähellä tehtävät työt niin lyhytaikaisia, että kirjausrajan ylitystä voidaan pitää hyvin epätodennäköisenä. Johtopäätökset varmistetaan työssä suunnitellulla mittausjärjestelyllä.

Simulation of the Interaction Mean Free Path between Neutrons and TRISO Particles

The interaction mean free path between neutrons and TRISO particles is simulated using scripts written in MATLAB to solve the increasing error present with an increase in the packing factor in the reactor physics code Serpent. Their movement is tracked both in an unbounded and in a bounded space. Their track is calculated, depending on the program, linearly directly using the position vectors of the neutrons and the surface equations of all the fuel particles; by dividing the space in multiple subspaces, each of which contain a fraction of the total number of particles, and choosing the particles from those subspaces through which the neutron passes through; or by choosing the particles that lie within an infinite cylinder formed on the movement axis of the neutron. The estimate from the current analytical model, based on an exponential distribution, for the mean free path, utilized by Serpent, is used as a reference result. The results from the implicit model in Serpent imply a too long mean free path with high packing factors. The received results support this observation by producing, with a packing factor of 17 %, approximately 2.46 % shorter mean free path compared to the reference model. This is supported by the packing factor experienced by the neutron, the simulation of which resulted in a 17.29 % packing factor. It was also observed that the neutrons leaving from the surfaces of the fuel particles, in contrast to those starting inside the moderator, do not follow the exponential distribution. The current model, as it is, is thus not valid in the determination of the free path lengths of the neutrons.

Numerical Studies of Dark Energy Models and Observations

The cosmological standard view is based on the assumptions of homogeneity, isotropy and general relativistic gravitational interaction. These alone are not sufficient for describing the current cosmological observations of accelerated expansion of space. Although general relativity is extremely accurately tested to describe the local gravitational phenomena, there is a strong demand for modifying either the energy content of the universe or the gravitational interaction itself to account for the accelerated expansion. By adding a non-luminous matter component and a constant energy component with negative pressure, the observations can be explained with general relativity. Gravitation, cosmological models and their observational phenomenology are discussed in this thesis. Several classes of dark energy models that are motivated by theories outside the standard formulation of physics were studied with emphasis on the observational interpretation. All the cosmological models that seek to explain the cosmological observations, must also conform to the local phenomena. This poses stringent conditions for the physically viable cosmological models. Predictions from a supergravity quintessence model was compared to Supernova 1a data and several metric gravity models were studied with local experimental results. Polytropic stellar configurations of solar, white dwarf and neutron stars were numerically studied with modified gravity models. The main interest was to study the spacetime around the stars. The results shed light on the viability of the studied cosmological models.

Monitoring Directed Energy Deposition Processes in Additive Manufacturing

The purpose of this study is to find out how laser based Directed Energy Deposition processes can benefit from different types of monitoring. DED is a type of additive manufacturing process, where parts are manufactured in layers by using metallic powder or metallic wire. DED processes can be used to manufacture parts that are not possible to manufacture with conventional manufacturing processes, when adding new geometries to existing parts or when wanting to minimize the scrap material that would result from machining the part. The aim of this study is to find out why laser based DED-processes are monitored, how they are monitored and what devices are used for monitoring. This study has been done in the form of a literature review. During the manufacturing process, the DED-process is highly sensitive to different disturbances such as fluctuations in laser absorption, powder feed rate, temperature, humidity or the reflectivity of the melt pool. These fluctuations can cause fluctuations in the size of the melt pool or its temperature. The variations in the size of the melt pool have an effect on the thickness of individual layers, which have a direct impact on the final surface quality and dimensional accuracy of the parts. By collecting data from these fluctuations and adjusting the laser power in real-time, the size of the melt pool and its temperature can be kept within a specified range that leads to significant improvements in the manufacturing quality. The main areas of monitoring can be divided into the monitoring of the powder feed rate, the temperature of the melt pool, the height of the melt pool and the geometry of the melt pool. Monitoring the powder feed rate is important when depositing different material compositions. Monitoring the temperature of the melt pool can give information about the microstructure and mechanical properties of the part. Monitoring the height and the geometry of the melt pool is an important factor in achieving the desired dimensional accuracy of the part. By combining multiple different monitoring devices, the amount of fluctuations that can be controlled will be increased. In addition, by combining additive manufacturing with machining, the benefits of both processes could be utilized.