Welding Technology (Materials Forming, Machining and Tribology)

✍ Scribed by J. Paulo Davim (editor)

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 430
• Category: Library

✦ Synopsis

This book presents some developments in the field of welding technology. It starts with classical welding concepts, covering then new approaches. Topics such as ultrasonic welding, robots welding, welding defects and welding quality control are presented in a clear, didactic way. Lower temperature metal-joining techniques such as brazing and soldering are highlighted as well.

✦ Table of Contents

Preface
Contents
About the Editor
1 Friction Stir Welding
1.1 Introduction
1.2 Fundamentals of FSW Process
1.3 Advantages and Limitations of FSW
1.4 Friction Stir Welding Tools
1.4.1 Materials for FSW Tool
1.4.2 Geometry of FSW Tool
1.5 Workpiece Materials Suitable for Friction Stir Welding
1.5.1 FSW of Aluminum Alloys
1.5.2 Magnesium Alloys
1.5.3 Copper Alloys
1.5.4 Steel
1.5.5 Titanium Alloys
1.5.6 Dissimilar Alloys and Metals
1.6 Friction Stir Welding Setup and Joining Configurations
1.6.1 Linear Welding
1.6.2 Circular Welding
1.6.3 Some of the Distinct FSW Setups Used Around the World
1.7 Important Parameters in FSW
1.7.1 Rotational Speed of Tool/Spindle
1.7.2 Traverse Speed
1.7.3 Tilt Angle of Tool
1.7.4 Other Parameters
1.8 Applications of FSW
1.8.1 Marine and Shipbuilding Industries
1.8.2 Aerospace and Aviation Industry
1.8.3 Railway Industry
1.8.4 Automobile Industry
1.8.5 Power Plants
1.9 Closure
References
2 Fundamentals of Friction Stir Welding, Its Application, and Advancements
2.1 FSW Introduction
2.1.1 History and Background
2.1.2 Nomenclature of FSW Process
2.1.3 Stages of FSW
2.2 Fundamentals of FSW
2.2.1 Material Flow and Mechanism of Bond Formation
2.2.2 Microstructural Zones in FSW
2.2.3 Advantages of FSW
2.2.4 Disadvantages of FSW
2.3 Effect of Input Process Parameters
2.3.1 Tool Design
2.3.2 Tool Material
2.3.3 Commonly Used Tool Materials
2.3.4 Tool Rotational Speed and Welding Speed
2.3.5 Tool Tilt Angle and Plunge Depth
2.4 Output Mechanical Responses of FSW
2.4.1 Temperature Distribution/heat Generation
2.4.2 Axial Force and Spindle Torque
2.4.3 Types of defects
2.5 Mechanical Property
2.5.1 Tensile Property and Hardness Variation
2.6 Metallurgical Aspect (Microstructure and Grain Size)
2.7 Applications
2.7.1 Industrial
2.7.2 Aerospace
2.7.3 Automobile
2.7.4 Others Application I.E. (Nuclear, Shipbuilding, Electronics)
2.8 Research Area
2.8.1 Overview of Friction Stir Welding for Similar Material
2.8.2 Dissimilar Welding Al–Cu, Al–Mg, Al–Steel
2.8.3 Tool Wear
2.8.4 Variants of Friction Stir Welding
2.9 Conclusion
References
3 Modeling of Friction Stir Welding Processes
3.1 Introduction
3.2 Friction Stir Welding Process
3.2.1 Working Principle
3.2.2 Parameters Affecting FSW Process
3.2.3 Defects in Welding
3.3 Basic Governing Equations of the Process
3.3.1 Modeling of Plastic Deformation
3.3.2 Thermal Modeling
3.4 Analytical Modeling of FSW
3.5 Numerical Modeling
3.5.1 Basics of Finite Element Modeling
3.5.2 Thermal Modeling
3.5.3 Material Flow Modeling
3.5.4 Evolution of Mechanical Properties
3.5.5 Cellular Automata Modeling of FSW
3.6 An Example
3.7 Future Challenges
3.8 Conclusion
References
4 An Application from a Defect—A Friction Stir Channeling Approach
4.1 Introduction to Friction Stir Welding (FSW)
4.1.1 Development of FSW
