Welding Metallurgy. Sindo Kou

interface with craters: (a) schematic sketch of stee...Figure 22.14 Intermetallic layers at weld/steel interfaces: (a) SEM image of...Figure 22.15 Lap welding of 3.2 mm 5754 Al (~Al‐3Mg) to 2.5 mm galvanized st...Figure 22.16 Effect of joint gap: (a) joint gap; (b) thickness of intermetal...Figure 22.17 Regular GMAW: (a) current; (b) voltage; (c) SEM of weld/steel i...Figure 22.18 Adaptive Pulsed GMAW: (a) current; (b) voltage; (c) SEM of weld...Figure 22.19 Lower heat input of adaptive pulsed GMAW resulting in higher jo...Figure 22.20 Arc brazing Al to stainless steel by GTAW: (a) with workpiece u...Figure 22.21 Effect of preheating on wetting angle and width of bonding in g...Figure 22.22 5A02 Al (~Al‐2.4Mg‐0.4Si) joined to 304 stainless steel by GTAW...Figure 22.23 Decreasing the interlayer thickness and increasing the joint st...Figure 22.24 Welding steel to Al by laser‐beam welding with a keyhole.Figure 22.25 Steel‐to‐Al laser‐beam welding: (a) welding with a keyhole; (b)...Figure 22.26 Dual‐beam laser welding of steel to Al: (a) process; (b) spatte...Figure 22.27 Butt joining of Mg to steel by keyhole laser brazing.Figure 22.28 Mg‐Fe phase diagram.Figure 22.29 Lap‐joined AZ31 Mg (Mg‐3Al‐1Zn) to galvanized steel, both 1.5 m...Figure 22.30 Example techniques developed by various investigators for Al‐to...Figure 22.31 Joining 2 mm 5052 Al to 1 mm low‐carbon steels that are: (a) ga...Figure 22.32 301L stainless steel welded to 6063 Al by RSW: (a) vertical sec...Figure 22.33 Example techniques developed by various investigators for dissi...Figure 22.34 Mechanism of resistance spot welding of Mg to galvanized steel:...Figure 22.35 5754 Al (2 mm) joined to AZ31 Mg (2 mm) by RSW with a galvanize...Figure 22.36 Tool for friction‐stir spot welding of 6061 Al (~Al‐1Mg‐0.6Si) ...Figure 22.37 Tool holder for wireless temperature measurements: (a) tool hol...Figure 22.38 A high‐strength weld between 6061 Al and Cu: (a) vertical cross...Figure 22.39 Strength of Al‐to‐Cu weld made by FSSW: (a) shear‐tension‐test ...Figure 22.40 Comparison between welds: (a) strong weld with a Cu ring extrud...Figure 22.41 Effect of plunge rate on strength of welds of 6061 Al and Cu ma...Figure 22.42 Wild fluctuations in joint strength in 100 Al‐to‐Cu welds made ...Figure 22.43 Tool left in sample after welding. 1.5 mm thick 6061‐T6 aluminu...Figure 22.44 Flow of material during FSSW of 6061 Al to Cu: (a) Al‐rich, sti...Figure 22.45 Buildup of brittle Cu‐rich intermetallics at pin tip in FSSW of...Figure 22.46 Vertical cross‐section of spot weld of A357 Al (~Al‐7Si) to gal...Figure 22.47 Microstructure and flow pattern in A357 Al (top) welded to galv...Figure 22.48 Optical micrograph near the triple junction between the stir zo...Figure 22.49 Optical micrographs of interfaces in welds made by FSSW between...Figure 22.50 Joining Al to bare steel by FSSW. The lamellar structure consis...Figure 22.51 Joining Al to coated steel by FSSW. No lamellar structure is fo...Figure 22.52 Testing the joint strength of Al‐to‐steel welds made by FSSW: (...Figure 22.53 Fracture surfaces of welds made by FSSW of 6061 Al welded to va...Figure 22.54 Refill FSSW: (a) tool assembly is brought in contact with Al, a...Figure 22.55 Loss of weld strength in refill FSSW of Al to galvanized DP600 ...Figure 22.56 Al‐to‐steel welds produced using 1800 rev/min, 1.0 mm penetrat...Figure 22.57 Linear friction welding of Al to Mg.Figure 22.58 Effect of pressure on formation of Al_xMg_y intermetallic compoun...Figure 22.59 Al‐to‐Cu joints made by rotary friction welding showing effect ...Figure 22.60 Al‐to‐Mg explosion weld.Figure 22.61 Al tube welded to carbon steel rod by magnetic pulse welding....Figure 22.62 Lap joint between AZ31 Mg and 3003 Al prepared by magnetic puls...Figure E22.1 An Al tube joined by solid‐state welding to a Cu tube with an ...Figure P22.1 Sample cut vertically from a weld made between three horizontal...

