Trends in Welding Research : proceedings of the 8th international conference ; Pine Mountain, June 2-6, 2008

832 Pages·2008·79.703 MB·English

by  ASM International

Trends in Welding Research

Proceedings of the
8th International Conference

June 1–6, 2008
Callaway Gardens Resort
Pine Mountain, Georgia, USA

Editors

Stan A. David
Tarasankar DebRoy
John N. DuPont
Toshihiko Koseki
Herschel B. Smartt

Sponsored by

Published by
ASM International®
Materials Park, Ohio 44073-0002
www.asminternational.org
Copyright (cid:2) 2009
by
ASM International®
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First printing, June 2009
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ISBN-13: 978-1-61503-002-6
ISBN-10: 1-61503-002-6
SAN: 204-7586
ASM International®
Materials Park, OH 44073-0002
www.asminternational.org
Printed in the United States of America
Cover images are orientation imaging micrographs showing grain distribution in a friction stir welded nickel-base
superalloy single crystal. Courtesy of Oak Ridge National Laboratory
Conference Co-Chairmen

Dr. Stan A. David, FASM
Oak Ridge National Laboratory
Oak Ridge, Tennessee

Dr. Tarasankar DebRoy, FASM Dr. Herschel B. Smartt
The Pennsylvania State University Idaho National Engineering and
University Park, Pennsylvania Environmental Laboratory
Idaho Falls, Idaho

Dr.Toshihiko Koseki Dr. John N. DuPont, FASM
The University of Tokyo Lehigh University
Tokyo, Japan Bethlehem, Pennsylvania

International Organizing Committee

Prof. Yixiong Wu Prof. Harry K.D.H. Bhadeshia Dr. John W. Elmer
Shanghai Jiaotong University University of Cambridge University of California
Shanghai, China Cambridge, United Kingdom Livermore, California, USA

Prof. P.S. Wei Mr. Chris Conrandy Prof. Konstantin Yushchenko
National Sun Yat-Sen University Edison Welding Institute E. O. Paton Electric Welding
Kaohsiung, Taiwan Columbus, Ohio, USA Institute
Kiev, Ukraine
Prof. Horst Cerjak Prof. Sindo Kou
Graz University of Technology University of Wisconsin Prof. Stephen Liu
Graz, Austria Madison, Wisconsin, USA Colorado School of Mines
Golden, Colorado, USA
Dr. Christoph Wiesner Prof. Yanhong Wei
TWI LTD, Granta Park Harbin Institute of Technology Prof. Hiroyuki Kokawa
Great Abingtonmadison, Harbin, China Tohoku University Sendai
Wisconsin, USA Japan
Prof. Amitava DeIndia
Institute of Technology,
Bombay Powai Mumbai, India

iii
Preface

The 8th International Conference on Trends in Welding Research (TWR) was held on
June 1–6, 2008, at the Callaway Garden Resort in Pine Mountain, Georgia (USA). About
190 papers were presented by delegates from 26 countries. The excellent technical
program was comprised of oral and poster presentations, eight keynote talks by world
renowned experts, and the excellent conference venue, which all contributed to the
success of the meeting. The Conference also provided ample opportunities for delegates
to meet world renowned experts in the field and have discussions in an informal setting.

The Trends conference has always attracted the world’s leading welding
researchers. This year the conference consisted of 23 technical sessions and a poster
session. The topics covered in these sessions included friction stir welding, sensing,
control and automation, microstructure and properties, welding processes, procedures and
consumables, weldability, modeling, phase transformations, residual stress and distortion,
physical processes in welding, and properties and structural integrity of weldments.

We thank the keynote speakers, participants, and the international organizing
committee members for making the conference an exciting event, as well as our
Endorsing Sponsors which include ASTM International, Japan Welding Society,
Association for Iron & Steel Technology (AIST), The Welding Institute, and American
Welding Society. We would like to thank the staff of ASM International, in particular,
Kim Schaefer and Anya Hodgson for their contributions, and we look forward to another
successful Trends Conference in 2011.

