Documente Academic
Documente Profesional
Documente Cultură
2
Azmi Kamardin
2015-2016 S01
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Crystal Structure Crystal Structure
ORTHORHOMBIC MONOCLINIC
FC-TETRAGONAL
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BC-ORTHORHOMBIC BaC-ORTHORHOMBIC
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Grain Structure Heat Input
Dendrites continue to Melt base metal & filler metal during welding
grow until the space Heat input: The amount of heat applied to the
between them is filler metal & base metal surface at the required
completely filled and rate to form a weld pool.
solidification is Heat input produces rapid heating, very high
Grain with
differing completed
temp & rapid cooling.
crystallographic Sources: electric arc, burning O2 + acetylene etc
orientation
Controlling heat input is essential heat input
affects structure & properties of metals.
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Heating Rate Cooling Rate
The rate of temp change at the weld joint from The rate of temp change at the weld joint from
room temp to welding temp welding temp to room temp
Influenced by: Influenced by:
Heat input Heat loss
Thermal conductivity
Thermal conductivity
Preheat & interpass temperatures
Mass of joint area
Preheat: Heating the joint area to predetermined
The max temp achieved must be sufficient to temp in order to slow the cooling rate.
melt the base metal & filler metal Interpass temperature control: maintaining the
temp range between weld passes.
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Completely melted fusion weld Narrow band of base metal adjacent to the weld
Solidified filler metal joint
Base metal at the boundaries Properties are affected by heat of welding
weld interface Metallurgical structure change at any region
> 732oC (carbon steels) or 315oC (Al alloys)
HAZ maybe weaker & more susceptible to
failure under service loads.
Width of HAZ is proportional to the amount of
heat input.
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Base Metal Effects on Physical Properties
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Physical properties that influence weldability: The temp at which a metal passes from a solid
Melting point state to a liquid state.
Pure metals possess a specific melting temp.
Thermal expansion
Alloys melt within a temp range.
Specific heat
Solidus: The highest temp at which alloy is
Thermal conductivity completely solid.
Electrical conductivity Liquidus: The lowest temp at which alloy is
Magnetism completely molten.
Oxidation
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Melting Point Thermal Expansion
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Thermal Conductivity Electrical Conductivity
The rate at which metal transmit heat. The rate at which electric current flows through a
In welding, thermal conductivity provides a metal.
measure for heat input required to compensate Higher electrical conductivity (EC) easier for
for the heat conducted away from the weld. electron to flow
Cu is difficult to weld with low-temp heat source Temp increases EC decreases
because thermal conductivity of Cu is very high. Electrical resistivity (ER): Electrical resistance of
Cu is excellent backing for welding because a unit volume of a material
rapid conduction of heat thru Cu backing ER = 1 / EC
prevents it from sticking to weld metal.
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Magnetism Oxidation
The ability of a metal to be attracted by a Metals form thin oxide layer at room temp.
magnet, or to develop residual magnetism when As temp increases, oxide layer thickens
placed in a magnetic or electrical field. Metal oxide layer must be removed during
Most steels are magnetic & may contain residual welding to prevent it from interfering with molten
magnetism weld.
Parts may need to be de-magnetized before Flux-coated filler metals & inert gas prevents
welding to prevent arc blow during welding. oxides from entering the weld area.
Welding arc deflects from its normal path due to
magnetic forces.
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Effects on Mechanical Properties Effects on Mechanical Properties
A property of metal that describes the behavior Mechanical properties of metals such as:
of metals under applied load. Strength
Welding may alter specific mechanical Ductility
properties of metals, leading to premature failure Malleability
under load.
Toughness
Welders should be familiar with basic terms and
concepts associated with the mechanical Embrittlement
properties of metals. Hardness
Fatique
Creep
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Strength Toughness
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Fatigue Fatigue
Failure of a material operating under cyclic load. Associated with service life of any components
that moves, rotates, vibrates or subjected to
thermal cycling.
All welding introduces stress concentrations into
a weld, reducing fatigue strength.
The effect is highest when the load is applied
transversally to the weld.
Fillet welds are particularly prone to fatigue
failure.
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Fatigue Creep
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Shrinkage Stress Residual Stress
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Residual Stress Reduction Residual Stress Reduction
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Peening relieves internal stress & help metal Microstructure: Appearance of the metallurgical
stretch as it cools structure when metals are specially prepared to
Low heat input reveal their features.
Post heating
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Metallurgical Microstructure
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