Trends in Welding Research Proceedings of the 8th International Conference June 1–6, 2008 Callaway Gardens Resort Pine Mountain, Georgia, USA Editors Stan A. David Tarasankar DebRoy John N. DuPont Toshihiko Koseki Herschel B. Smartt Sponsored by Published by ASM International® Materials Park, Ohio 44073-0002 www.asminternational.org Copyright (cid:2) 2009 by ASM International® All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, June 2009 Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. 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ISBN-13: 978-1-61503-002-6 ISBN-10: 1-61503-002-6 SAN: 204-7586 ASM International® Materials Park, OH 44073-0002 www.asminternational.org Printed in the United States of America Cover images are orientation imaging micrographs showing grain distribution in a friction stir welded nickel-base superalloy single crystal. Courtesy of Oak Ridge National Laboratory Conference Co-Chairmen Dr. Stan A. David, FASM Oak Ridge National Laboratory Oak Ridge, Tennessee Dr. Tarasankar DebRoy, FASM Dr. Herschel B. Smartt The Pennsylvania State University Idaho National Engineering and University Park, Pennsylvania Environmental Laboratory Idaho Falls, Idaho Dr.Toshihiko Koseki Dr. John N. DuPont, FASM The University of Tokyo Lehigh University Tokyo, Japan Bethlehem, Pennsylvania International Organizing Committee Prof. Yixiong Wu Prof. Harry K.D.H. Bhadeshia Dr. John W. Elmer Shanghai Jiaotong University University of Cambridge University of California Shanghai, China Cambridge, United Kingdom Livermore, California, USA Prof. P.S. Wei Mr. Chris Conrandy Prof. Konstantin Yushchenko National Sun Yat-Sen University Edison Welding Institute E. O. Paton Electric Welding Kaohsiung, Taiwan Columbus, Ohio, USA Institute Kiev, Ukraine Prof. Horst Cerjak Prof. Sindo Kou Graz University of Technology University of Wisconsin Prof. Stephen Liu Graz, Austria Madison, Wisconsin, USA Colorado School of Mines Golden, Colorado, USA Dr. Christoph Wiesner Prof. Yanhong Wei TWI LTD, Granta Park Harbin Institute of Technology Prof. Hiroyuki Kokawa Great Abingtonmadison, Harbin, China Tohoku University Sendai Wisconsin, USA Japan Prof. Amitava DeIndia Institute of Technology, Bombay Powai Mumbai, India iii Preface The 8th International Conference on Trends in Welding Research (TWR) was held on June 1–6, 2008, at the Callaway Garden Resort in Pine Mountain, Georgia (USA). About 190 papers were presented by delegates from 26 countries. The excellent technical program was comprised of oral and poster presentations, eight keynote talks by world renowned experts, and the excellent conference venue, which all contributed to the success of the meeting. The Conference also provided ample opportunities for delegates to meet world renowned experts in the field and have discussions in an informal setting. The Trends conference has always attracted the world’s leading welding researchers. This year the conference consisted of 23 technical sessions and a poster session. The topics covered in these sessions included friction stir welding, sensing, control and automation, microstructure and properties, welding processes, procedures and consumables, weldability, modeling, phase transformations, residual stress and distortion, physical processes in welding, and properties and structural integrity of weldments. We thank the keynote speakers, participants, and the international organizing committee members for making the conference an exciting event, as well as our Endorsing Sponsors which include ASTM International, Japan Welding Society, Association for Iron & Steel Technology (AIST), The Welding Institute, and American Welding Society. We would like to thank the staff of ASM International, in particular, Kim Schaefer and Anya Hodgson for their contributions, and we look forward to another successful Trends Conference in 2011. Stan A. David Tarasankar DebRoy John N. DuPont Toshihiko Koseki Herschel B. Smartt Co-Chairmen, 8th International Conference on Trends in Welding Research iv Contents Keynote 1 – Friction