Trends in Welding Research: Proceedings of the 6th International Conference, Callaway Gardens Resort, Phoenix, Arizona Usa, 15-19 April 2002 PDF
Preview Trends in Welding Research: Proceedings of the 6th International Conference, Callaway Gardens Resort, Phoenix, Arizona Usa, 15-19 April 2002
Trends in Welding Research Proceedings ofthe 6th International Conference Callaway Gardens Resort Phoenix, Arizona USA, 15-19 April 2002 Sponsored by TheMaterials InformatloRSociety ASM Intemational® Materials Park, OH 44073-0002 www.asmintemational.org Copyright © 2003 by ASM International® Allrightsreserved No part ofthisbook may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. Firstprinting, January2003 Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITYOR FITNESSFORAPARTICULARPURPOSE, ARE GIVENINCONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use ofthis publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions ofproduct or material use are outsideofASM's control, ASMassumesnoliability orobligation inconnectionwithanyuse ofthis information.No claimofanykind, whether astoproductsorinformationinthispublication, andwhetherornotbased onnegligence, shall be greater in amount than the purchase price ofthis product or publication in respect ofwhich damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. Aswithanymaterial, evaluation ofthe material under end-use conditionsprior tospecificationisessential. Therefore,specifictestingunder actualconditions isrecommended. Nothing contained inthis book shallbe construed as agrant ofany right ofmanufacture, sale,use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letterspatent,copyright, ortrademark,andnothing contained inthisbook shallbeconstrued asadefenseagainstany allegedinfringement ofletters patent,copyright,ortrademark,orasadefense againstliabilityforsuchinfringement. Comments,criticisms, andsuggestionsareinvited,andshouldbe forwarded toASMInternational. ISBN:0-87170-780-2 SAN:204-7586 ASMInternational® MaterialsPark,OH44073-0002 www.asminternational.org PrintedintheUnitedStatesofAmerica Multiplecopyreprints ofindividualarticlesareavailablefromTechnical Department,ASM International. Conference Co-Chairmen Dr.StanA.David,FASM OakRidge National Laboratory Oak Ridge,Tennessee Dr.TarasankarDebRoy,FASM The Pennsylvania StateUniversity UniversityPark,Pennsylvania Prof.JohnC.Lippold,FASM The Ohio StateUniversity Columbus, Ohio Dr.HerschelB.Smartt IdahoNationalEngineeringandEnvironmental Laboratory(INEEL) Idaho Falls,Idaho Dr.JohnM. Vitek,FASM OakRidge National Laboratory Oak Ridge,Tennessee International Organizing Committee Prof.HarryK. D.H. Bhadeshia Prof.Hugh W. Kerr University ofCambridge University ofWaterloo GreatAbington, Cambridge, UnitedKingdom Waterloo, Ontario, Canada Prof.HorstCerjak Dr.Mustafa Kocak GrazUniversity ofTechnology Institute ofMaterials Research Graz, Styria,Austria Geesthacht, Hamburg, Germany Dr.Richard Dolby Prof.K. S.SreenivasaMurthy TWI, Ltd. Indian Institute ofScience GreatAbington, Cambridge, UnitedKingdom Bangalore, India Prof.ThomasW. Eagar,FASM Ms. MarieAQuintana Massachusetts Institute ofEngineering TheLincoln Electric Company Cambridge, Massachussetts Cleveland, Ohio Mr.Ted Ford Mr.ChrisSmallbone Edison Welding Institute WeldingTechnologyInstitute ofAustralia Columbus, Ohio Silverwater, Australia Dr.RobertJ.Gottschall,FASM Dr. Nobutaka Yurioka U. S.Department ofEnergy Nippon Steel Corporation Germantown, Maryland Chiba,Japan Dr.TarsemJutla Dr.SergioD.Brandi Caterpillar, Inc. University ofSaoPaulo Peoria, Illinois SaoPaulo, Brazil iii Preface The 6thInternationalConferenceon Trendsin WeldingResearch(TWR) washeldattheCallowayGardens