Trends in Welding Research: Proceedings of the 6th International Conference, Callaway Gardens Resort, Phoenix, Arizona Usa, 15-19 April 2002

1042 Pages·2006·53.08 MB·English

by  DebRoy

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®
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Firstprinting, January2003
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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