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.

Advanced instrumentation combined with effective test procedures gives manufacturers an edge in measuring and analyzing welds.

This article identifies several factors that are not fully addressed in most fracture toughness test standards and explains how they may influence calculated values obtained from ferritic steels. Of particular consequence are test temperatures within the ductile-to-brittle transition regime and test specimen geometries when measuring the toughness of weld metal and heat-affected zones.

Compared to traditional power plant materials, creep strength enhanced ferritic steels require new approaches to nondestructive examination and weld repair. The metallurgical complexity of these steels prompted EPRI to conduct research to define and/or improve the detection limits of ultrasonic testing techniques, explore novel electromagnetic techniques, evaluate the sensitivity and applicability of acoustic emission testing, and conduct studies on improved weld repair procedures.

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.

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.

Phase coherence imaging is a new approach for processing ultrasonic signals generated during nondestructive testing. This article shows how it compares with amplitude-based focusing methods for detecting hydrogen-related microfissures, creep-induced damage, and stainless-steel weld voids.

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.

A new design and welding process may extend the life of furnace rolls in hot-dip coating lines, which often fail in less than one year. This article is a case study of analysis of a failed furnace roll that led to a proposed improved design to extend component 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.

Launching an aluminum vehicle into production is a far greater challenge than building a fleet of prototypes. This installment in the series reviews progress made in the 1990s.

During the past 30 years, enormous research has been devoted to developing titanium-base intermetallics for use in gas turbine engines as lightweight alternative to nickel-base superalloys. This article presents a brief history of Ti 2 AlNb and efforts to mature this material for commercial component production. The article includes processing experience insights gained from a current R&D program in China.

From its earliest beginnings to today, hardness testing has evolved in a parallel manner to the engineering innovations of the times.

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.

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.

A new solid-state joining process for medical guidewire applications increases joint strength, provides superior bending properties, and does not require tertiary metals or ferrules. This process may be a superior method to create joints between dissimilar metals such as stainless steel and Nitinol.

This article describes the investigation conducted by the National Transportation Safety Board following an explosion triggered by a natural gas pipeline rupture. In addition to determining the likely cause of the rupture, the NTSB issued safety recommendations calling for hydrostatic pressure testing of similar gas lines and making them more amenable to inline inspection methods.

This article discusses the development of a new metallographic technique to identify defects in aluminum alloy joints produced by friction stir welding. This method won the Jacquet-Lucas Award for Excellence in Metallography at the International Metallographic Contest held during MS&T in Pittsburgh, October 2017.

Orion’s Exploration Flight Test 1 vehicle used four additively manufactured vent assemblies to equalize pressure between unpressurized portions of the spacecraft and the external environment.

Several key materials processes and techniques positively impact weight reduction and reusability of parts designed for travel to the moon, Mars, and beyond. This article addresses how advances in technologies such as additive manufacturing, friction stir welding, and surface analysis, can help further enhance design and fabrication of space systems.