Stan A. David
Tarasankar DebRoy
John N. DuPont
Toshihiko Koseki
Herschel B. Smartt

Co-Chairmen, 8th International Conference on Trends in Welding Research
iv
Contents

Keynote 1 – Friction Stir Welding I

Thermomechanical Modelling of Friction Stir Welding ............................................................1
J.H. Hattel, H.N.B. Schmidt, C. Tutum; Technical University of Denmark,
Lyngby, Denmark

Keynote 2 – Microstructure

Grain Boundary Engineering of Austenitic Stainless Steels .................................................11
H. Kokawa, M. Michiuchi, M. Shimada, Z.J. Wang, Y.S. Sato;
Tohoku University, Sendai, Japan

Keynote 3 – Sensing

Process Control and Automation Developments in Welding .................................................17
J. Norrish, University of Wollongong, NSW, Australia

Keynote 4 – Friction Stir Welding II

Recent Developments of FSW Technologies: Evaluation of Root Defects,
Composite Refractory Tools for Steel Joining, and One-Pass Welding of
Thick Sections Using Self-Reacting Bobbin Tools .................................................................25
W.M. Thomas, C.S. Wiesner; TWI Ltd, Cambridge, UK

Keynote 5 – Advances in Welding

Generation II Materials Science for Welds and Advanced Materials .....................................35
D.L. Olson1, J.E. Jackson1, B. Mishra1, M.J. Kaufman1, A.N. Lasseigne-Jackson2,
R.B. Thompson3, A. Landau4, M. Pinkas4; (1) Colorado School of Mines,
Golden, CO, USA, (2) National Institute of Standards and Technology,
Boulder, CO, USA, (3) Center for Nondestructive Evaluation, Iowa State University,
Ames, IA, USA, (4) Nuclear Research Center, Negev, Beer Sheva, Israel

Keynote 7 – Residual Stress and Distortion

Distortion and Residual Stress in Welds: The Next Generation ............................................45
J. Goldak; Carleton University, Ottawa, Canada

Keynote 8 – Transport Phenomena

Macrosegregation in Arc Welds Caused by Dissimilar Filler Metals .....................................53
S. Kou, Y.K. Yang; University of Wisconsin, Madison, WI, USA
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Friction Stir Welding – Processing

An Experimental and Numerical Approach to Evaluate the Effect of
Welding Conditions on Temperature during Friction Stir Spot Welding ..............................60
D. Kim1, K. Chung1, H. Badarinarayan2; (1) Seoul National University,
Seoul, Korea, (2) Hitachi America Ltd., Farmington Hills, MI, USA

Properties and Forces of Immersed Friction Stir Welded AA6061-T6 ...................................67
T.S. Bloodworth, G.E. Cook, A.M. Strauss; Vanderbilt University,
Nashville, TN, USA

Effect of Welding Speed on Lap Joint Quality of
Friction Stir Welded AZ31 Magnesium Alloy ...........................................................................72
X. Cao, M. Jahazi; National Research Council Canada, Montreal, QB, Canada

Joint Tracking in Friction Stir Welding ....................................................................................81
P.A. Fleming1, D.H. Lammlein1, D.M. Wilkes1, G.E. Cook1, A.M. Strauss1,
D.R. DeLapp1, D.A. Hartman2; (1) Vanderbilt University, Nashville, TN, USA,
(2) Beyond6 Sigma, Santa Fe, NM, USA

Friction Stir Welding of Aluminium-Silicon-Coated Steel ......................................................85
C.H.J. Gerritsen1, C.A. Weis Olea2; (1) ArcelorMittal Research Industry
Gent/OCAS N.V., Zelzate, Belgium, (2) GKSS-Forschungszentrum
Geesthacht G.m.b.H, Geesthacht, Germany

Friction Stir Processing of AA6061-T4 - Cold Rolled vs. As Cast .........................................90
M. Iordachescu1, J. Ruiz-Hervias1, D. Iordachescu1, P. Vilaça2, J. Planas1;
(1) Universidad Politécnica de Madrid, Madrid, Spain, (2) Instituto Superior Tecnico,
Lisbon, Portugal

Shoulder-Less Conical FSW Tools:
An Evaluation on 1/8” Thickness Al-6061 Butt Welds ............................................................96
D. Lammlein, D. DeLapp, P. Fleming, A. Strauss, G. Cook;
Vanderbilt Welding Automation Lab, Nashville, TN, USA

Parameterization of Friction Stir Welding of Al 6061/SiC/17.5p ...........................................102
T. Prater, G. Cook, A. Strauss, J. Davidson; Vanderbilt University
Welding Automation Laboratory, Nashville, TN, USA