      23 Chapter 23Figure 23.1 Spatter and vapor deposition on 1.6 mm‐thick AZ31 Mg after GMAW....Figure 23.2 Low Mg density is why Mg globule is light and unable to detach b...Figure 23.3 Conventional GMAW of Mg alloy showing a nearly horizontal globul...Figure 23.4 Voltage and current waveforms during conventional GMAW of AZ31 M...Figure 23.5 First use of GMAW‐CSC welding for Mg sheets. No sudden expansion...Figure 23.6 Voltage and current waveforms during GMAW‐CSC of AZ31 Mg: (a) cu...Figure 23.7 First weld of AZ31 Mg made by GMAW‐CSC, butt weld between 1.6‐mm...Figure 23.8 Lap weld of 1.6‐mm‐thick AZ31 Mg made by GMAW‐CSC: (a) top view ...Figure 23.9 Elimination of fingers from lap weld of 1.6‐mm‐thick AZ31 Mg: (a...Figure 23.10 Gas porosity in AZ31 Mg alloy (~Mg‐3Al‐1Zn) welded by conventio...Figure 23.11 Gas porosity in AZ31 Mg alloy welded by GMAW‐CSC: (a) as‐receiv...Figure 23.12 Tensile testing curves showing porosity can significantly reduc...Figure 23.13 Mechanism of gas‐porosity formation in GMAW of Mg alloys: (a) m...Figure 23.14 Filler wires on spools after extended exposure to air: (a) surf...Figure 23.15 Much higher H solubility (and drop upon solidification) in Mg t...Figure 23.16 Entrapment of oxide films in weld #002: (a) rough edge caused b...Figure 23.17 As‐sheared edges of 1.6‐mm‐thick sheets: (a) rough edge of AZ31...Figure 23.18 Proposed mechanism of oxide‐film entrapment and remedies: (a) m...Figure 23.19 Elimination of oxide films from weld #007: (a) milling of edge ...Figure 23.20 Elimination of oxide films from weld #008: (a) rough edge cause...Figure 23.21 High crowns on butt welds made at travel speeds of: (a) 7.6 mm/...Figure 23.22 Weld #052 with a high crown: (a) top view of weld; (b) transver...Figure 23.23 Mechanism and reduction of high‐crown formation: (a) during sol...Figure 23.24 High crown in Mg butt welding and its reduction: (a) high crown...Figure 23.25 Grain refining of AZ31 Mg by stirring weld pool with an ultraso...Figure 23.26 Grain refining AZ91 Mg weld by transverse arc oscillation at 1 ...Figure 23.27 Crack susceptibility ranking of some commercial Mg alloys: (a) ...Figure 23.28 By welding right next to the starting edge of the workpiece and...Figure 23.29 Liquation cracking in a Mg‐6Zn cast plate (100 mm × 100 mm × 10...Figure 23.30 SEM image of fracture surface caused by liquation cracking in G...Figure 23.31 Liquation cracking at starting edges of workpiece after GTAW: (...Figure 23.32 Effect of Zn content on extents of liquation (GB liquation and ...Figure 23.33 AZ31 Mg workpiece for circular‐weld test. A circular weld can b...Figure 23.34 AZ91 Mg welded with AZ31 Mg filler wire: (a) T‐f _S curves predic...Figure 23.35 AZ31 Mg welded with AZ92 Mg filler wire: (a) T‐f _S curves predic...Figure 23.36 Grain growth in heat‐affected zone (HAZ) of weld of 1.6 mm‐thic...Figure 23.37 Friction stir weld of AZ31B‐H24 (work‐hardened): (a) grain size...Figure E23.1 Partially melted zone (PMZ) in a weld made by GTAW of an as‐cas...Figure E23.2 Lap welding of Mg sheets by GMAW‐CSC with a stationary steel ba...Figure P23.1 Curves of T vs. f _S for AZ91 Mg (workpiece, i.e., the outer piec...Figure P23.2 Transverse cross‐section of butt joint of Weld #002 (left) flip...

      24 Chapter 24Figure 24.1 Microstructure near weld pools: (a) CoCrFeNiCu₀ showing secondar...Figure 24.2 T‐f _S curves of high‐entropy alloys: (a) CoCrFeNiCu₀ showing a ve...Figure 24.3 Susceptibility to hot cracking: (a) CoCrFeNiCu₀ showing no crack...Figure 24.4 6061 Al reinforced with 20% Al₂O₃ particles welded by gas‐tungst...Figure 24.5 Transverse macrographs of bead‐on‐plate welds made by GTAW of 6 ...Figure 24.6 Top views of welds made by GTAW of 6 mm‐thick A356 alloy cast wi...Figure 24.7 Nanoparticles and weld size: (a) smaller pool and weld without n...Figure 24.8 As‐cast Al‐Si alloys: (a) without nanoparticles; (b) with 1 wt% ...Figure 24.9 Weld of Al‐7Si‐0.3Mg‐0.5Cu without nanoparticles: (a) transverse...Figure 24.10 Weld of Al‐7Si‐0.3Mg‐0.5Cu with nanoparticles: (a) transverse m...Figure 24.11 Al‐rich (α) dendrites and α/Si interdendritic eutectic in welds...Figure 24.12 Micrographs of full‐penetration welds of as‐cast A356 plates (6...Figure 24.13 Nanoparticles reducing cracking during solidification: (a) hot ...Figure 24.14 Friction stir welding (FSW) of Al‐matrix composite with 30 vol%...Figure 24.15 Friction stir weld of Mg‐matrix nanocomposite with 5%SiC nanopa...Figure P24.1 Microstructure at the top surface of a CoCrFeNiCu₁ weld near th...

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