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Tapany Udomphol
Sep-Dec 2007
Tapany Udomphol
Sep-Dec 2007
Objectives
This chapter provides information on the development of grain structure in the fusion zone, partially melted zone and heat affected zone. This also includes the background of nucleation and grown of grain in the weld pool, the formation of the partially melted zone and phase transformation of heat affected zone Students are required to identify the effect of welding parameter on the grain structure in the fusion zone, heat affected zone and techniques used for weld microstructure improvement.
Tapany Udomphol
Sep-Dec 2007
Cast structure
Fusion welding
Suranaree University of Technology
Tapany Udomphol
Welding structure
Sep-Dec 2007
Columnar grains
250 mm/min
Axial grains
Columnar grains
Columnar grains
GTAW of 99.96% aluminium (a) 1000 mm/min and (b) 250 mm/min welding speeds.
Suranaree University of Technology
Tapany
Axial grains of GTAW (a) 1100 aluminium at 12.7 mm/s welding speed, (b) 2014 aluminium at 3.6/s welding speed. Sep-Dec 2007 Udomphol
Heat input
Sep-Dec 2007
where
LC LS CS
Tm Hm T
is the surface energy of the liquid-crystal interface is the surface energy of the liquid-substrate interface is the surface energy of the crystal-substrate interface is the equilibrium melting temperature is the latent heat of melting. is the undercooling temperature below Tm is the contact angle
Tapany Udomphol
Sep-Dec 2007
Note: for FCC and BCC structures, columnar dendrites (or cell) grow in the <100> direction.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Base metal
Examples Aluminium alloys Austenitic stainless steels Carbon steels, ferritic stainless steels Titanium, magnesium Tin
Sep-Dec 2007
[111]
[001] [010]
Random orientation
Fusion zone
HAZ
HAZ
(b)
Preferred orientation
Base metal
Base metal
0.5 mm
Fusion line Grain orientations in (a) base metal and (b) fusion zone obtained from EBSD analysis
Tapany Udomphol
Sep-Dec 2007
Fusion boundary
Base metal
Non-epitaxial growth at the fusion boundary of 409 stainless steel (bcc) welded with Monel (70Ni30Cu) filler wire (fcc), (a) optical, (b) SEM.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Epitaxial growth from the fusion boundary of autogenous TIG welding of titanium alloy.
HAZ Ti base metal
Ti base metal
HAZ
2 mm
Fusion zone
Ti alloy
Non-epitaxial growth from the fusion boundary of Ti-679 alloy TIG welding with titanium alloy as filler metal.
HAZ
HAZ
Fusion zone
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Solidification modes
The fusion zone microstructure depends on the solidification behaviour of the weld pool, which controls the size and shape of the grains, segregation, and the distribution of inclusions and porosity. As constitutional supercooling increases, the solidification mode changes from planar cellular dendritic.
Planar
Supercooling
Heterogeneous nucleation
Cellular
Time
Equiaxed dendritic
Size of dendrite
Tapany Udomphol
Sep-Dec 2007
Weld pool
G G << R CL R FL
Sep-Dec 2007
Sep-Dec 2007
Fusion line
Planar to cellular and cellular to dendritic transitions in 1100 Al welded Sep-Dec 2007 with 4047 filler.
Grain detachment
Weld pool convection also causes partially melted grains to detach themselves from the solid-liquid mixture surrounding the weld pool giving nucleii for new grains.
Heterogeneous nucleation
Foreign particles present in the weld pool can act as heterogeneous nuclei.
Surface nucleation
Surface nucleation is induced by applying cooling gas or by instantaneous reduction or removal of heat input at the weld pool surface.
Suranaree University of Technology
Nucleation mechanisms during welding (a) top view, (b) side view.
Tapany Udomphol
Sep-Dec 2007
Heterogeneous nucleation
Ex: 1) In GTAW of aluminium, TiB2 particle is found to act as heterogeneous nuclei (grain refiner as in casting). 2) In GTAW of ferritic stainless steel, TiN particles act as heterogeneous nuclei.
Suranaree University of Technology
Heterogeneous nuclei in GTAW of 6061 Al (a) optical, (b) EDS analysis, (c ) SEM. Sep-Dec 2007
(a) 70Ax11V heat input and 5.1 mm/s welding speed, (b) 120Ax11V heat input and 12.7 mm/s welding speed.
Tapany Udomphol
Sep-Dec 2007
PMM(S+L) MZ(S+L)
PMM(S+L)
Sep-Dec 2007
The mushy zone behind the shaded area consists of solid dendrites (S) and interdendritic liquid (L).
Fusion line
Partially melted materials (PMM) consists of solid grains (S) that are partially melted and intergranular liquid (L).
Microstructure around the weld pool boundary of aluminium alloy (a) phase diagram, (b) thermal cycles, (c ) microstructure of solid plus liquid around weld pool.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Weld direction
High speed
Top view
Teardrop
Elliptical
Low speed
Effect of welding speed on columnar grain structure in weld metal.
Tapany Udomphol
Sep-Dec 2007
Electrode diameter Weld bead size Amount of weld bead HAZ size Increase the electrode diameter will increase the heat input and this also coarse microstructure. increase the cooling time.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Inoculation Arc oscillation Arc pulsation Stimulated surface nucleation Manipulation of columnar grains Gravity
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Inoculation
Similar to casting, inoculants are added into the liquid weld metal to promote heterogeneous nucleation, giving very fine equiaxed grains.
Weld metal structure
1) Titanium carbide powder and ferrotitanium-titanium carbide mixture used in SAW of mild steels. 2) Titanium used in SAW of C-Mn stainless steels and GTAW of Al-Li-Cu alloy. 3) Ti and Zr used in aluminium welds. 4) Aluminium nitride used in Cr-Ni iron base alloys.
Weld metal structure Effect of inoculation on grain structure in SAW of C-Mn steel (a) without inoculation (b) inoculation with titanium.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Effect of inoculants on grain structure in GTAW of 2090 Al-Li-Cu alloy (a) 2319 Al-Cu filler metal, (b) 2319 Al-Cu filler metal inoculated with 0.38% Ti.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Effect of electromagnetic pool stirring on grain structure in GTAW of 409 ferritic stainless steel (a) without stirring, (b) with stirring.
Tapany Udomphol
Sep-Dec 2007
Arc oscillation
Arc oscillation can be produced by 1) Magnetically oscillating the arc column using a single or multiple magnetic probe. 2) Mechanically vibrating the welding torch. Grain refining is achieved by dendrite fragmentation and heterogeneous nucleation.
Arc oscillating
Grain size
Sep-Dec 2007
Tapany Udomphol
Sep-Dec 2007
Arc pulsation
Arc pulsation is obtained by pulsing the weld current (using peak and base current).
AC pulsed current
The liquid metal was undercooled when the heat input was suddenly reduced during the low-current cycle of pulsed arc welding. Grain refinement is due to surface nucleation and/or heterogeneous nucleation in pulsed welding with the aid of grain refiner such as 0.04wt% Ti in 6061 Al alloy.
Equiaxed grains in pulsed arc weld of 6061 aluminium.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
(a) No arc pulsing or oscillation, (b) with arc pulsing, (c ) with arc oscillation, (d) with both arc pulsing and oscillation.
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Tapany Udomphol
Sep-Dec 2007
Gravity
GTAW of 2195 aluminium under high gravity produced by a centrifuge welding system and eliminated the narrow band of nondendritic equiaxed grains along the fusion boundary.
Tapany Udomphol
Sep-Dec 2007