Resort inPineMountain, Georgia (USA),April 15-19, 2002. Sponsored byASMInternational,®theconference wasaresoundingsuccess with270delegates inattendance representing22 countries around theglobe. Theideal weather andrelaxing venueweretheperfect complementstotheweek'sexcellent technical program, comprising both oralandposterpresentations. A highlight ofthis year'sconference wasthe Trevor GoochStainlessSteelSymposium held inhonor ofthelateDr. Trevor Gooch forhisoutstanding contributiontowelding ofstainless steels. The symposium featured 18 presentationsin3technical sessionsanddrew veryhigh attendance. For over30years, wehave substantially expanded ourunderstandingofthewelding metallurgyprinciples ofstainless steels. During histenure atThe Welding Institute inCambridge (UK),Dr.Gooch was acentralfigure and motivational forceinthe development of thisunderstanding. TheTWR conferencehas awell-deserved reputationforbeing theonlyevent ofitskindthatattracts theworld's leading welding researchers; andthisyearwasnoexception. Weproudlyfeatured seven world-renownedexpertsin welding science andtechnologyaskeynotepresenters. Throughouttheweek, our international delegates enjoyed somethirty-two technical sessions covering recent and innovative developments inthe fieldofwelding science andtechnology, characterized bytheintegrationof modeling andexperimentsacrossanumber ofdisciplines toyieldamore comprehensive picture ofthewelding process. Topics covered includedtransport phenomena; solidification andphase transformation; advanced techniques tocharacterizeweldedstructures; laser welding; advanced processes includinghybrid welding; welding consumables; weldability; properties ofweldments; sensing, controland automation; andresidual stress modeling andmeasurement. Ofspecial interestwerethe sessions onfriction stirwelding. Thelargenumber ofpapers presented andhigh session attendance wereclear indications ofthegrowing interest inthisrelatively new welding technique. Another session ofspecialinterest was oninternational welding research, whererepresentativesfrom Australia, Europe, andtheUnited Statesdiscussed potential internationalcollaborations inwelding science, and hosted anexciting panel discussion. The consensus ofthe sponsors, organizers andmost importantly, theattendees isthatthe 6thInternational Conference onTrends inWeldingResearch wasperhapsthemostsuccessful intheseries sofar. Plans arecurrently underway tohold the7thTWR conference in2005. v Theconferencechairmenwouldliketothankthe organizersand speakersforthe technicalexcellenceofthe conference. Our specialthankstothe ASM staffand Shirin BadlaniofOakRidgeNationalLaboratoryfor their administrationofthe event. Thanksare also extendedtotheDivisionofMaterialsSciencesand Engineering, OfficeofBasic EnergySciences,U.S. DepartmentofEnergy; theOakRidgeNationalLaboratory;theIdaho NationalEngineeringand EnvironmentalLaboratory;The Ohio State University;andThe PennsylvaniaState University, fortheir encouragementand support. Respectfully, Stan A.David TarasankarDebRoy John C.Lippold Herschel B. Smartt JohnM. Vitek 2002 Co-Chairmen 6thInternationalConferenceonTrendsinWelding Research (L-R: Dr.JohnC Lippold,FASM,TheOhioStateUniversity;Dr.Stan A.David, FASM,Oak RidgeNational Laboratory; Dr.Herschel B. Smartt, INEEL;Dr.JohnM.Vitek, FASM,OakRidgeNational Laboratory, andDr.TarasankarDebRoy,FASM,ThePennsylvania StateUniversity.) vi Contents TREVORGOOCHSTAINLESSSTEELSYMPOSIUM KEYNOTEADDRESS RecentDevelopmentsin theUnderstandingofStainlessSteelWeldingMetallurgy•••••••••••••••••••••••••1 J. C.Lippold.TheOhioStateUniversity, Columbus. Ohio Tailoringthe PhaseBalanceDuringLaserand