4.1.2 FSW Process
4.1.3 Principles of FSW
4.1.4 FSW Terminologies
4.1.5 Important Parameters in FSW
4.1.6 Advantages of FSW Process
4.1.7 Disadvantages of FSW Process
4.1.8 Variations in FSW Process
4.1.9 Applications
4.2 Defects in FSW Process
4.2.1 Defects Generated Due to Excessive Heat Generation
4.2.2 Defects Generated Due to Insufficient Heat Generation
4.2.3 Defects Generated Due to Improper Mixing
4.3 Recent Market Demands of FSW Process
4.4 Wormhole Defect—Invention of Friction Stir Channeling
4.4.1 Importance of Compact Heat Exchanger
4.4.2 Conventional Techniques and Limitations
4.4.3 Potential of FSC Process
4.5 FSC Process
4.5.1 FSC Principle
4.5.2 FSC Parameters and Their Influence
4.6 Evolution of FSC Process
4.6.1 Conventional FSC (CFSC)
4.6.2 New FSC (NFSC)
4.6.3 Modified FSC (MFSC)
4.6.4 Hybrid FSC (HFSC)
4.7 Case Study on FSC
4.8 Future of FSC: Complex Heat Exchanger Used in Different Components
4.9 Conclusion
References
5 Welding of Dissimilar Metals—Challenges and a Way Forward with Friction Stir Welding
5.1 Introduction to Welding of Dissimilar Metals
5.1.1 Applications of the Structures of Dissimilar Metals
5.2 Welding—A Permanent Joining Approach
5.3 Influencing Factors for Dissimilar Welding
5.3.1 Solubility
5.3.2 Intermetallic Compound
5.3.3 Weldability
5.3.4 Melting Temperature
5.3.5 Thermal Conductivity
5.3.6 Thermal Expansion
5.3.7 Corrosion
5.4 Welding Methods—Difficulties and Opportunities for Dissimilar Metals
5.4.1 Gas Tungsten Arc Welding (GTAW)
5.4.2 Gas Metal Arc Welding (GMAW)
5.4.3 Shielded Metal Arc Welding (SMAW)
5.4.4 Submerged Arc Welding (SAW)
5.4.5 Flux-Cored Arc Welding (FCAW)
5.4.6 Laser Beam Welding (LBW)
5.4.7 Electron Beam Welding (EBW)
5.4.8 Friction Welding
5.4.9 Explosive Welding
5.4.10 Ultrasonic Welding
5.4.11 Friction Stir Welding (FSW)
5.5 Mechanism of Joining Dissimilar Materials in FSW
5.6 Case Study on Dissimilar Material Welding by FSW
5.6.1 Joint Strength of Welds
5.6.2 IMCs
5.6.3 Weld Microstructure at the Interface
5.7 Summary
References
6 Microstructure and Texture in Welding: A Case Study on Friction Stir Welding
6.1 Introduction
6.2 Microstructure in Welding
6.2.1 Microstructure in Fusion Welding
6.2.2 Microstructure in Solid-State Welding
6.2.3 Microstructure of Steel and Its Weldability
6.2.4 Microstructure of Aluminium and Its Weldability
6.3 Texture in Welding
6.3.1 Texture in Fusion Welding
6.3.2 Texture in Solid-State Welding
6.4 Case Study for Microstructure and Texture Evolution in Solid-State Welding of Dissimilar Materials
6.4.1 FSW Process and Microstructural Zones
6.4.2 Experimental Details
6.4.3 Results and Discussion
6.5 Conclusion
References
7 Tubular Structures: Welding Difficulty and Potential of Friction Stir Welding
7.1 Introduction
7.2 Welding Techniques Used to Manufacture Tubes
7.2.1 Arc Welding
7.2.2 Electric Resistance Welding (ERW)
7.2.3 High Energy Beam Welding
7.2.4 Solid-State Welding
7.3 Potential of FSW in Fabrication of Tubes
7.3.1 Fixture
7.3.2 Tool Design
7.3.3 Process Parameters
7.4 Limitations of FSW of Tubes Over Other Welding Techniques
7.5 Case Study: Longitudinal FSW of Tubes Fabricated from AA5083
7.5.1 Experimental Procedure
7.5.2 Results and Discussion
7.6 Conclusion
References
8 Industry 4.0 in Welding
8.1 Welding as a Manufacturing Process
8.1.1 Need of Automation in Welding
8.1.2 Focus of This Chapter