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V ........................................108
J.A. Querin, H.A. Rubisoff, J.A. Schneider; Mississippi State University,
Mississippi State, MS, USA

The Influence of the Tool Profile in Friction Stir Spot Welding of the
Aluminum Alloy AA6181-T4 ....................................................................................................113
F.D. Ramos1, M. Tier1, A.A.M. da Silva1, T. Rosendo1, J.A.E. Mazzaferro1,
C.C.P. Mazzaferro1, A. Reguly2, T.R. Strohaecker2, J.F. dos Santos1;
(1) GKSS Research Centre, Geesthacht, Germany,
(2) PPGEM – UFRGS, Porto Alegre, Brazil
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Robotic Welding and Inspection System ...............................................................................121
H.B. Smartt, D.P. Pace, E.D. Larsen, T.R. McJunkin, C.I. Nichol, D.E. Clark, K.L. Skinner,
M.L. Clark, T.G. Kaser, C.R. Tolle; Idaho National Laboratory, Idaho Falls, ID, USA

Experimental Investigation of Material Flows within
FSWs Using 3D Tomography ..................................................................................................126
C.R. Tolle, T.A. White, K.S. Miller, D.E. Clark, H.B. Smartt; Idaho National Laboratory,
Idaho Falls, ID, USA

Investigation into Interface Lifting within FSW Lap Welds ..................................................133
K.S. Miller, C.R. Tolle, D.E. Clark, C.I. Nichol, T.R. McJunkin, H.B. Smartt;
Idaho National Laboratory, Idaho Falls, ID, USA

The Effect of Aging Heat Treatments on the Mechanical Properties of
Gamma Prime Strengthened Nickel Based Superalloy Weld Metal .....................................140
G. Chirieleison1, L. Snyder2, T. Hansen2, R. Sharma2, H. White2; (1) Haynes Wire Company,
Mountain Home, NC, USA, (2) Haynes International, Kokomo, IN, USA

Physical Processes in Welding

Development of Weldable Fe-Al-Cr-Based Corrosion Resistant Overlay Coatings ...........149
K.D. Adams, J.N. DuPont; Lehigh University, Bethlehem, PA, USA

Fine Grained Nb-Ti Steel Welded by a GMAW Process .......................................................154
H.G. Svoboda1, N.M. Ramini de Rissone2, L.F.G. de Souza3, D.B. Santos4, I. de S. Bott5;
(1) University National of Buenos Aires, Argentina, (2) National Technological University,
Argentina, (3) CEFET/RJ, Brazil, (4) UFMG/MG, Brazil, (5) PUC-Rio/ Rio de Janeiro, Brazil

Three-Dimensional Reconstruction of Microstructure in
AA5754 Aluminum Alloy and Its Welded Joints ....................................................................159
J. Kang1, F. Feng2; (1) Northern College, Kirkland Lake, ON, Canada,
(2) Novelis Global Technology Centre, Kingston, ON, Canada

Procedure for the Alloy Development Considering Weldability ..........................................166
Y. Mae; Maetech, Saitama, Japan

Scaling Laws for the Welding Arc, Weld Penetration, and Friction Stir Welding ...............172
K. Tello, U. Duman, P. Mendez; Colorado School of Mines, Golden, CO, USA

Deformation Effects during Variable High Frequency Welding of Modern Steels .............182
J. Swenson, Y. Adonyi, R. Warke; LeTourneau University, Longview, TX, USA

Bubble Entrapped in Solid during Solidification ...................................................................190
C.C. Hsiao, P.S. Wei, S.Y. Hsiao; National Sun Yat-Sen University, Kaohsiung, Taiwan

Crack Mitigation in Buttering and Cladding Processes for a Nuclear Application ............194
Y.-P. Yang1, S. Babu1,S. Vaze1, J. Kikel2, D. Dewees2; (1) Edison Welding Institute,
Columbus, OH, USA, (2) BWXT Technologies, Barberton, OH, USA

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Experimental Characterization of GTA Weld Pool Surface Flow Using PIV .......................201
C.X. Zhao1, V. van Steijn2, I.M. Richardson1, Z. Saldi1, C.R. Kleijn2;
(1) Materials Innovation Institute, Mekelweg, The Netherlands,
(2) Delft University of Technology, Prins Bernhardlaan, The Netherlands

