Module 1
Module 1 – Introduction Introduction
Overview
1-2
Module 1 – Introduction Introduction
1-3
Module 1 – Introduction Introduction
Expectations
Periodic Review
Discussion and review of modules when time permits
No final exam requirement
Feedback
Surveys on individual topics
End of course survey
1-4
Module 1 – Introduction Introduction
What is a Weld?
1-5
Module 1 – Introduction Introduction
What is Welding?
1-6
Module 1 – Introduction Introduction
What is Welding?
1-7
Module 1 – Introduction Introduction
What is Welding?
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Module 1 – Introduction Introduction
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Module 1 – Introduction Introduction
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Module 1 – Introduction Introduction
Cost
Fitness-for-service
Process Industrial Electrical
Technologies Engineering Engineering
Materials Mechanical Nondestructive
Science Engineering Evaluation
1-11
Module 1 – Introduction Introduction
Duration
Topic Instructor
(Days)
Introduction 1 Steve Levesque
1-12
Module 1 – Introduction Introduction
Expectations
1-13
Welding and Cutting Processes
Overview
Module 1A
Module 1 – Introduction Welding and Cutting Overview
Fusion Welding
1-15
Module 1 – Introduction Welding and Cutting Overview
Solid-State Welding
1-16
Module 1 – Introduction Welding and Cutting Overview
1-17
Module 1 – Introduction Welding and Cutting Overview
Non-consumable tungsten
electrode
Can be performed with or without
filler material
Gas shielding
Manual, semi-automatic,
automatic
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Module 1 – Introduction Welding and Cutting Overview
1-20
Module 1 – Introduction Welding and Cutting Overview
1-21
Module 1 – Introduction Welding and Cutting Overview
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Module 1 – Introduction Welding and Cutting Overview
Stud Welding
Friction Welding
Ultrasonic Welding
Resistance Welding
Applications
Cladding
Seam welds
1-29
Module 1 – Introduction Welding and Cutting Overview
1-30
Module 1 – Introduction Welding and Cutting Overview
Welding Automation
Semi-automatic Automatic
Machine
(Mechanized)
1-31
Welding Metallurgy Overview
Module 1B
Module 1 – Introduction Welding Metallurgy Overview
Atomic Bonds
Metallic Bonding
Fe is the solvent
Elastic modulus
C is the solute
Crystal Structures
Defects
Solid Solutions
Phase Diagrams
γ α + Fe3C
Diffusion γ
γ
Strengthening Mechanisms γ
Grain Size
Temperature
α+γ γ + Fe3C
α
Solid Solutions
Cold Work (Strain Hardening) α + Fe3C
γ
γ
Precipitation
Fe Composition C
1-33
Module 1 – Introduction Welding Metallurgy Overview
Atomic bonds
Ionic, covalent, metallic
Metallic bonding
Free electrons + Attractive force
Elastic behavior (Coulomb attraction)
Total
force
Force
Metallic Bonding Bond
Distance
Metal ions
+ - + - + - + Length
“Sea” of
- + - + - + - Repulsive force
-
+ - + - + - +
electrons
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Module 1 – Introduction Welding Metallurgy Overview
Crystal structures
BCC
Iron & ferritic steels BCC
FCC
Ni alloys & Al alloys
HCP
Ti (alpha alloys) & Zr
FCC
HCP
1-35
Module 1 – Introduction Welding Metallurgy Overview
Solid solutions
Substitutional
Ni-Cu alloys
Interstitial Ni is the solvent
Steels Cu is the solute
Substitutional
Fe is the solvent
C is the solute
Interstitial
1-36
Module 1 – Introduction Welding Metallurgy Overview
Defects
Dislocations & grain boundaries Grain boundaries
Diffusion
Vacancy, interstitial, interdiffusion
Strengthening mechanisms
Grain size reduction
Solid solutions
Strain hardening (cold work)
Precipitation hardening
Cold work expressed in
terms of area reduction:
Ainitial − A final
%CW = *100
Ainitial
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Module 1 – Introduction Welding Metallurgy Overview
Phase Diagrams
Liquidus line
Solvus line
L
Temperature
L+α
L+β
α β
Solidus line
α+β
A B
Composition
1-38
Module 1 – Introduction Welding Metallurgy Overview
Phase Transformations
Welding Metallurgy
Mechanical
Properties
1-40
Module 1 – Introduction Welding Metallurgy Overview
Solidification
Nucleation
Heterogeneous nucleation is dominate in welding
Occurs from a foreign particle (oxide, nitride, sulfide, etc.)
Weld pool shape
Teardrop vs. elliptical
Teardrop
Elliptical
1-41
Module 1 – Introduction Welding Metallurgy Overview
Fusion
Boundary
Composite Region
True Heat-
Affected Zone
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Module 1 – Introduction Welding Metallurgy Overview
Dilution
Amount of melted base metal mixed
with the filler metal
Significant effect on microstructure
and properties
a+c
May exhibit three regions Dilution (%) =
a+b+c
x 100
Composite zone
Transition zone Austenitic
Stainless Steel
Unmixed zone
Weld
Metal Former
UMZ
SEM
1-43
Module 1 – Introduction Welding Metallurgy Overview
1-44
Module 1 – Introduction Welding Metallurgy Overview
Alloys
Carbon steels
Stainless steels
Ni-alloys
Al-alloys
Ti-alloys
Cu-alloys
Polymers
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Module 1 – Introduction Welding Metallurgy Overview
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Module 1 – Introduction Welding Metallurgy Overview
Local Hardening/Softening
1-48
Module 1 – Introduction Welding Metallurgy Overview
Ductility
Ductility Dip
1-49
Module 1 – Introduction Welding Metallurgy Overview
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Module 1 – Introduction Welding Metallurgy Overview
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Module 1 – Introduction Welding Metallurgy Overview
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Module 1 – Introduction Welding Metallurgy Overview
POLYMER
THERMOSET THERMOPLASTIC
AMORPHOUS SEMI-CRYSTALLINE
Thermoset
Amorphous Semi-crystalline
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