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fusion welding
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290079
EISBN: 978-1-62708-306-5
... Abstract This chapter discusses the fusion welding processes, namely oxyfuel gas welding, oxyacetylene braze welding, stud welding (stud arc welding and capacitor discharge stud welding), high-frequency welding, electron beam welding, laser beam welding, hybrid laser arc welding, and thermit...
Abstract
This chapter discusses the fusion welding processes, namely oxyfuel gas welding, oxyacetylene braze welding, stud welding (stud arc welding and capacitor discharge stud welding), high-frequency welding, electron beam welding, laser beam welding, hybrid laser arc welding, and thermit welding.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290099
EISBN: 978-1-62708-306-5
... Abstract During fusion welding, the thermal cycles produced by the moving heat source causes physical state changes, metallurgical phase transformations, and transient thermal stresses and metal movement. This chapter begins by discussing weld metal solidification behavior and the solid-state...
Abstract
During fusion welding, the thermal cycles produced by the moving heat source causes physical state changes, metallurgical phase transformations, and transient thermal stresses and metal movement. This chapter begins by discussing weld metal solidification behavior and the solid-state transformations of the main classes of metals and alloys during fusion welding. The main classes include work- or strain-hardened metals and alloys, precipitation-hardened alloys, transformation-hardened steels and cast irons, stainless steels, and solid-solution and dispersion-hardened alloys. The following section provides information on the residual stresses and distortion that remain after welding. The focus then shifts to distortion control of weldments. Inclusions and cracking are discussed in detail. The chapter also discusses the causes for reduced fatigue strength of a component by a weld: stress concentration due to weld shape and joint geometry; stress concentration due to weld imperfections; and residual welding stresses. Inspection and characterization of welds are described in the final section of this chapter.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280149
EISBN: 978-1-62708-267-9
... decisions. It discusses the basic concepts of fusion welding and the differences between solid-solution-hardened and precipitation-hardened wrought superalloys. It addresses joint integrity, design, weld-related cracking, and the effect of grain size, precipitates, and contaminants. It covers common fusion...
Abstract
Superalloys, except those with high aluminum and titanium contents, are welded with little difficulty. They can also be successfully brazed. This chapter describes the welding and brazing processes most often used and the factors that must be considered when making application decisions. It discusses the basic concepts of fusion welding and the differences between solid-solution-hardened and precipitation-hardened wrought superalloys. It addresses joint integrity, design, weld-related cracking, and the effect of grain size, precipitates, and contaminants. It covers common fusion welding techniques, defect prevention, fixturing, heat treatments, and general practices, including the use of filler metals. It also discusses several solid-state welding methods, superplastic forming, and transient liquid phase bonding, a type of diffusion welding process. The chapter includes extensive information on brazing processes, atmospheres, filler metals, and surface preparation procedures. It also includes examples of nickel-base welded components for aerospace use.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290001
EISBN: 978-1-62708-306-5
... examining the various joining processes, namely fusion welding, solid-state welding, brazing, soldering, mechanical fastening, and adhesive bonding. In addition, it provides information on several design considerations related to the joining process and selection of the appropriate process for joining...
Abstract
Joining comprises a large number of processes used to assemble individual parts into a larger, more complex component or assembly. The selection of an appropriate design to join parts is based on several considerations related to both the product and the joining process. Many product design departments now improve the ease with which products are assembled by using design for assembly (DFA) techniques, which seek to ensure ease of assembly by developing designs that are easy to assemble. This chapter discusses the general guidelines for DFA and concurrent engineering rules before examining the various joining processes, namely fusion welding, solid-state welding, brazing, soldering, mechanical fastening, and adhesive bonding. In addition, it provides information on several design considerations related to the joining process and selection of the appropriate process for joining.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290137
EISBN: 978-1-62708-306-5
... weld zone. When metallurgical reactions occur, they can either benefit or adversely affect the properties of the joint. From a metallurgical perspective, the application of both fusion welding and solid-state welding processes must be evaluated using appropriate weldability testing methods for their...
Abstract
Solid-state welding processes are those that produce coalescence of the faying surfaces at temperatures below the melting point of the base metals being joined without the addition of brazing or solder filler metal. This chapter discusses solid-state welding processes such as diffusion welding, forge welding, roll welding, coextrusion welding, cold welding, friction welding, friction stir welding, explosion welding, and ultrasonic welding.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290023
EISBN: 978-1-62708-306-5
... welding gas metal arc welding plasma arc welding plasma-GMAW welding shielded metal arc welding shielding gases submerged arc welding FUSION WELDING PROCESSES involve localized melting and solidification and are normally used when joining similar material combinations or materials belonging to...
Abstract
Arc welding applies to a large and diversified group of welding processes that use an electric arc as the source of heat to melt and join metals. This chapter provides a detailed overview of specific arc welding methods: shielded metal arc welding, flux cored arc welding, submerged arc welding, gas metal arc welding, gas tungsten arc welding, plasma arc welding, plasma-GMAW welding, electroslag welding, and electrogas welding. The basic characteristics of gases used for shielding during arc welding are briefly discussed.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290061
EISBN: 978-1-62708-306-5
... cause melting (or fusion) in any metal or alloy and can do so very quickly. When the flow of current ceases, the electrode force is maintained while the weld metal rapidly cools and solidifies. The electrodes are retracted after each weld, which usually is completed in a fraction of a second. The...