Modeling

Evaluation of Swept Friction Stir Spot Welding through
Sealants and Surface Treatments ..........................................................................................211
J. Brown1, C. Widener1, D. Burford1, B. Tweedy2, W. Horn1, G. Talia1;
(1) Wichita State University, Wichita, KS, USA, (2) HF Webster Engineering Services,
Rapid City, SD, USA

Thermo Mechanical Finite Element Modelling of the
High Speed Resistance Welding Process ..............................................................................220
R. Burrows, S.G.R. Brown; Swansea University, UK

Thermal Modeling of Gas Metal Arc Girth Weld with Narrow Groove .................................226
Y. Chen, Y.-Y. Wang; Center for Reliable Energy Systems, Dublin, OH, USA

Inverse Modeling of Layer-by-Layer Liquid-Metal Deposition .............................................234
K.P. Cooper, S.G. Lambrakos; Naval Research Laboratory, Washington, DC, USA

Arc Welding of Dissimilar Metals: FEA and Experiments ....................................................241
E. Scutelnicu1, M. Iordachescu2, M. Blasco2, D. Iordachescu2;
(1) Dunarea de Jos University of Galati, Romania, (2) Universidad Politécnica de Madrid, Spain

Sensitivity Issues Concerning Inverse Heat Transfer Analysis of Welds ...........................247
S.G. Lambrakos1, H.N. Jones1, A.D. Zervaki2, G.N. Haidemenopoulos2;
(1) Naval Research Laboratory, Washington, DC, USA, (2) University of Thessaly, Greece

A Finite Element Based Study of Dynamic Processes in Ultrasonic Welding ....................254
C. Zhang, L. Li; Utah State University, Logan, UT, USA

Welding Simulation of Cast Aluminium A356 ........................................................................258
X.-T. Pham, P. Gougeon, F.-O. Gagnon; National Research Council Canada,
Chicoutimi, QB, Canada

Phase Transformations

Ferrite Transformation Behaviors from Steel-Oxide Interface during
HAZ Thermal Cycle ..................................................................................................................264
K. Kasai, H. Kato, J. Inoue, T. Koseki; University of Tokyo, Tokyo, Japan

Controlling the Phase Evolutions during Welding Toward Developments of
High Strength Steel Weld Metal with Martensite Microstructure .........................................268
Y. Komizo, H. Terasaki; Osaka University, Ibaraki, Osaka, Japan

In-situ Observation of Phase Transformation in Steels ........................................................272
N. Oku, K. Asakura, J. Inoue, T. Koseki; The University of Tokyo, Tokyo, Japan
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Formation of Retained Austenite in Triplex Stainless Steel Weld Metal .............................277
K. Saida1, K. Nishimoto1, K. Ogawa2, K. Fujiwara2; (1) Osaka University, Osaka, Japan
(2) Sumitomo Metal Industries, Ltd., Hyogo, Japan

Reverse Transformation Behaviour in B Containing High Cr
Heat Resistant Steel HAZ ........................................................................................................284
T. Shirane, M. Shimizu, S. Tsukamoto, K. Tsuzaki, Y. Adachi, T. Hanamura, F. Abe;
National Institute for Materials Science, Tsukuba, Ibaraki, Japan

Effect of Oxides and Their Volume Fraction on
Intragranular Ferrite Formation in Steel .................................................................................292
T. Suzuki, J. Inoue, T. Koseki; The University of Tokyo, Tokyo, Japan

Prevention of Type IV Failure in High Cr Ferritic Heat Resistant
Steel Welded Joint ...................................................................................................................296
S. Tsukamoto, M. Tabuch, T. Shirane, F. Abe;
National Institute for Materials Science, Tsukuba, Ibaraki, Japan

Other Experimental/Modeling Investigations

Evaluation of a Drilling Model Approach to Represent Laser Spot Microwelding .............303
P. Colegrove, P.-E. Simiand, A. Varughese, S. Williams, D. Yapp;
Cranfield University, Bedfordshire, UK

Arc-Laser Interactions and Heat Transfer and Fluid Flow in Hybrid Welding ....................313
B.D. Ribic, R. Rai, T.A. Palmer, T. DebRoy; Pennsylvania State University,
University Park, PA, USA

A Model Equation for the Convection Coefficient for
Thermal Analysis of Welded Structures ................................................................................321
R. Goyal1, E. Johnson1, M. El-Zein1, J. Goldak2, M. Coulombe2, S. Tchernov3;
(1) Deere and Company, Moline, IL USA, (2) Carleton University, Ottawa, ON, Canada,
(3) Goldak Technologies, Ottawa, ON, Canada