GTAKeyholeWeldingofSAF2205Duplex StainlessSteel••••11 K.Baughn,HoneywellFederalManufacturing& Technology. KansasCity, Missouri N.Ahmed,L.Jarvis,D. Viano, CSIROManufacturingScienceand Technology. Woodville, Australia PittingCorrosionResistanceofDuplex StainlessSteelsMultipassWelds ••••••••••••••••••••••••••••••••17 C.P.Serna,B.N.Alonso-Falleros,S.D.Brandi.UniversityofSiloPaulo,SiloPaulo,Brazil A.J. Ramirez,TheOhioStateUniversity, Columbus. Ohioand UniversityofSiloPaulo.Silo Paulo,Brazil Investigationofthe Kineticsofthe Ferrite/AustenitePhase Transformationinthe HAZofa2205Duplex StainlessSteelWeldment 23 T. A.Palmer.J. W.Elmer.J. Wong, LawrenceLivermoreNationalLaboratory, Livermore,California S.S.Babu,J. M Vitek. OakRidgeNationalLaboratory, OakRidge,Tennessee Effect ofGTAW Flux on the Microstructureand PropertiesofAustenitic,SuperAusteniticAnd Super DuplexStainlessSteelWelds 29 N.D.Ames,M Q.Johnson,EdisonWeldingInstitute, Columbus, Ohio J. C.Lippold,TheOhioStateUniversity. Columbus, Ohio Columnar-to-EquiaxedTransitionDuringSolidificationofSteelWelds ••••••••••••••••••••.••••••••••••35 T. Koseki, H.Inoue,A.Nogami, NipponSteelCorporation, Futtsu, Chiba, Japan Y. Fukuda, NSSolutionsCorporation, Futtsu,Chiba, Japan AnalysisofAutogenousGas TungstenArc and LaserWeldingofSuperausteniticStainlessSteels for NavalCombatantHulls 41 J. L.Kalp,M.E. Wells, NavalSurfaceWarfare Center, WestBethesda,Maryland LaserWeldingofSuperausteniticStainlessSteels ••••••••••••••••••••••••••••••••••••••••••••••••••••47 M J.Perricone, J.N.Duront, LehighUniversity, Bethlehem. Pennsylvania PredictionofSolidificationMode and HotCrackingSusceptibilityin LaserWelds ofHigh Nitrogen Stainless Steels•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.•53 K.Nishimoto, H.Mori,OsakaUniversity. Suita,Osaka,Japan HAZ PropertiesofHighNitrogenAusteniticStainlessSteel•••••••••••••••••••••••••••••••••••••••••••59 Y. Sato,T. Shiotsu,K.Uegami, OsakaCityUniversity, Sumiyoshi-ku, Osaka. Japan Y. Kikuchi.OsakaUniversity, Ibaraki, Osaka,Japan Ductility-DipCrackingSusceptibilityofAusteniticAlloys••••••••••••••••••••••••••••••••••••••••.••••64 N.E.Nissley, J. C.Lippold.TheOhioStateUniversity. Columbus. Ohio FatigueCrackPropagationofStainless SteelWelds •••••••••••••••••••••••••••..•••••••••••••••••••••70 C.S.Kusko,J.N.DuPont,A.R.Marder. LehighUniversity, Bethlehem,Pennsylvania Hot CrackingResistanceofLaserand Hybrid WeldedAusteniticStainlessSteels•••••••••••••••••••••••.•76 H.Schobbert, Th. Bbellinghaus, M Wolf, FederalInstitutefor MaterialsResearchand Testing, Berlin. Germany vii ImprovedModels for PredictingFerriteContentinStainlessSteel Welds••••••••••••••••••••.•••••••••••82 J.M Vitek, S.A.David. OakRidgeNationalLaboratory, OakRidge.Tennessee ProgressinJoiningAusteniticStainless SteelsbyFrictionStirWelding•••••••••••••••••••••••••••••••• 88 R.Johnson. P.L.Threadgill, TWI, Ltd.,Cambridge. UnitedKingdom Effect ofTwin-InducedGrainBoundaryEngineeringonIntergranularCorrosioninAusteniticStainless Steel........................................................................................ 93 M Shimada, H.Kokawa, Z.J. Wang, Y. S.Sato, Tohoku University. Sendai, Japan EffectofCTE on FatigueCrackingofStainless SteelVessels•••••••••••••.•••••••••.••••••.••....•••••99 c: E.L.Bird.T.M Mustaleski, BWXTY-12, L.L. OakRidge,Tennessee HEAT TRANSFER,FLUID FLOWANDMASSTRANSFER KEYNOTEADDRESS Recent Developmentsin TransportPhenomenainFusion Welding •••••••••.••••••••••••••••••••••••••104 S.Kou,UniversityofWisconsin. Madison. Wisconsin LaserWeldKeyholeDynamics 112 M.H. Cho, D.F.Farson. B.Zoofan, TheOhioStateUniversity. Columbus, Ohio J. Y. Lee.C.D. Yoo. KAIST, Taejon, Korea ComputerModelingofKeyholeMode LaserWelding toAvoidMacro-Porosity••••.