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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.
Actual cooling rates for Grade 91 welds were measured for the SMAW and GTAW processes and found to be in the range of 13oC/s and 43oC/s, correspondingly. Based on these measured cooling rates and on the developed ICHAZ CCT diagram, it has been concluded that formation of ferrite in the ICHAZ of Grade 91 steel welds is possible during shielded metal arc welding. Welding parameters such as heat input, preheat and interpass temperature can be selected to ensure faster cooling rates to reduce or potentially avoid formation of ferrite in the ICHAZ. Reducing or eliminating the presence of ferrite in the ICHAZ may reduce the susceptibility of Type IV cracking in Grade 91 welds. However, further investigations are needed to clarify the potential role of ferrite in the ICHAZ on Type IV cracking in welds of creep strength enhanced ferritic steels.
Hybrid laser-arc welding (HLAW) is a combination of laser welding with arc welding that overcomes many of the shortfalls of both processes. This important book gives a comprehensive account of hybrid laser-arc welding technology and applications. The first part of the book reviews the characteristics of the process, including the properties of joints produced by hybrid laser-arc welding and ways of assessing weld quality. Part two discusses applications of the process to such metals as magnesium alloys, aluminium and steel as well as the use of hybrid laser-arc welding in such sectors as ship building and the automotive industry. With its distinguished editor and international team of contributors, Hybrid laser-arc welding is a valuable source of reference for all those using this important welding technology. Reviews arc and laser welding including both advantages and disadvantages of the hybrid laser-arc approach Explores the characteristics of the process including the properties of joints produced by hybrid laser-arc welding and ways of assessing weld quality Examines applications of the process including magnesium alloys, aluminium and steel with specific focus on applications in the shipbuilding and automotive industries
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.
Computational Welding Mechanics (CWM) provides readers with a complete introduction to the principles and applications of computational welding including coverage of the methods engineers and designers are using in computational welding mechanics to predict distortion and residual stress in welded structures, thereby creating safer, more reliable and lower cost structures. Drawing upon years of practical experience and the study of computational welding mechanics the authors instruct the reader how to: - understand and interpret computer simulation and virtual welding techniques including an in depth analysis of heat flow during welding, microstructure evolution and distortion analysis and fracture of welded structures, - relate CWM to the processes of design, build, inspect, regulate, operate and maintain welded structures, - apply computational welding mechanics to industries such as ship building, natural gas and automobile manufacturing. Ideally suited for practicing engineers and engineering students, Computational Welding Mechanics is a must-have book for understanding welded structures and recent technological advances in welding, and it provides a unified summary of recent research results contributed by other researchers.
A study of microstructure as a function of distance from the fusion line was conducted for an instrumented weld in HY-130 steel plate. Thermocouples were positioned in the plate at various distances from the fusion line and were used to obtain the welding thermal history at these locations. A correlation was then developed between the microstructures observed and the thermal history experienced. Additionally, the tempering of the heat affected zones of the initial weld passes by subsequent weld passes was calculated and correlated with hardness and microstructural data. Finally, a further study of the metallurgical notch phenomenon postulated by Brucker was undertaken. (Author).
A study of microstructure as a function of distance from the fusion line was conducted for an instrumented weld in HY-130 steel plate. Thermocouples were positioned in the plate at various distances from the fusion line and were used to obtain the welding thermal history at these locations. A correlation was then developed between the microstructures observed and the thermal history experienced. Additionally, the tempering of the heat affected zones of the initial weld passes by subsequent weld passes was calculated and correlated with hardness and microstructural data. Finally, a further study of the metallurgical notch phenomenon postulated by Brucker was undertaken. (Author).
This edited volume presents the research results of the Collaborative Research Center 1026 “Sustainable manufacturing - shaping global value creation”. The book aims at providing a reference guide of sustainable manufacturing for researchers, describing methodologies for development of sustainable manufacturing solutions. The volume is structured in four chapters covering the following topics: sustainable manufacturing technology, sustainable product development, sustainable value creation networks and systematic change towards sustainable manufacturing. The target audience comprises both researchers and practitioners in the field of sustainable manufacturing, but the book may also be beneficial for graduate students.
The papers collected in this special issue clearly reflect the modern research trends in materials science. These fields of specific attention are high-Mn TWIP steels, high-Cr heat resistant steels, aluminum alloys, ultrafine grained materials including those developed by severe plastic deformation, and high-entropy alloys. The major portion of the collected papers is focused on the mechanisms of microstructure evolution and the mechanical properties of metallic materials subjected to various thermo-mechanical, deformation or heat treatments. Another large portion of the studies is aimed on the elaboration of alloying design of advanced steels and alloys. The changes in phase content, transformation and particle precipitation and their effect on the properties are also broadly presented in this collection, including the microstructure/property changes caused by irradiation.