Stir Welding I Thermomechanical Modelling of Friction Stir Welding ............................................................1 J.H. Hattel, H.N.B. Schmidt, C. Tutum; Technical University of Denmark, Lyngby, Denmark Keynote 2 – Microstructure Grain Boundary Engineering of Austenitic Stainless Steels .................................................11 H. Kokawa, M. Michiuchi, M. Shimada, Z.J. Wang, Y.S. Sato; Tohoku University, Sendai, Japan Keynote 3 – Sensing Process Control and Automation Developments in Welding .................................................17 J. Norrish, University of Wollongong, NSW, Australia Keynote 4 – Friction Stir Welding II Recent Developments of FSW Technologies: Evaluation of Root Defects, Composite Refractory Tools for Steel Joining, and One-Pass Welding of Thick Sections Using Self-Reacting Bobbin Tools .................................................................25 W.M. Thomas, C.S. Wiesner; TWI Ltd, Cambridge, UK Keynote 5 – Advances in Welding Generation II Materials Science for Welds and Advanced Materials .....................................35 D.L. Olson1, J.E. Jackson1, B. Mishra1, M.J. Kaufman1, A.N. Lasseigne-Jackson2, R.B. Thompson3, A. Landau4, M. Pinkas4; (1) Colorado School of Mines, Golden, CO, USA, (2) National Institute of Standards and Technology, Boulder, CO, USA, (3) Center for Nondestructive Evaluation, Iowa State University, Ames, IA, USA, (4) Nuclear Research Center, Negev, Beer Sheva, Israel Keynote 7 – Residual Stress and Distortion Distortion and Residual Stress in Welds: The Next Generation ............................................45 J. Goldak; Carleton University, Ottawa, Canada Keynote 8 – Transport Phenomena Macrosegregation in Arc Welds Caused by Dissimilar Filler Metals .....................................53 S. Kou, Y.K. Yang; University of Wisconsin, Madison, WI, USA v Friction Stir Welding – Processing An Experimental and Numerical Approach to Evaluate the Effect of Welding Conditions on Temperature during Friction Stir Spot Welding ..............................60 D. Kim1, K. Chung1, H. Badarinarayan2; (1) Seoul National University, Seoul, Korea, (2) Hitachi America Ltd., Farmington Hills, MI, USA Properties and Forces of Immersed Friction Stir Welded AA6061-T6 ...................................67 T.S. Bloodworth, G.E. Cook, A.M. Strauss; Vanderbilt University, Nashville, TN, USA Effect of Welding Speed on Lap Joint Quality of Friction Stir Welded AZ31 Magnesium Alloy ...........................................................................72 X. Cao, M. Jahazi; National Research Council Canada, Montreal, QB, Canada Joint Tracking in Friction Stir Welding ....................................................................................81 P.A. Fleming1, D.H. Lammlein1, D.M. Wilkes1, G.E. Cook1, A.M. Strauss1, D.R. DeLapp1, D.A. Hartman2; (1) Vanderbilt University, Nashville, TN, USA, (2) Beyond6 Sigma, Santa Fe, NM, USA Friction Stir Welding of Aluminium-Silicon-Coated Steel ......................................................85 C.H.J. Gerritsen1, C.A. Weis Olea2; (1) ArcelorMittal Research Industry Gent/OCAS N.V., Zelzate, Belgium, (2) GKSS-Forschungszentrum Geesthacht G.m.b.H, Geesthacht, Germany Friction Stir Processing of AA6061-T4 - Cold Rolled vs. As Cast .........................................90 M. Iordachescu1, J. Ruiz-Hervias1, D. Iordachescu1, P. Vilaça2, J. Planas1; (1) Universidad Politécnica de Madrid, Madrid, Spain, (2) Instituto Superior Tecnico, Lisbon, Portugal Shoulder-Less Conical FSW Tools: An Evaluation on 1/8” Thickness Al-6061 Butt Welds ............................................................96 D. Lammlein, D. DeLapp, P. Fleming, A. Strauss, G. Cook; Vanderbilt Welding Automation Lab, Nashville, TN, USA Parameterization of Friction Stir Welding of Al 6061/SiC/17.5p ...........................................102 T. Prater, G. Cook, A. Strauss, J. Davidson; Vanderbilt University Welding Automation Laboratory, Nashville, TN, USA Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V ........................................108 J.A. Querin, H.A. Rubisoff, J.A. Schneider; Mississippi State University, Mississippi State, MS, USA The Influence of the Tool Profile in Friction Stir Spot Welding of the Aluminum Alloy AA6181-T4 ....................................................................................................113 F.D. Ramos1, M. Tier1, A.A.M. da Silva1, T. Rosendo1, J.A.E. Mazzaferro1, C.C.P. Mazzaferro1, A. Reguly2, T.R. Strohaecker2, J.F. dos Santos1; (1) GKSS Research Centre, Geesthacht, Germany, (2) PPGEM – UFRGS, Porto Alegre, Brazil vi Robotic Welding and Inspection System ...............................................................................121 H.B. Smartt, D.P. Pace, E.D. Larsen, T.R. McJunkin, C.I. Nichol, D.E. Clark, K.L. Skinner, M.L. Clark, T.G. Kaser, C.R. Tolle; Idaho National Laboratory, Idaho Falls, ID, USA Experimental Investigation of Material Flows within FSWs Using 3D Tomography ..................................................................................................126 C.R. Tolle, T.A. White, K.S. Miller, D.E. Clark, H.B. Smartt; Idaho National Laboratory, Idaho Falls, ID, USA Investigation into Interface Lifting within FSW Lap Welds ..................................................133 K.S. Miller, C.R. Tolle, D.E. Clark, C.I. Nichol, T.R. McJunkin, H.B. Smartt; Idaho National Laboratory, Idaho Falls, ID, USA The Effect of Aging Heat Treatments on the Mechanical Properties of Gamma Prime Strengthened Nickel Based Superalloy Weld Metal .....................................140 G. Chirieleison1, L. Snyder2, T. Hansen2, R. Sharma2, H. White2; (1) Haynes Wire Company, Mountain Home, NC, USA, (2) Haynes International, Kokomo, IN, USA Physical Processes in Welding Development of Weldable Fe-Al-Cr-Based Corrosion Resistant Overlay Coatings ...........149 K.D. Adams, J.N. DuPont; Lehigh University, Bethlehem, PA, USA Fine Grained Nb-Ti Steel Welded by a GMAW Process .......................................................154 H.G. Svoboda1, N.M. Ramini de Rissone2, L.F.G. de Souza3, D.B. Santos4, I. de S. Bott5; (1) University National of Buenos Aires, Argentina, (2) National Technological University, Argentina, (3) CEFET/RJ, Brazil, (4) UFMG/MG, Brazil, (5) PUC-Rio/ Rio de Janeiro, Brazil Three-Dimensional Reconstruction of Microstructure in AA5754 Aluminum Alloy and Its Welded Joints ....................................................................159 J. Kang1, F. Feng2; (1) Northern College, Kirkland Lake, ON, Canada, (2) Novelis Global Technology Centre, Kingston, ON, Canada Procedure for the Alloy Development Considering Weldability ..........................................166 Y. Mae; Maetech, Saitama, Japan Scaling Laws for the Welding Arc, Weld Penetration, and Friction Stir Welding ...............172 K. Tello, U. Duman, P. Mendez; Colorado School of Mines, Golden, CO, USA Deformation Effects during Variable High Frequency Welding of Modern Steels .............182 J. Swenson, Y. Adonyi, R. Warke; LeTourneau University, Longview, TX, USA Bubble Entrapped in Solid during Solidification ...................................................................190 C.C. Hsiao, P.S. Wei, S.Y. Hsiao; National Sun Yat-Sen University, Kaohsiung, Taiwan Crack Mitigation in Buttering and Cladding Processes for a Nuclear Application ............194 Y.-P. Yang1, S. Babu1,S. Vaze1, J. Kikel2, D. Dewees2; (1) Edison Welding Institute, Columbus, OH, USA, (2) BWXT Technologies, Barberton, OH, USA vii Experimental Characterization of GTA Weld Pool Surface Flow Using PIV .......................201 C.X. Zhao1, V. van Steijn2, I.M. Richardson1, Z. Saldi1, C.R. Kleijn2; (1) Materials Innovation Institute, Mekelweg, The Netherlands, (2) Delft University of Technology, Prins Bernhardlaan, The Netherlands Modeling Evaluation of Swept Friction Stir Spot Welding through Sealants and Surface Treatments ..........................................................................................211 J. Brown1, C. Widener1, D. Burford1, B. Tweedy2, W. Horn1, G. Talia1; (1) Wichita State University, Wichita, KS, USA, (2) HF Webster Engineering Services, Rapid City, SD, USA Thermo Mechanical Finite Element Modelling of the High Speed Resistance Welding Process ..............................................................................220 R. Burrows, S.G.R. Brown; Swansea University, UK Thermal Modeling of Gas Metal Arc Girth Weld with Narrow Groove .................................226 Y. Chen, Y.