••••••••••••••••••.•lI8 H.Zhao.T.Debkoy, ThePennsylvaniaStateUniversity. UniversityPark,Pennsylvania DimensionlessRelationshipsfor the KeyholeWeld CharacteristicsinAZSOMagnesiumAlloy••••••••.••• 124 M.P.Marya, G.R.Edwards, ColoradoSchoolofMines. Golden. Colorado NumericalModelingofStationaryGTA Welding 130 M Tanaka, H. Terasaki, M Ushio, OsakaUniversity. Ibaraki, Osaka. Japan J.J.Lowke,CSIRO. Sydney, NewSouth Wales. Australia ValidationofComputedWeld PoolTemperatureProfilesfor GTA Welding ofGammaTiAl•.•....•.••.•.136 K.B.Bisen,M F.Arenas.N.El-Kaddah, V. L.Acoff,TheUniversityofAlabama,Tuscaloosa. Alabama Anode HeatTransferinGTA Welding•••••••••••••••••.•••••••••••••••••••••••••••••••.••.••••.••142 H. Terasaki, M.Tanaka, H.Fujii. M. Ushio, OsakaUniversity. Ibaraki, Osaka. Japan Ak-EModelfor TurbulentWeldPoolConvection inGas MetalArc Welding Processes •..•....•..•.•... 147 J.Jaidi,K.S.S.Murthy. P.Dutta,IndianInstituteofScienceBangalore, Karnataka, India AnalysisofFrictionStirWeldsUsingthe Inverse-ProblemApproach••••••••••••••••.•••••••••.•••.•••153 S.G.Lambrakos, R.W. Fonda, NavalResearchLaboratory, Washington, DC J.0. Milewski, LosAlamosNationalLaboratory, LosAlamos,NewMexico J.E.Mitchell, Vanderbilt University, Nashville. Tennessee PHASE TRANSFORMATIONSANDMICROSTRUCTURALCHARACTERIZATION Phase Distributionand TransformationDynamics inFusion Welds UsingIn-SituSynchrotron DiffractionMethods 158 J. Wong, LawrenceLivermoreNationalLaboratory, Livermore, California Advanced CharacterizationTechniquesfor Weld Microstructures••••••••••••••••••••••••••••••••••••164 S.S.Babu,S.A.David. M K.Miller, OakRidgeNationalLaboratory. OakRidge,Tennessee Vlll NonequiUbriumSolidificationinFe-C-Al-MnSteelWelds ••••••••••••••••••••••••••••••••••••••••••••169 S.S.Babu,S.A.David,OakRidgeNationalLaboratory, OakRidge,Tennessee J. W. Elmer,LawrenceLivermoreNationalLaboratory, Livermore, California M.Quintana, TheLincolnElectricCompany, Cleveland, Ohio MappingPhaseTransformationsin the Heat-Affected-ZoneofCarbonManganeseSteel Welds Using SpatiallyResolvedX-RayDiffraction 174 J. W. Elmer,J. Wong, T. Ressler,T. Palmer,LawrenceLivermoreNationalLaboratory,Livermore, California Modeling ofFerritetoAusteniteTransformationand Real TimeMappingofPhasesDuringGTAWelding of1005Steel 180 W. Zhang,T. DebRoy,ThePennsylvaniaStateUniversity, UniversityPark,Pennsylvania J. W. Elmer,LawrenceLivermoreNationalLaboratory, Livermore, California MagneticForceMicroscopyasaToolfor Weld MetalStudies ••••••••••••••••••.•••••••••••••••••.•••186 M.Thuvander, L.Karlsson, ESABAB,Gateborg, Sweden O.Kazakova, ChalmersUniversityofTechnology, Goteborg, Sweden CharacterizationofDeltaFerriteContentinGTAWDeposited StainlessSteelCladding•••••••••••••.••••191 A.Demmons,D.Gibbs, D. W. Walsh, CaliforniaPolytechnicStateUniversity, SanLuisObispo, California GrainGrowthinthe Heat-AffectedZone ofTi-6Al-4VWelds: Measurementsand Three•••••••••••••••••197 DimensionalMonteCarloSimulation S.Mishra, T. DebRoy,ThePennsylvaniaStateUniversity, UniversityPark,Pennsylvania WELDINGPROCESSESANDPROCEDURES FrictionStirWelding KEYNOTEADDRESS FrictionStirWeldingDevelopments 203 W. M.Thomas, R.E.Dolby, TWI, Ltd.,Cambridge, UnitedKingdom ADetailed Three-DimensionalTransientHeatTransferModel for FrictionStirWelding•••••••••••••••••212 M Song,R.Kovacevic,J.Ouyang, M. Valant, SouthernMethodistUniversity, Richardson,Texas InputTorqueBasedThermalModel ofFrictionStirWelding ofAl-6061•••••••••••••••••••••••••••••••218 M Z.H.Khandkar,J.A.Khan, A.P.Reynolds,UniversityofSouthCarolina, Columbia, SouthCarolina High-SpeedVideo Flow VisualizationinFrictionStirWelds ofPolycarbonate•••••••••••••••••••••••••• 224 B.M Nowak, UniversityofTexas, ElPaso,Texas A.C.Hall,G.A.Knorovsky, SandiaNationalLaboratories,Albuquerque,NewMexico VisualizationofMaterialFlowDuringFrictionStirWelding (FSW) ofthe Same and DissimilarAluminum Alloys 229 J.H.Ouyang,D.Jandric, R.Kovacevic, M Song,M Valant, SouthernMethodistUniversity, Richardson, Texas ForceSensing inFrictionStirWelding••••••••••••••••••••••••••••••••••••••••••••.