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KEY W O R D S
Acoustic Emission
AE Signals
Martensite Formation
High-Carbon Steel
Hardenable Alloys
Weld Porosity
Martensitic Transformation
Multiple-Pass Welding
Monitoring AE Signals
Welding Gun
Experimental
A gas metal arc welding system was
utilized for the experiments, with specimens consisting of 1.5-in. (38-mm) diameter 1018 and 4340 steel bars, 28 in. (711
mm) in length. The welding conditions included a welding current of 300 A, voltage
of 30 V, 13.1 ft/min (4 m/min) wire feed
rate, Vi6-in. (1.6-mm) mild-steel wire diameter, 17.7 in./min (7.5 mm/s) welding
speed, and a welding time of 20 s, using
argon (Ar) as the shielding gas. The piezoelectric transducer used was a wide-band
PAC WD-445, which was mounted on the
surface at the end of the bar. The signals
were first preamplified by 40 dB and then
further amplified by 15 dB during welding,
and 35 dB after welding. They were
band-pass filtered between 30 and 1000
kHz, and then recorded with a modified
video recorder for later analysis. An oscilloscope was used to monitor the signals
while the AE RMS voltage was sampled at
30 Hz using a 12-bit data-acquisition systemFig. 1. O n play back, the recorded
AE signal was passed through a gating unit
where a 16.7-ms length of the signal was
clipped for sampling, with the recorder
put in a pause mode at a desired location
of the tape. To avoid saturation, the signal
was then passed through an attenuator to
reduce the amplitude to a level between
254 and -F254 mV compatible with the
8-bit high-speed waveform digitizer,
which was set at a sampling rate of 4 MHz.
Sixteen kbytes sample data points were
used for analysis, covering a time period
of 4 ms.
Three types of experiments were undertaken promoting the following three
as-welded conditions: 1) martensite formation, 2) porous weld and 3) sound
weld. Each set of experiments was conducted under essentially the same conditions. AISI 4340 steel was used to ensure
martensitic transformation, since a nearly
complete transformation occurs at cooling rates greater than 6C/s (Ref. 4). Porosity was introduced by shutting off the
Ar gas supply during the welding of a 1018
steel. For a sound weld, 1018 steel and Ar
gas were used during welding, and no
porosity was found on the surface or inside the specimens. Since 1018 steel has
very low hardenability, no martensite
formed.
Oscilloscope
Fig. 1 Experimental setup for monitoring AF signals from welding.
A total of 18 experiments were conducted, with each class having six experiments. For each experiment, about 15
2.0
cn
0.6
>
co
20
32
40
Time (s)
Fig. 2 RMS voltage during and after welding of a 4340 steel with 65 dB
gain.
samples w e r e o b t a i n e d f o r martensite
f o r m a t i o n , p o r o u s a n d s o u n d w e l d s . They
w e r e s a m p l e d at a b o u t u n i f o r m t i m e
intervals.
48
Time (s)
Fig. 3 - RMS voltage during (55 dB) and after (75 dB) welding of a 4340
steel.
signal g e n e r a t e d d e p e n d s o n t h e cooling
rate and t h e a m o u n t of material i n v o l v e d
(Ref. 13). T h e t e m p e r a t u r e a n d c o o l i n g
rate for a w e l d e d specimen in t u r n d e p e n d o n t h e w e l d i n g c o n d i t i o n s such as
arc v o l t a g e , c u r r e n t , w e l d i n g t i m e , size o f
t h e s p e c i m e n , etc. Martensitic t r a n s f o r m a t i o n normally occurs b e l o w 4 0 0 C (752F)
in m a n y steels (Ms = 3 0 0 C / 5 7 2 F f o r
the 4 3 4 0 steel). Since t h e w e l d deposit
generally cools s l o w l y , t h e t r a n s f o r m a t i o n
can b e d e t e c t e d after w e l d i n g is c o m p l e t e d . For a multipass w e l d i n g process,
d e t e c t i o n of martensitic t r a n s f o r m a t i o n
after each pass w o u l d p r o v i d e a w a r n i n g
t o t h e w e l d i n g system, enabling p r o p e r
action t o b e taken b e f o r e the next pass.
