In the quest to improve the reliability of partial penetration welding validation, advanced ultrasonic testing techniques have replaced other less accurate methods. This case study compares weld penetration inspection results from phased array ultrasonic testing and the total focusing method in a rib-to-deck assembly on the top part of an orthotropic steel bridge deck.

This guide outlines recent advances in the various methods of laser technology and appropriate manufacturing applications. Each process has unique requirements and matching the laser source to the project is essential for developing a robust solution.

A novel approach in the field of narrow gap laser welding produces superior weld joint quality, especially the configuration of weld toe, which has a positive effect on fatigue life.

This article describes research leading to the development of a new grade of low temperature bainitic steels, named Kinetically Activated Bainite (KAB) steels. with exceptionally rapid transformation kinetics at temperatures below 200°C. This entry won the Jacquet-Lucas Award for Best in Show at the 2015 International Metallographic Contest.

A new welding process known as hybrid induction arc welding (HIAW) or high deposition arc welding (HiDep) uses a hybrid approach to reduce—or even eliminate—weld distortion and greatly increase productivity. Operating directly in front of the arc welding torch, a portable induction coil heats the surfaces of the weld to, or near, the melting point. Heat generated by the welding arc is primarily used to melt the welding wire. This novel process operates at speeds two to four times faster than conventional arc welding and substantially reduces weld distortion.

Typical vehicles contain more than 3000 spot welds, and failure parameters for these welds must be accurately predicted in crash simulations. A testing protocol developed at EWI for the purpose of creating spot weld failure parameters has been used since 2010 to establish these parameters for automotive manufacturers for a range of steel and aluminum stack-ups. Crash simulations in full-vehicle models show that the failure parameters created by this method are accurate for predicting the initiation of spot weld failure by comparing results with experimental data.

Automobile performance and passenger safety both rely on sound spot welds in advanced high-strength steels. A new, high-frequency ultrasonic matrix phased array probe performs nondestructive inspection of these welds, saving time and cost.

This article describes how shielding gas composition, either argon or nitrogen, affects the hardness, tensile strength, and toughness of high-power, high-brightness laser welds made on various base materials, including A508 forging steel, 316L stainless steel, Inconel 690, and solution-annealed IN718.