Analytical and Experimental Validation of Distortion
Using State of the Art Techniques .........................................................................................328
E. Johnson1, M. El-Zein1, J. Goldak2, T. Schmidt3; (1) Deere and Company,
Moline, IL, USA, (2) Carleton University, Ottawa, ON, Canada, (3) Trilion Quality Systems,
West Conshohocken, PA, USA

Characterisation of Dynamic Mechanical Behaviour of
Resistance Spot Welding Machines .......................................................................................333
P. Van Rymenant1, D. Yapp2; (1) De Nayer Institute, St. Katelijne Waver, Belgium,
(2) Cranfield University, Bedfordshire, UK

Arc and Weld Profile Predictions for Zinc-Coated Thin Steel Plates:
Trends in Welding Research 2008 ..........................................................................................339
X. Zhang1, A. Daneryd1, B. Holmgren1, D. Skarin2; (1) ABB Corporate Research,
Västerås, Sweden, (2) ABB Robotics, Västerås, Sweden
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Weldability

Ultrasonic Metal Welding of Advanced Alloys: The Weldability of
Stainless Steel, Titanium, and Nickel-Based Superalloys ....................................................348
M. Bloss1, K. Graff2; (1) The Ohio State University, Columbus, OH, USA,
(2) Edison Welding Institute, Columbus, OH, USA

In-situ High Temperature Straining Tests to Study Welding:
Solid State Cracking Phenomena ...........................................................................................354
E.A. Torres1, F.G. Peternella1, A.J. Ramirez1, R. Caram2; (1) Brazilian Synchrotron
Light Laboratory, Campinas-SP, Brazil, (2) State University of Campinas,
Campinas-SP, Brazil

Friction Stir Welding – Microstructure and Properties

Microstructure-Property Development in Friction Stir Welds of Al-Mg Alloys ...................358
M.M. Attallah, C.L. Davis, M. Strangwood; University of Birmingham, Birmingham, UK

Influence of Welding Parameters and Tool Geometry on the
Mechanical Performance of Friction Stir Spot Welded Al-Mg Alloys ..................................364
A. Echeverria, A. Zabaleta, P. Alvarez, E. Aldanondo, J. Solis, A.A.M. da Silva;
LORTEK – Centro de Investigación en Tecnologías de Unión, Guipúzcoa, Spain

Research Concerning the Friction Stir Welding of Linepipe Steels ....................................371
D. Fairchild1, A. Kumar1, S. Ford1, N. Nissley1, R. Ayer2, H. Jin2, A. Ozekcin2;
(1) ExxonMobil Upstream Research Co., Houston, TX, USA,
(2) ExxonMobil Corporate Strategic Research Co., Annandale, NJ, USA

Influence of Process Parameters in the TMAZ Microstructural Evolution of
C-Mn Steels Friction Hydro-Pillar Welded Joints ..................................................................381
J.U. Silgado1, T.F. Hermenegildo1, A.J. Ramirez1, M.T.P. Paes2, A. Pope2;
(1) Brazilian Synchrotron Light Laboratory, Campinas-SP, Brazil,
(2) Petrobras, Rio de Janeiro-RJ, Brazil

Friction-Stir Welding – Heavy Inclusions in Bi-Metallic Welds of Al 2219/2195 .................385
W.W. Rietz, Jr.; Lockheed Martin Michoud Space Systems, New Orleans, LA USA

Characterization of Microstructures and Transformation Behavior in
Friction Stir Welded HSLA-65 .................................................................................................391
L. Wei, T.W. Nelson; Brigham Young University, Provo, UT, USA

Evolution of Microstructure and Properties for Friction Stir Welded
Martensitic Precipitation-Hardening Steels ...........................................................................398
T. Weinberger, B. Führer, S. Khosa, N. Enzinger, H. Cerjak, H. Schöttner, S. Mitsche;
Graz University of Technology, Austria

Microstructural Evolution in Friction Stir Welding of Ti-5111 ..............................................403
J. Wolk1, C. Davis1, L. Salamanca-Riba2; (1) Naval Surface Warfare Center,
Bethesda, MD, USA, (2) University of Maryland, College Park, MD, USA

x