••••••••••••••235 J.E.Mitchell, G.E.Cook, A.M.Strauss,Vanderbilt University, Nashville, Tennessee MicrostructuralAnalysis andModelingofthe HeatAffected Zone in AI2519FrictionStirWelds •••••••••,,241 R.W. Fonda,S.G.Lambrakos, U.S. NavalResearchLaboratory, Washington, DC ix Thermo-MechanicalAnalysesofWeldingAluminumAlloywithTIGand FrictionStirWelding•••••••••••247 Q-YShi,T. Dickerson, H.R.SherclijJ, UniversityofCambridge, Cambridge, UnitedKingdom ResidualStressDistributionsinFrictionStirWeldedAISheets DeterminedbyNeutronStrainScanning••••253 P.Staron,M.Kocak, GKSSForschungszentrum, Geesthacht, Germany S. Williams, BAESystems, Bristol, UnitedKingdom Effect ofPin Tool Shapeon MetalFlowDuringFrictionStirWelding•••••••••••••••••••••••••••••••••257 J.C.McClure. E.Coronado, S.Aloor.B.Nowak, L.E.Murr, UniversityofTexas, EIPaso,Texas A.C.Nunes. NASA-MarshallSpaceFlightCenter, Huntsville, Alabama ReproductionofUltra-FineGrainsin EqualChannelAngularPressedAIAlloy5083by FrictionStir Process 262 Y. S.Sato,M. Urata, H.Kokawa, K.Ikeda,Tohoku University, Sendai,Japan ImprovementofMechanicalPropertiesin ThixomoldedMgAlloyAZ91D byFrictionStirWelding••••••••267 S.H. C.Park,Y. S.Sato,H.Kokawa, Tohoku University, Sendai,Japan T. Tsukeda, TheJapanSteelWorks, Ltd.,Hiroshima. Japan The EvaluationoftheMechanicalPropertiesofAAS083FrictionStirWelds byElectronicSpeckle PatternInterferometry 273 M.J.Peel,M.Preuss,A.Steuwer, M.Turski, P.J. Withers, UniversityofManchester-UMIST, Manchester, UnitedKingdom InvestigatingPost-WeldHeatTreatmentstoIncreasethe Corrosionand the EnvironmentalCracking Behaviorof7075-T6 FrictionStirWeld •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••279 C.S.Paglia,B.C.Pitts, M.C.Carroll, R.G. Buchheit, TheOhioStateUniversity, Columbus, Ohio A.P.Reynolds, UniversityofSouthCarolina. Columbia, SouthCarolina PittingCorrosionBehaviorofFrictionStirWelded7050-T74AluminumAlloy••••••••••••••••••••••••• 284 K.K.Sankaran, H.L.Smith, TheBoeingCompany, St.Louis,Missouri K.Jata,AirForceResearchLaboratory, Wright-Patterson AFB,Ohio The EffectoftheWeldingConditionson the Nugget Zone in FrictionStirWelds in an AA7010 Alloy••.•.••287 Kh.A.A.Hassan, A.F.Norman, P.B.Prangnell, UniversityofManchester-UMIST, Manchester, UnitedKingdom .. MetallurgicalCharacterizationofFrictionStirWelded 7050-T74 andC458-T3 AluminumAlloys•••••.••• 293 K.K.Sankaran, R.J.Lederich, TheBoeingCompany, St.Louis,Missouri K.Jata,AirForceResearchLaboratory, Wright-Patterson AFB,Ohio K.Rajan,RensselaerPolytechnicInstitute,Troy, NewYork D.Schwartz, LosAlamosNationalLaboratory, LosAlamos, NewMexico Weld EfficiencyandDefect Formation: CorrelationBetween ExperimentandSimpleModels••••••••••.••297 A.P.Reynolds, W.Tang, UniversityofSouthCarolina, Columbia, SouthCarolina K.Lindner,UniversityofKarls-Ruhe, Ruhe,Germany T. U. Seidel,AndreasStihlAG,Waiblingen, Germany Low PlasticityBurnishingofFrictionStirWelds in 2219AluminumtoIncreaseCorrosionFatigueLife ••••.302 D.Hombach, P.Prevey, LambdaResearch, Cincinnati, Ohio M.W.Mahoney, RockwellScientificCompany, ThousandOaks,California D.Waldron, TheBoeingCompany, Huntington Beach, California J.Cammett, LambdaResearch, Inc.,Cincinnati, Ohio x
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