Details

A Practical Guide to Welding Solutions


A Practical Guide to Welding Solutions

Overcoming Technical and Material-Specific Issues
1. Aufl.

von: Robert W. Messler

133,99 €

Verlag: Wiley-VCH
Format: EPUB
Veröffentl.: 14.01.2019
ISBN/EAN: 9783527818808
Sprache: englisch
Anzahl Seiten: 344

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Beschreibungen

As critically important as welding is to a wide spectrum of manufacturing, construction, and repair, it is not without its problems. Those dependent on welding know only too well how easy it is to find information on the host of available processes and on the essential metallurgy that can enable success, but how frustratingly difficult it can be to find guidance on solving problems that sooner or later arise with welding, welds, or weldments.<br> <br> Here for the first time is the book those that practice and/or depend upon welding have needed and awaited. A Practical Guide to Welding Solutions addresses the numerous technical and material-specific issues that can interfere with success. Renowned industrial and academic welding expert and prolific author and speaker Robert W. Messler, Jr. guides readers to the solutions they seek with a well-organized search based on how a problem manifests itself (i.e., as distortion, defect, or appearance), where it appears (i.e., in the fusion zone heat-affected zone, or base metal), or it certain materials or situations.<br>
<p>Preface xi</p> <p><b>1 Introduction 1</b></p> <p>Further Reading 6</p> <p><b>2 Categorization of Welding and Weld Problems 7</b></p> <p>2.1 What Is Welding? 7</p> <p>2.2 Microstructural Zones of Welds 13</p> <p>2.3 Origin of Problems in Welding and Welds 19</p> <p>2.4 How Problems Can Be Logically Categorized? 20</p> <p>References 21</p> <p>Further Reading 21</p> <p><b>Part I Manifestation of Problems with Welds and Weldments 23</b></p> <p><b>3 Problems with Joint Setup and Weld Joints 25</b></p> <p>3.1 Joint Efficiency 25</p> <p>3.2 Weld Joint Types and Weld Configurations 26</p> <p>3.3 Joint Setup Problems 31</p> <p>3.4 Problems with Weld Profile 35</p> <p>3.5 Troubleshooting Guide 42</p> <p>References 45</p> <p>Further Reading 45</p> <p><b>4 Shape Distortion, Dimensional Shrinkage, and Geometric Instability 47</b></p> <p>4.1 Thermal Versus Mechanical Stresses in a Structure 47</p> <p>4.2 Residual Stresses Versus Distortion 48</p> <p>4.3 Origin and Effect of Volumetric Shrinkage 48</p> <p>4.4 Origin and Effect of Thermal Contraction 52</p> <p>4.5 Problems from Nonuniform Thermal Contraction and CTE Mismatches 57</p> <p>4.6 Problems from Distortion and from Residual Stresses 60</p> <p>4.7 Distortion Control and Residual Stress Reduction 60</p> <p>4.8 Troubleshooting Guide 65</p> <p>References 65</p> <p>Further Reading 66</p> <p><b>5 Porosity 67</b></p> <p>5.1 The Most Common Problem in Welds 67</p> <p>5.2 Types of Weld Porosity 70</p> <p>5.3 Gases in Molten Weld Metal 73</p> <p>5.4 The Many Possible Causes of Porosity in Welds 79</p> <p>5.5 Attempting to Minimize Porosity Formation in Fusion Welds 84</p> <p>5.6 Troubleshooting Porosity Problems in Welds 85</p> <p>References 87</p> <p>Further Reading 87</p> <p><b>6 Cracks 89</b></p> <p>6.1 The Most Dreaded Defect in Welds 89</p> <p>6.2 Classification of Cracking and Cracks in Welds and Welding 90</p> <p>6.3 Hot Cracking and Cracks 91</p> <p>6.4 Cold Cracking and Cracks 98</p> <p>6.5 Other Weld-Related Cracking and Cracks 101</p> <p>6.6 Crack-Prone Metals and Alloys 102</p> <p>6.7 Troubleshooting Cracking Problems in Welds 105</p> <p>References 106</p> <p>Further Reading 107</p> <p><b>7 Nonmetallic and Metallic Inclusions 109</b></p> <p>7.1 Solid Versus Gas Inclusions 109</p> <p>7.2 Nonmetallic Inclusions in Welds 110</p> <p>7.3 Metallic Inclusions in Welds 114</p> <p>7.4 Troubleshooting Problems with Inclusions in Welds 115</p> <p>References 116</p> <p>Further Reading 116</p> <p><b>8 Weld Appearance 117</b></p> <p>8.1 Can You Judge a Book by Its Cover? Is Beauty Only Skin Deep? 117</p> <p>8.2 Weld Crown Bead Faults 118</p> <p>8.3 Weld Root Bead Faults 121</p> <p>8.4 Fillet Weld Faults 123</p> <p>8.5 Reading Weld Ripple Marks 124</p> <p>8.6 Weld Spatter 126</p> <p>8.7 Arc Strikes 128</p> <p>8.8 Weld