8.2 Industrial Transformation – Journey from Industry 1.0 to Industry 4.0
8.2.1 Primitive Manufacturing and Industry 1.0 – the First Industrial Revolution
8.2.2 Industry 2.0 – the Second Industrial Revolution
8.2.3 Industry 3.0 – the Third Industrial Revolution
8.2.4 Industry 4.0 – the Fourth Industrial Revolution
8.3 Monitoring and Control of Various Welding Techniques
8.3.1 Direct Monitoring
8.3.2 Indirect Monitoring
8.3.3 Context Setting—A Summary
8.3.4 Role of Industry 4.0 in Welding
8.3.5 Digital Tools of Industry 4.0
8.3.6 A Concept Block Diagram for Implementing Industry 4.0 in Welding
8.4 Case Study—Application of Industry 4.0 in Welding
8.4.1 Selection of Manufacturing Attribute—Problem Formulation
8.4.2 Application of Internet of Things, Cyber-Physical System and Tele-Welding
8.4.3 Data Collection, and Domain Knowledge
8.4.4 Signal Processing, Feature Extraction and Building of a Database
8.4.5 Real-Time Weld Quality Prediction and Control
8.4.6 Discussion
8.5 Conclusion
References
9 Comparative Study of Laser Weldability of Titanium Alloys
9.1 Introduction
9.2 Experimental Procedure
9.3 Results and Discussion
9.4 Conclusions
References
10 A Novel High-Efficiency Keyhole Tungsten Inert Gas (K-TIG) Welding: Principles and Practices
10.1 Overview
10.1.1 High Current Tungsten Inert Gas (TIG) Welding
10.1.2 Keyhole Tungsten Inert Gas (K-TIG) Welding
10.1.3 Equipment of K-TIG Welding
10.1.4 HDR Imaging of K-TIG Welding
10.2 Operation of K-TIG Welding
10.2.1 Operating Windows
10.2.2 K-TIG Welding Process Parameters
10.2.3 Application Extensions of K-TIG
10.2.4 Keyhole Stability
10.2.5 Arc Forces in K-TIG Welding Keyhole
10.2.6 The Input and Conductivity of Heat
10.3 Signal Characteristics in K-TIG Welding
10.3.1 Electrical Signal Characteristics
10.3.2 Acoustic Signal Characteristics
10.3.3 Penetration Recognition
10.4 K-TIG Welding of Duplex Stainless Steels
10.4.1 Effect of the Welding Parameters on the Weld Geometry Profile
10.4.2 Microstructure
10.4.3 Misorientation Angle Distribution of Grain Boundary (MADGB)
10.4.4 Mechanical Properties
10.5 K-TIG Welding of Titanium Alloy
10.5.1 Weld Geometry Profile
10.5.2 Mechanical Properties
10.5.3 Microstructural Characterization
10.5.4 MADGB of the TC4 Titanium Alloy K-TIG Welded Joint
10.6 Conclusions
References
11 Fatigue Analysis of Dissimilar Metal Welded Joints of 316L Stainless Steel/Monel 400 Alloy Using GTAW
11.1 Introduction
11.2 Materials and Methods
11.3 Welding
11.4 Microhardness
11.5 Optical Microscopy
11.6 Fatigue Testing
11.6.1 Quantitative Fatigue Analysis
11.6.2 S-N Curve
11.6.3 Fatigue Damage
11.7 SEM for Fractures Surfaces
11.8 Conclusions
References
12 Industrial Pipeline Welding
12.1 Introduction to Energy Sector Pipeline Projects
12.2 Matching Tomorrow Challenges Today
12.2.1 Extreme Conditions
12.2.2 Sour Service
12.2.3 Arctic Environment
12.2.4 Deep-Sea Projects
12.2.5 Reeling Demands
12.3 Industrial Welding Methods
12.3.1 High Frequency Induction Welding (HFIW)
12.3.2 Submerged Arc Welding (SAW)
12.4 Microstructure-Property Relationships for Pipeline Steel—An Overview
12.4.1 Microstructure Evolution During Heating and Cooling
12.4.2 Welding Microstructures of Pipeline Steels
12.4.3 Pipe Weld Structural Integrity Considerations
12.4.4 Hydrogen-Induced-Cracking-Related Issues
12.4.5 Low Temperature Behavior and Weld Microstructures
12.4.6 Pipeline Collapse Considerations
References
Index