Abstract
Resistance welding is a group of processes in which the heat for welding is generated by the resistance to the flow of an electrical current through the parts being joined. This chapter discusses the processes, advantages, and limitations of specific resistance welding processes, namely resistance spot welding, resistance seam welding, projection welding, flash welding, and upset welding.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.tb.ssde.t52310201
EISBN: 978-1-62708-286-0
... microsegregation in the fusion zone with increasing alloy content. There are thermodynamically metastable conditions due to the low diffusion rates in the face-centered cubic (fcc) matrix. The influence of carbon has been well addressed using low-carbon versions of all grades whenever welding involves...
Abstract
This chapter provides a basis for understanding the influence of stainless steel alloy composition and metallurgy on the welding process, which involves complex dynamics associated with melting, refining, and thermal processing. It begins with an overview of the welding characteristics of the categories of stainless steels, namely austenitic, duplex, ferritic, martensitic, and precipitation-hardening stainless steels. This is followed by a discussion of the selection criteria for materials to be welded. Various welding processes used with stainless steel are then described. The chapter ends with a section on some of the practices to ensure safety and weld quality.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290279
EISBN: 978-1-62708-306-5
... the joint should be considered. However, when dissimilar metals are joined by fusion welding processes, alloying between the base metals and a filler metal, when used, becomes a major consideration. The resulting weld metal can behave much differently from one or both base metals during subsequent...
Abstract
This chapter reviews materials issues encountered in joining, including challenges involved in welding of dissimilar metal combinations; joining of plastics by mechanical fastening, solvent and adhesive bonding, and welding; joining of thermoset and thermoplastic composite materials by mechanical fastening, adhesive bonding, and, for thermoplastic composites, welding; the making of glass-to-metal seals; and joining of oxide and nonoxide ceramics to themselves and to metals by solid-state processes and by brazing. The classification, types, applications, and the mechanism of each of these methods are covered. The factors influencing joint integrity and the main considerations in welding dissimilar metal combinations are also discussed.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130503
EISBN: 978-1-62708-284-6
.... By far, the most common steel welding problems are associated with poor workmanship, such as lack of fusion, lack of penetration, porosity, undercut, arc strikes, and others. The number and size of such discontinuities may be cause for rejection by most codes and can act as stress-concentration sites...
Abstract
Failure analysis of steel welds may be divided into three categories. They include failures due to design deficiencies, weld-related defects usually found during inspection, and failures in field service. This chapter emphasizes the failures due to various discontinuities in the steel weldment. These include poor workmanship, a variety of hydrogen-assisted cracking failures, stress-corrosion cracking, fatigue, and solidification cracking in steel welds. Hydrogen-assisted cracking can appear in four common forms, namely underbead or delayed cracking, weld metal fisheyes, ferrite vein cracking, and hydrogen-assisted reduced ductility.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2013
DOI: 10.31399/asm.tb.imub.t53720411
EISBN: 978-1-62708-305-8
... root of a weld joint to support molten weld metal Shrinkage voids: Cavity-type discontinuities normally formed by shrinkage during solidification Oxide inclusions: Particles of surface oxides that have not melted and are mixed into the weld metal Incomplete fusion (also known as lack of...
Abstract
Weldments made by the various welding processes may contain discontinuities that are characteristic of that process. This chapter discusses the different welding processes as well as the discontinuities typical of each process. It provides a detailed discussion on the methods of nondestructive inspection of weldments including visual inspection, liquid penetrant inspection, magnetic particle inspection, radiographic inspection, ultrasonic inspection, leak testing, and eddy current and electric current perturbation inspection. The chapter also describes the properties of brazing filler metals and the types of flaws exhibited by brazed joints.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740325
EISBN: 978-1-62708-308-9
... paint by their inorganic composition and the fusion of the coating matrix to the substrate metal. Porcelain enamels of all compositions are fired at 425 °C (800 °F) or above. The basic material of the porcelain enamel coating is called a frit, which is a special glass of small friable particles produced...
Abstract
This chapter covers a wide range of finishing and coating operations, including cleaning, honing, polishing and buffing, and lapping. It discusses the use of rust-preventative compounds, conversion coatings, and plating metals as well as weld overlay, thermal spray, and ceramic coatings and various pack cementation and deposition processes. It also discusses the selection and use of industrial paints and paint application methods.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280211
EISBN: 978-1-62708-267-9
... effect of coating and welding processes. chemical composition creep-rupture properties microstructure physical properties precipitation hardening superalloys tensile properties solution heat treatment directional solidification...