Heat Tint 129</p> <p>8.9 Troubleshooting Weld Appearance Problems 132</p> <p>References 133</p> <p>Further Reading 134</p> <p><b>Part II Location of Problems in Welds 135</b></p> <p><b>9 Fusion Zone of Fusion Welds 137</b></p> <p>9.1 A Refresher on Microstructural Zones in and Around Welds 137</p> <p>9.2 Gas Porosity in the Fusion Zone of Welds 141</p> <p>9.3 Cracking in the Fusion Zone of Welds 143</p> <p>9.4 Inclusions in the Fusion Zone of Welds 151</p> <p>9.5 Macrosegregation in the Fusion Zone of Welds 152</p> <p>9.6 Troubleshooting Problems in the Fusion Zone of Welds 153</p> <p>References 155</p> <p>Further Reading 156</p> <p><b>10 Partially Melted Zone of Fusion Welds 157</b></p> <p>10.1 Origin and Location of the PMZ in Fusion Welds 157</p> <p>10.2 Conventional Hot Cracking in the PMZ 161</p> <p>10.3 Constitutional Liquation Cracking in the PMZ 161</p> <p>10.4 Cold Cracking in the PMZ 164</p> <p>10.5 Overcoming Cracking Problems in the PMZ 166</p> <p>10.6 Troubleshooting Problems in the PMZ 167</p> <p>References 167</p> <p>Further Reading 168</p> <p><b>11 Heat-Affected Zone of Fusion Welds 169</b></p> <p>11.1 Origin and Location of the HAZ for Fusion Welds 169</p> <p>11.2 Manifestation of Problems in the HAZ of Fusion Welds 170</p> <p>11.3 Precipitation-Hardening Alloy HAZ Problems 171</p> <p>11.4 Sensitization in the HAZ of Austenitic Stainless Steels 176</p> <p>11.5 Transformation-Hardening Steel HAZ Problems 179</p> <p>11.6 Reheat Cracking 183</p> <p>11.7 Troubleshooting Problems in the HAZ of Fusion Welds 186</p> <p>References 187</p> <p>Further Reading 188</p> <p><b>12 Unaffected Base Metal Cracking Associated with Welding 189</b></p> <p>12.1 Weld-Related Problems in the Unaffected Base Metal 189</p> <p>12.2 Lamellar Tearing in Thick Steel Weldments 189</p> <p>12.3 Corrosion Cracking Caused by Fusion Welding 192</p> <p>12.4 Fatigue Cracking Outside Fusion Welds 195</p> <p>12.5 Troubleshooting Weld-Related Problems in the Unaffected Base Metal 199</p> <p>References 200</p> <p>Further Reading 201</p> <p><b>13 Discontinuities in Multi-pass Welds 203</b></p> <p>13.1 Needs for Multi-pass Welding and Welds 203</p> <p>13.2 Various Functions of Multi-pass Welding and Welds 205</p> <p>13.3 Defects Found in Multi-pass Welds 207</p> <p>13.4 Composition Adjustment with Multi-pass Welding 210</p> <p>13.5 Property Alteration with Multi-pass Welding 213</p> <p>13.6 Troubleshooting Problems in Multi-pass Welding and Welds 216</p> <p>References 217</p> <p>Further Reading 217</p> <p><b>14 Problems with Non-fusion Welding and Non-fusion Welds 219</b></p> <p>14.1 Non-fusion Welding Processes Versus Fusion Welding Processes 219</p> <p>14.2 Overview of Non-fusion Processes 220</p> <p>14.2.1 Pressure Welding Processes 222</p> <p>14.2.2 Friction Welding Processes 222</p> <p>14.2.3 Diffusion Welding Processes 222</p> <p>14.2.4 Solid-State Deposition Welding 223</p> <p>14.3 Problems with Non-fusion Welds and Non-fusion Welding Processes 223</p> <p>14.4 Inspection and Repair Challenges with Non-fusion Welds 229</p> <p>14.5 Troubleshooting Problems with Non-fusion Welds 230</p> <p>References 230</p> <p>Further Reading 231</p> <p><b>Part III Material-Specific Weld-Related Problems 233</b></p> <p><b>15 Embrittlement of Carbon and Low- and Medium-alloy Steels 235</b></p> <p>15.1 The Importance of Steel 235</p> <p>15.2 Four Causes of Embrittlement in Carbon and Low- and Medium-alloy Steels 238</p> <p>15.3 Hydrogen Embrittlement: A Misnomer in Steels 239</p> <p>15.4 Secondary Hardening in Steels 240</p> <p>15.5 Ductile-to-Brittle Transition in Steels 241</p> <p>15.6 Compromise of Fatigue and Impact Behavior by Residual Stresses in Steels 243</p> <p>15.7 Troubleshooting Problems from Embrittlement of Steels by Welding 244</p> <p>References 245</p> <p>Further Reading 245</p> <p><b>16 Sensitization or Weld Decay and Knife-line Attack in Stainless Steels 247</b></p> <p>16.1 A Primer on the Metallurgy of Stainless Steels 247</p> <p>16.2 Sensitization of Austenitic Stainless Steels by Welding 249</p> <p>16.3 Sensitization of Other Grades of Stainless Steel 252</p> <p>16.4 Knife-line Attack in Stabilized Austenitic Stainless Steels 252</p> <p>16.5 Troubleshooting Problems from Sensitization or Knife-line