-Y. Wang; Center for Reliable Energy Systems, Dublin, OH, USA Inverse Modeling of Layer-by-Layer Liquid-Metal Deposition .............................................234 K.P. Cooper, S.G. Lambrakos; Naval Research Laboratory, Washington, DC, USA Arc Welding of Dissimilar Metals: FEA and Experiments ....................................................241 E. Scutelnicu1, M. Iordachescu2, M. Blasco2, D. Iordachescu2; (1) Dunarea de Jos University of Galati, Romania, (2) Universidad Politécnica de Madrid, Spain Sensitivity Issues Concerning Inverse Heat Transfer Analysis of Welds ...........................247 S.G. Lambrakos1, H.N. Jones1, A.D. Zervaki2, G.N. Haidemenopoulos2; (1) Naval Research Laboratory, Washington, DC, USA, (2) University of Thessaly, Greece A Finite Element Based Study of Dynamic Processes in Ultrasonic Welding ....................254 C. Zhang, L. Li; Utah State University, Logan, UT, USA Welding Simulation of Cast Aluminium A356 ........................................................................258 X.-T. Pham, P. Gougeon, F.-O. Gagnon; National Research Council Canada, Chicoutimi, QB, Canada Phase Transformations Ferrite Transformation Behaviors from Steel-Oxide Interface during HAZ Thermal Cycle ..................................................................................................................264 K. Kasai, H. Kato, J. Inoue, T. Koseki; University of Tokyo, Tokyo, Japan Controlling the Phase Evolutions during Welding Toward Developments of High Strength Steel Weld Metal with Martensite Microstructure .........................................268 Y. Komizo, H. Terasaki; Osaka University, Ibaraki, Osaka, Japan In-situ Observation of Phase Transformation in Steels ........................................................272 N. Oku, K. Asakura, J. Inoue, T. Koseki; The University of Tokyo, Tokyo, Japan viii Formation of Retained Austenite in Triplex Stainless Steel Weld Metal .............................277 K. Saida1, K. Nishimoto1, K. Ogawa2, K. Fujiwara2; (1) Osaka University, Osaka, Japan (2) Sumitomo Metal Industries, Ltd., Hyogo, Japan Reverse Transformation Behaviour in B Containing High Cr Heat Resistant Steel HAZ ........................................................................................................284 T. Shirane, M. Shimizu, S. Tsukamoto, K. Tsuzaki, Y. Adachi, T. Hanamura, F. Abe; National Institute for Materials Science, Tsukuba, Ibaraki, Japan Effect of Oxides and Their Volume Fraction on Intragranular Ferrite Formation in Steel .................................................................................292 T. Suzuki, J. Inoue, T. Koseki; The University of Tokyo, Tokyo, Japan Prevention of Type IV Failure in High Cr Ferritic Heat Resistant Steel Welded Joint ...................................................................................................................296 S. Tsukamoto, M. Tabuch, T. Shirane, F. Abe; National Institute for Materials Science, Tsukuba, Ibaraki, Japan Other Experimental/Modeling Investigations Evaluation of a Drilling Model Approach to Represent Laser Spot Microwelding .............303 P. Colegrove, P.