Abstract
This chapter examines the effect of heat treating and other processes on the microstructure-property relationships that occur in superalloys. It discusses precipitation and grain-boundary hardening and how they influence the phases, structures, and properties of various alloys. It explains how the delta phase, which is used to control grain size in IN-718, improves strength and prevents stress-rupture embrittlement. It describes heat treatments for different product forms, discusses the effect of tramp elements on grain-boundary ductility, and explains how section size and test location influence measured properties. It also provides information and data on the physical and mechanical properties of superalloys, particularly tensile strength, creep-rupture, fatigue, and fracture, and discusses related factors such as directionality, porosity, orientation, elongation, and the effect of coating and welding processes.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130001
EISBN: 978-1-62708-284-6
... performance of the design process of a component. A heat-transfer model, coupling with a phase transformation model, a thermomechanical model, and a thermochemical model, is also considered. The chapter further provides information on the failure aspects of and heat treatment procedures applied to welded...
Abstract
A systematic procedure for minimizing risks involved in heat treated steel components requires a combination of metallurgical failure analysis and fitness for service with respect to safety and reliability based on risk analysis. This chapter begins with an overview of heat treat processing of steels. This is followed by sections on various aspects of heat treatment design and heat treating practices for minimizing distortion. Influence of design, steel grade, and condition is then illustrated in the examples of failures due to heat treatment. A procedure is analyzed to improve the performance of the design process of a component. A heat-transfer model, coupling with a phase transformation model, a thermomechanical model, and a thermochemical model, is also considered. The chapter further provides information on the failure aspects of and heat treatment procedures applied to welded components. It ends with a section on risk-based approach applicable to heat treated steel components.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2001
DOI: 10.31399/asm.tb.aub.t61170351
EISBN: 978-1-62708-297-6
... article also explains how primary alloying elements affect corrosion and wear behaviors and how they influence fabrication processes such as forming, forging, welding, brazing, and soldering. alloying elements aluminum alloys corrosion behavior wear behavior Composition Cast aluminum alloys...
Abstract
This article discusses the composition, structures, properties, and behaviors of aluminum alloys and explains how they correspond to specific alloying elements. It begins with an overview of the general characteristics of wrought and cast aluminum alloys, the four-digit classification system by which they are defined, and the applications for which they are suited. It then explains how primary alloying elements, second-phase constituents, and impurities affect yield strength, phase formation, and grain size and how they induce structural changes that help refine certain alloys. The article also explains how primary alloying elements affect corrosion and wear behaviors and how they influence fabrication processes such as forming, forging, welding, brazing, and soldering.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870183
EISBN: 978-1-62708-314-0
..., thermoplastic composites can be joined by melt fusion, dual resin bonding, resistance welding, ultrasonic welding, or induction welding, as well as by conventional adhesive bonding and mechanical fastening. In general, structural bonds using thermoset such as epoxy adhesives produce...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280203
EISBN: 978-1-62708-267-9
... fusion welding or solid-state bonding to remove residual smut, which can cause poor-quality weldments. There is less need for pickling prior to arc, electron beam, or other fusion welding, unless an inspection of the test weldments reveals porosity or inclusions that are a result of pickup from the...
Abstract
Superalloys are susceptible to damage from a variety of surface contaminants. They may also require special surface finishes for subsequent processing steps such as coating applications. This chapter describes some of the cleaning and finishing procedures that have been developed for superalloys and how they work. It discusses the effect of metallic contaminants, tarnish, oxide, and scale and how they can be detected and removed. It also discusses chemical and mechanical surface finishing techniques and where they are used, and presents several application examples.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 1999
DOI: 10.31399/asm.tb.lmcs.9781627082914
EISBN: 978-1-62708-291-4
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2012
DOI: 10.31399/asm.tb.lmub.t53550223
EISBN: 978-1-62708-307-2
... Machining of cast structures or mill products is required, and welding invariably is needed in casting repair or buildup of structures from castings or mill products. Powder metallurgy processing is used for some applications. At each of these steps, the mechanical and physical properties of the titanium in...
Abstract
Titanium is a lightweight metal used in a growing number of applications for its strength, toughness, stiffness, corrosion resistance, biocompatibility, and high-temperature operating characteristics. This chapter discusses the applications, metallurgy, properties, compositions, and grades of commercially pure titanium and alpha and near-alpha, alpha-beta, and beta titanium alloys. It describes primary and secondary fabrication processes, including melting, forging, forming, heat treating, casting, machining, and joining as well as powder metallurgy and direct metal deposition. It also compares and contrasts the properties of wrought, cast, and powder metal titanium products and discusses corrosion behaviors.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2012
DOI: 10.31399/asm.tb.lmub.t53550033
EISBN: 978-1-62708-307-2
... alloys can be difficult to fusion weld. The copper content in some of the 2 xxx and 7 xxx alloys makes them susceptible to weld cracking during fusion welding operations. Fig. 2.1 Fatigue strength comparison for aluminum. Source: Ref 2.1...
Abstract
This chapter provides basic engineering information on aluminum alloys with an emphasis on their use in applications where weight is a significant design factor. It discusses the advantages and limitations of various types of aluminum along with their compositions, designations, and achievable strengths. It explains how some alloys are hardened through solution strengthening and cold working, while others are strengthened by precipitation hardening. It also describes production and fabrication processes such as melting, casting, rolling, forging, forming, extruding, heat treating, and joining, and includes a section on the causes and effects of corrosion and how they are typically controlled.