For the 6-in. (152-mm) w e l d beads in o u r
experiments, the transformation was
found to occur for a period of about 4 0 6 0 s after c o m p l e t i o n of t h e w e l d . Signals
f r o m martensite f o r m a t i o n are c o n t i n u o u s
t y p e , giving a s m o o t h RMS v o l t a g e c u r v e .
C o m p a r i n g Figs. 3 and 4 , w e notice that
ra 0.6 -
ra 0.6 -
>
>
CT)
40
Time (s)
Fig. 4 RMS voltage for sound welding of a 1018 steel.
Fig. 5-RMS
20
40
Time (s)
60
80
-10
^ H B Martensite
I I
Porosity
H i Normal
-16-
-20
"
-30
-18-
i * f
3
o
* \
Ooo0c
20-
-40 -
* * *
<b o f %.
0o
Q.
"
'
-50
0.0
i
0.2
0.4
Martensite
lu
o Porosity
??
-27
1.0
0.6
| M 1 II II 1 1 | l l IL! 1 1 1 1 |
-26
Frequency (MHZ)
A p a t t e r n - r e c o g n i t i o n system requires
t h r e e essential steps (Ref. 11):
1) Sampling or scanning the input signal
t o p r o d u c e t h e p a t t e r n space.
2) Extraction of the features, w h i c h often involves t r a n s f o r m a t i o n o f the signal
f r o m the p a t t e r n into the feature space,
f r o m w h i c h useful i n f o r m a t i o n can b e o b tained, a n d subsequent r e d u c t i o n of the
data size.
Signal discrimination is f u n d a m e n t a l t o
AE m o n i t o r i n g of processes. The high
sensitivity inherent in t h e AE t e c h n i q u e
leads t o p r o b l e m s in distinguishing b e t w e e n signals o f interest a n d those that
are not desirable, i.e., noise. D u r i n g w e l d ing, martensite f o r m a t i o n , p o r o s i t y a n d
the s o u n d w e l d all g e n e r a t e d intense AE
Fig. 8 Decision
space plot for
martensite
formation-porous
weld.
//
<*>
0*
>.
17>
o
o
DL
%o
\0-_
0.5-
/ x
'
0.0-
//
/
/
^&t
Vb
*
%-s,
' Martensite
**
0.0
0.5
Martensite
392-s | O C T O B E R
1990
1 | 1 1 1 . 1 1 1 1 1
H l |
-22
-21
-20
weld.
o Porosity
-0.5 '
-0.5
Ill ] 1
-23
signals. T h e p a t t e r n - r e c o g n i t i o n t e c h n i q u e
p r o v i d e s a means by w h i c h positive signal
sorting, classification and source identification can b e o b t a i n e d . T h e b a c k g r o u n d
o n the p a t t e r n - r e c o g n i t i o n scheme used
f o r classifying the AE signals is p r e s e n t e d in
an earlier p a p e r (Ref. 11) a n d will n o t be
r e p e a t e d here.
Pattern-Recognition Analysis
-24
3 3 0 KHz
-25
1.0
1.5
AE Signals
a)
-35
Normal
Weld
-40
AE Signals
*x
on
o
b)
Martensite Formation
& Porous Weld
Normal Weld
-45H
CO
0)
-50-
* Martensite
Porosity
Martensite Formation
Porous Weld
x Normal
-55
30
a) Simultaneous Decision
b) Binary Decision
40
45
50
Power (dB)
35
Fig. 10-Feature
sound weld.
weld,
Martensite
Formation
Porous
Weld
Normal
Weld
5
8
11
14
17
80.0
67.3
100
98.2
96.4
38.0
40
60
62.0
70.0
95.6
97.8
97.8
100.0
100.0
Number
of
Features
1
2
5
8
11
14
17
Martensite
Formation/
Porous
Weld vs.
Normal Weld
Martensite
Formation vs.
Porous Weld
99.1
100
97.1
99.1
100
100
100
92.7
94.6
90.9
96.4
94.6
96.4
92.7
86.7
88.9
95.6
100
100
100
100
80.0
74.0
78.0
76.0
80.0
76.0
76.0
Acknowledgment
The support of this work by the National Science Foundation under grant No.
is
gratefully
acknowl-