Welding is a process that uses high heat to melt and join materials together upon cooling. The welding process as we know it has been around since the early 1800’s. Porosity defects, or air bubbles, commonly form in welds. Porosity is a problem that can weaken welds and lead to unwanted cracking. Current research looks at reducing porosity formation in welds by introducing ultrasonic vibrations (high frequency) into the liquid metal prior to cooling.
Ultrasonic vibrations create a physical phenomenon in liquid metal known as acoustic cavitation which helps to break up and remove the gas bubbles that may lead to porosity.
Porosity Problem TEK8 Student Handout
The student handout will be given to all students working on the design challenge. It gives a brief recap of the story, it helps the students identify what they are attempting to achieve, and it recaps the design process.
Porosity Problem TEK8 Facilitator Guide
This Instructor’s Guide provides the instructor additional information on how to run the design challenge with alternatives for materials and test setups as well as information to help make the design challenge a good educational experience.
The Telling the Story Video conveys the societal impact of the student’s research that is the basis for the design challenge and will set the problem-solving context for students.
The Design Challenge Video leads students through the design process. It indicates materials available, states what the criteria are for success and any constraints. It also gives a second ‘level’ of the design challenge that allows ‘early completers’ to move on to a slightly more difficult challenge.