Attack 254</p> <p>References 255</p> <p>Further Reading 255</p> <p><b>17 Stress Relief Cracking of Precipitation-Hardening Alloys 257</b></p> <p>17.1 Different Names, Same Phenomenon 257</p> <p>17.2 Stress Relief Cracking in Ferritic Alloy Steels 260</p> <p>17.3 Stress Relaxation Cracking in Stainless Steels 265</p> <p>17.4 Strain-age Cracking in Ni-Based Superalloys 267</p> <p>17.5 Troubleshooting Problems from Stress Relief or Strain-age Cracking 270</p> <p>References 271</p> <p>Further Reading 271</p> <p><b>18 Loss of Properties in Cold-Worked Metals and Alloys 273</b></p> <p>18.1 Cold Work, Recovery, Recrystallization, and Grain Growth 273</p> <p>18.2 Cold-Worked Metals and Alloys in Engineering 278</p> <p>18.3 Avoiding or Recovering Properties Loss from Fusion Welding 281</p> <p>18.4 The Worked Zone in Pressure-Welded Metals and Alloys 284</p> <p>18.5 Troubleshooting Welding Problems in Cold-Worked Metals and Alloys 285</p> <p>References 285</p> <p>Further Reading 286</p> <p><b>19 Embrittlement with High-chromium Contents 287</b></p> <p>19.1 Phase Formation and Structure 287</p> <p>19.2 Adverse Effects of σ-Phase 291</p> <p>19.3 Susceptible Alloys 291</p> <p>19.4 Guidelines for Avoiding or Resolving Problems from σ-Phase 293</p> <p>19.5 Troubleshooting Problems with σ-Phase Associated with Welding 294</p> <p>References 295</p> <p>Further Reading 295</p> <p><b>20 Weld Dilution and Chemical Inhomogeneity 297</b></p> <p>20.1 The Designer’s Druthers 297</p> <p>20.2 Chemical Inhomogeneity in Welds 300</p> <p>20.3 Weld Dilution 302</p> <p>20.4 The Unmixed Zone in the Weld Metal 304</p> <p>20.5 Impurities in the Weld Metal 307</p> <p>20.6 Troubleshooting Problems from Weld Dilution and Chemical Inhomogeneity 307</p> <p>References 308</p> <p>Further Reading 308</p> <p><b>21 Dissimilar Metal and Alloy Welding 309</b></p> <p>21.1 Joining Dissimilar Materials 309</p> <p>21.2 The Need for Welding Dissimilar Metals and Alloys 311</p> <p>21.3 Chemical Incompatibility 311</p> <p>21.4 Mechanical Incompatibility 315</p> <p>21.5 Thermal Incompatibility 315</p> <p>21.6 Troubleshooting Problems with Dissimilar Metal and Alloy Welding 318</p> <p>References 318</p> <p>Further Reading 319</p> <p>Closing Thoughts 321</p> <p>Index 323</p>
<p><b><i>Robert W. Messler, Jr., Ph.D., FASM, FAWS,</i></b><i> is Emeritus Professor of Materials Science & Engineering at Rensselaer Polytechnic Institute, Troy, NY. His career spans more than four decades in diverse areas of advanced materials and processes in public and private industry and in academia, with unparalleled expertise in all aspects of joining. This "engineer who teaches" has authored more than a hundred technical papers and seven other engineering books. A Practical Guide to Welding Solutions being the logical complement to his renowned Principles of Welding, also by Wiley.</i>
<p>As critically important as welding is to a wide spectrum of manufacturing, construction, and repair, it is not without its problems. Those dependent on welding know only too well how easy it is to find information on the host of available processes and on the essential metallurgy that can enable success, but how frustratingly difficult it can be to find guidance on solving problems that sooner or later arise with welding, welds, or weldments. <p>Here for the first time is the book those that practice and/or depend upon welding have needed and awaited. <i>A</i> <i>Practical Guide to Welding Solutions</i> addresses the numerous technical and material-specific issues that can interfere with success. Renowned industrial and academic welding expert and prolific author and speaker Robert W. Messler, Jr. guides readers to the solutions they seek with a well-organized search based on how a problem manifests itself (i.e., as distortion, defect, or appearance), where it appears (i.e., in the fusion zone, heat-affected zone, or base metal), or in which materials or situations. <p>True to form, Dr. Messler makes readers feel he is speaking directly to them with his clear conversational but unambiguous writing style. Figures, tables and footnotes complement and augment the text suited to welding neophytes and veterans alike.

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