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resistance welding

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Published: 01 June 2019
Fig. 1 Resistance-welded 4615 steel chain link that broke because of a weld defect. (a) A fracture surface of the chain link showing fatigue beach marks (arrow) progressing across the surface from the inside of the link. (b) Nital-etched longitudinal section through the link showing fracture More
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001116
EISBN: 978-1-62708-214-3
...-appearing microstructures, one of which is cracked. Nital etch. 200×. Fig. 8 Closeup view of cracking (arrows) in a band of hard microstructure. Nital etch. 500×. Abstract Two failures of AP15A grade J-55 electric resistance welded (ERW) tubing in as our gas environment were investigated...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0047681
EISBN: 978-1-62708-229-7
... Abstract A fluorescent liquid-penetrant inspection of an experimental stator vane of a first-stage axial compressor revealed the presence of a longitudinal crack over 50 mm (2 in.) long at the edge of a resistance seam weld. The vane was made of titanium alloy Ti-6Al-4V (AMS 4911). The crack...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048048
EISBN: 978-1-62708-224-2
... Abstract A resistance-welded chain link made from 16 mm diam 4615 steel failed while lowering a 9070 kg load of billets into a rail car after being in service for 13 months. Beach marks, typical of fatigue were found to have originated at the inside of the link which broke at the weld. Cracks...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001909
EISBN: 978-1-62708-235-8
... Abstract Welded low-carbon steel bomb fins were rejected because of poor weld practice. Visual and metallographic examination revealed that the resistance plug welds that attach the outer skin to the inner spar displayed inadequate weld penetration. Recommended changes to the resistance welding...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c9001567
EISBN: 978-1-62708-230-3
... extended radially from the electric resistant weld into the base metal. Metallographic examination revealed the cracks were transgranular and branching, characteristic of SCC in austenitic stainless steels. The fracture surfaces had a brittle cleavage-like appearance, typical of SCC in austenitic stainless...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001603
EISBN: 978-1-62708-228-0
... Abstract The genesis of failure of 6.1 mm thick electric resistance welded API 5L X-46 pipes during pretesting at a pressure equivalent to 90% of specified minimum yield strength was investigated. Cracks were found to initiate on the outer surface of the pipes in the fusion zone and propagate...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0048318
EISBN: 978-1-62708-234-1
... Abstract A resistance-welded carbon steel superheater tube made to ASME SA-276 specifications failed by pitting corrosion and subsequent perforation, which caused the tube to leak. The perforation was found to have occurred at a low point in a bend near the superheater outlet header...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047673
EISBN: 978-1-62708-217-4
... Abstract A series of resistance spot welds joining Z-shape and C-shape members of an aircraft drop-tank structure failed during ejection testing. The members were fabricated of alclad aluminum alloy 2024-T62. The back surface of the C-shape members showed severe electrode-indentation marks off...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001823
EISBN: 978-1-62708-241-9
... X46 line pipe steel, approximately 22 cm (8.7 in.) OD x 0.5 cm (0.2 in.) wall thickness, which was electric resistance welded along the longitudinal seam. The pressure at the time and location of the failure was 2760 kPa, which corresponds to 20% of the specified minimum yield strength. The cause...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001156
EISBN: 978-1-62708-218-1
... stresses in normal service these cracks propagated through the piston rod made less tough by the extended weld heat-affected zone. Heat affected zone Piston rods Resistance welding Welded joints Welded steel Joining-related failures Fatigue fracture The piston rod of a steering damper...
Image
Published: 01 June 2019
Fig. 1 Micrograph showing shear failure of a resistance plug weld (1× magnification) More
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047935
EISBN: 978-1-62708-225-9
... used grease was nonconductive. It was concluded that the pits were formed by momentary welding between the ball and ring surfaces. The lubricant was replaced by electrically conductive grease as a corrective measure. Lubricants Melting Resistivity Welding 440C UNS S44004 (Other...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047677
EISBN: 978-1-62708-217-4
... Abstract Resistance spot welds joining aluminum alloy 2024-T8511 stiffeners to the aluminum alloy 6061-T62 skin of an aircraft drop tank failed during slosh and vibration testing. Visual examination of the fracture surfaces showed that the failure was by tensile or bending overload...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001134
EISBN: 978-1-62708-214-3
... of material and identification of heat treatment, showed no indications of the resistance weld or of processing defects because of manufacturing. Hardness values, while possibly in excess of the recommended norm, did not indicate extensive cold work that would indicate abuse. The carburized case...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001820
EISBN: 978-1-62708-180-1
...-hardness region (b) (a) Electric flash welding, electric-resistance welding, or electric-induction welding without the addition of extraneous metals. (b) These arc a problem in gathering lines carrying sour gas (gas containing H 2 S). Causes of Preservice Test Failures As shown...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006822
EISBN: 978-1-62708-329-4
... Electric resistance weld flaws Flash weld flaws Furnace butt weld flaws Hook cracks Cold welds Incomplete fusion Stitching Inclusions Shielded metal arc welding flaws Gas metal arc welding flaws Submerged arc welding flaws Misalignment Porosity Incomplete fusion Incomplete...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001612
EISBN: 978-1-62708-218-1
... Abstract The fan used to cool a diesel engine fractured catastrophically after approximately 100 h of operation. The fan failed at a spider, which was resistance spot welded to a shim placed between two circular spiders of 3 mm thickness. The detailed analysis of the fracture indicated...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003509
EISBN: 978-1-62708-180-1
... that, although the wrought form of a metal or alloy is resistant to corrosion in a particular environment, the welded counterpart is not. Conversely, there are also many instances in which the weld exhibits corrosion resistance superior to that of the unwelded base metal. There also are times when the weld...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001609
EISBN: 978-1-62708-229-7
... of its resistance to chloride and sulfuric acid dewpoint corrosion under conditions potentially present in the HRSG low-pressure feedwater economizer. Intergranular corrosion and cracking were found in the weld metal and heat-affected zones. The hardness in these regions was up to 35 HRC, and the weld...