-E. Simiand, A. Varughese, S. Williams, D. Yapp; Cranfield University, Bedfordshire, UK Arc-Laser Interactions and Heat Transfer and Fluid Flow in Hybrid Welding ....................313 B.D. Ribic, R. Rai, T.A. Palmer, T. DebRoy; Pennsylvania State University, University Park, PA, USA A Model Equation for the Convection Coefficient for Thermal Analysis of Welded Structures ................................................................................321 R. Goyal1, E. Johnson1, M. El-Zein1, J. Goldak2, M. Coulombe2, S. Tchernov3; (1) Deere and Company, Moline, IL USA, (2) Carleton University, Ottawa, ON, Canada, (3) Goldak Technologies, Ottawa, ON, Canada Analytical and Experimental Validation of Distortion Using State of the Art Techniques .........................................................................................328 E. Johnson1, M. El-Zein1, J. Goldak2, T. Schmidt3; (1) Deere and Company, Moline, IL, USA, (2) Carleton University, Ottawa, ON, Canada, (3) Trilion Quality Systems, West Conshohocken, PA, USA Characterisation of Dynamic Mechanical Behaviour of Resistance Spot Welding Machines .......................................................................................333 P. Van Rymenant1, D. Yapp2; (1) De Nayer Institute, St. Katelijne Waver, Belgium, (2) Cranfield University, Bedfordshire, UK Arc and Weld Profile Predictions for Zinc-Coated Thin Steel Plates: Trends in Welding Research 2008 ..........................................................................................339 X. Zhang1, A. Daneryd1, B. Holmgren1, D. Skarin2; (1) ABB Corporate Research, Västerås, Sweden, (2) ABB Robotics, Västerås, Sweden ix Weldability Ultrasonic Metal Welding of Advanced Alloys: The Weldability of Stainless Steel, Titanium, and Nickel-Based Superalloys ....................................................348 M. Bloss1, K. Graff2; (1) The Ohio State University, Columbus, OH, USA, (2) Edison Welding Institute, Columbus, OH, USA In-situ High Temperature Straining Tests to Study Welding: Solid State Cracking Phenomena ...........................................................................................354 E.A. Torres1, F.G. Peternella1, A.J. Ramirez1, R. Caram2; (1) Brazilian Synchrotron Light Laboratory, Campinas-SP, Brazil, (2) State University of Campinas, Campinas-SP, Brazil Friction Stir Welding – Microstructure and Properties Microstructure-Property Development in Friction Stir Welds of Al-Mg Alloys ...................358 M.M. Attallah, C.L. Davis, M. Strangwood; University of Birmingham, Birmingham, UK Influence of Welding Parameters and Tool Geometry on the Mechanical Performance of Friction Stir Spot Welded Al-Mg Alloys ..................................364 A. Echeverria, A. Zabaleta, P. Alvarez, E. Aldanondo, J. Solis, A.A.M. da Silva; LORTEK – Centro de Investigación en Tecnologías de Unión, Guipúzcoa, Spain Research Concerning the Friction Stir Welding of Linepipe Steels ....................................371 D. Fairchild1, A. Kumar1, S. Ford1, N. Nissley1, R. Ayer2, H. Jin2, A. Ozekcin2; (1) ExxonMobil Upstream Research Co., Houston, TX, USA, (2) ExxonMobil Corporate Strategic Research Co., Annandale, NJ, USA Influence of Process Parameters in the TMAZ Microstructural Evolution of C-Mn Steels Friction Hydro-Pillar Welded Joints ..................................................................381 J.U. Silgado1, T.F. Hermenegildo1, A.J. Ramirez1, M.T.P. Paes2, A. Pope2; (1) Brazilian Synchrotron Light Laboratory, Campinas-SP, Brazil, (2) Petrobras, Rio de Janeiro-RJ, Brazil Friction-Stir Welding – Heavy Inclusions in Bi-Metallic Welds of Al 2219/2195 .................385 W.W. Rietz, Jr.; Lockheed Martin Michoud Space Systems, New Orleans, LA USA Characterization of Microstructures and Transformation Behavior in Friction Stir Welded HSLA-65 .................................................................................................391 L. Wei, T.W. Nelson; Brigham Young University, Provo, UT, USA Evolution of Microstructure and Properties for Friction Stir Welded Martensitic Precipitation-Hardening Steels ...........................................................................398 T. Weinberger, B. Führer, S. Khosa, N. Enzinger, H. Cerjak, H. Schöttner, S. Mitsche; Graz University of Technology, Austria Microstructural Evolution in Friction Stir Welding of Ti-5111 ..............................................403 J. Wolk1, C. Davis1, L. Salamanca-Riba2; (1) Naval Surface Warfare Center, Bethesda, MD, USA, (2) University of Maryland, College Park, MD, USA x