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Control of Microstructures and Properties in Steel Arc Welds provides an overview of the most recent developments in welding metallurgy. Topics discussed include common welding processes, the thermal cycle during welding, defects that may occur during the welding process, the metallurgy of the material, metallurgical processes in the heat-affected zone and the fused metal, and the relationship between microstructures and mechanical properties. The book's final chapter presents examples of welded joints, illustrating how modern theories are capable of predicting the microstructure and properties of these joints. This book is an excellent resource for welding engineers, metallurgists, materials scientists, and others interested in the subject.
The heat-affected zone (HAZ) is the most common region of weld failures. The weld failures are directly related to the microstructure. Microstructure control of the HAZ is crucial to weld quality and prevention of weld failures. However, publications on modeling the development of the HAZ are relatively limited. Moreover, no efforts have been made to predict the HAZ microstructures in real-time. The primary goal of this research is to present a methodology to enable real-time predictions of microstructure evolution in the HAZ and its mechanical properties. This goal was achieved by an approach based on materials science principles and real-time sensing techniques. In this study, the entire welding process was divided into a series of sub-processes. Real-time multiple measurements from multiple sensors were incorporated into the sub-processes. This resulted in an integrated welding system upon which the predictions for the final HAZ microstructure are based. As part of the integrated system, the microstructural model was used to predict the TTT curves, volume fractions of the decomposition products, and hardness numbers of the heat-affected zones of steel alloys. Actual welds were performed under two different sets of conditions, and the resulting experimental data were compared with predictions made using the microstructural model. The predicted and experimental microstructure and hardness are found to be in good agreement, indicating that the microstructural model can be used in real applications. This research can act as an important component of future research to enable physics-based flexible control of welding.
This book describes the fundamentals of residual stresses in friction stir welding and reviews the data reported for various materials. Residual stresses produced during manufacturing processes lead to distortion of structures. It is critical to understand and mitigate residual stresses. From the onset of friction stir welding, claims have been made about the lower magnitude of residual stresses. The lower residual stresses are partly due to lower peak temperature and shorter time at temperature during friction stir welding. A review of residual stresses that result from the friction stir process and strategies to mitigate it have been presented. Friction stir welding can be combined with additional in-situ and ex-situ manufacturing steps to lower the final residual stresses. Modeling of residual stresses highlights the relationship between clamping constraint and development of distortion. For many applications, management of residual stresses can be critical for qualification of component/structure. Reviews magnitude of residual stresses in various metals and alloys Discusses mitigation strategies for residual stresses during friction stir welding Covers fundamental origin of residual stresses and distortion
Updated to include new technological advancements in welding Uses illustrations and diagrams to explain metallurgical phenomena Features exercises and examples An Instructor's Manual presenting detailed solutions to all the problems in the book is available from the Wiley editorial department.
Emphasizes applications of fracture mechanics to prevent fracture and fatigue failures in structures, rather than the theoretical aspects of fracture mechanics. The concepts of driving force and resistance force are used to differentiate between the mathematical side and the materials side. Case studies of actual failures are new to the third edition. Annotation copyrighted by Book News, Inc., Portland, OR
The continued use of coal as a means of generating electricity and an increasing demand for cleaner, more efficient energy production has led to advances in power plant technology. Ultra-supercritical coal power plants reviews the engineering, operation, materials and performance of ultra-supercritical coal power plants. Following a chapter introducing advanced and ultra-supercritical coal power plants, part one goes on to explore the operating environments, materials and engineering of ultra-supercritical coal power plants. Chapters discuss the impacts of steam conditions on plant materials and operation, fuel considerations and burner design, and materials and design for boilers working under supercritical steam conditions. Chapters in part two focus on improving ultra-supercritical coal power plant performance and operability. Ash fouling, deposition and slagging in ultra-supercritical coal power plants are highlighted along with pollution control measures and the estimation, management and extension of the life of ultra-supercritical power plants. Further chapters provide an economic and engineering analysis of a 700°C advanced ultra-supercritical pulverised coal power plant and discuss CO2 capture-ready ultra-supercritical coal power plants. Ultra-supercritical coal power plants is a comprehensive technical reference for power plant operators and engineers, high-temperature materials scientists, professionals in the power industry who require an understanding of ultra-supercritical coal power plants and researchers and academics interested in the field. Provides a comprehensive reference on the developments, materials, design and operation of ultra-supercritical power plant Considers the degradation issues affecting this type of plant, as well as emissions control and CO2 capture technology; improved plant controls critical to improved operation and environmental performance Contains operational assessments for plant safety, plant life management, and plant economics
Hydrogen introduced during shielded metal arc welding with cellulosic welding consumables can severely degrade the fracture resistance of the deposited weld metal and promote Weld Metal Hydrogen Assisted Cold Cracking (WM HACC), which is a particular type of weld defect with distinctive characteristics. Failure typically occurs after the deposited weld has cooled down to temperatures below 200°C and can initiate within minutes to even days after welding. Due to its time-delayed nature the onset of WM HACC may be undetected and can result in catastrophic failure. Many important properties of weld metal such as strength, toughness and the resistance to WM HACC are a function of its microstructure, comprised of diverse constituents with characteristic features and different mechanical properties, which co-exist and interact at the smallest microstructural dimensions. Hence, conventional test methods used to determine the bulk material's properties are not suitable to evaluate the intrinsic properties of its individual microstructural constituents. Because of these experimental limitations, there is a lack of understanding of microstructural aspects that control the mechanical properties and the resistance to HACC at the micro-scale. Therefore, a major objective of the current work was to address these limitations by employing advanced characterisation and micro-mechanical testing techniques to evaluate the fundamental link between microstructure, mechanical properties and HACC susceptibility for individual weld metal microstructural constituents.