Revealing internal flow behaviour in arc welding and additive manufacturing of metals

Internal flow behaviour during melt-pool-based metal manufacturing remains unclear and hinders progression to process optimisation. In this contribution, we present direct time-resolved imaging of melt pool flow dynamics from a high-energy synchrotron radiation experiment. We track internal flow streams during arc welding of steel and measure...

Understanding the effect of a paint bake cycle on the microstructure–mechanical properties relationship of a resistance spot welded advanced high strength steel

The effect of an automotive paint bake (PB) thermal cycle on the microstructural evolution and the mechanical properties of resistance spot welded advanced high strength steel is presented in this work. Mechanical behavior of the heat-treated welds reveals an increase in maximum cross-tension strength, displacement and subsequently energy...

Study of solidification cracking in a transformation-induced plasticity-aided steel

In situ high-temperature laser scanning confocal microscopy is applied to study solidification cracking in a TRIP steel. Solidification cracking was observed in the interdendritic region during the last stage of solidification. Atom probe tomography revealed notable enrichment of phosphorus in the last remaining liquid. Phase field...

Experimental evidence of liquid feeding during solidification of a steel

Sufficient liquid feeding under constrained solidification conditions like, those experienced in welding and casting, is vital to avoid solidification cracking. We present the results of unique in-situ experimental observations of liquid feeding in a solidifying steel melt pool. Liquid feeding was observed in the inter-cellular regions during...

Control of welding distortion during gas metal arc welding of AH36 plates by stress engineering

Welding residual stress and distortion are strongly linked together. One of the ways to control or reduce the welding distortions is the manipulation of the generated stresses during welding, and final residual stresses exist in the workpiece (stress engineering). In this paper, the control of gas metal arc butt welding distortion of 500 × 250 ×...

The microstructural evolution and elemental distribution of a 3rd generation 1 GPa advanced high strength steel during double pulse resistance spot welding

This paper presents the effects of double pulse resistance spot welding (RSW) on the microstructural evolution, elemental distribution and mechanical properties of a 3rd generation 1 GPa advanced high strength steel (AHSS). In order to investigate the effect of double pulsing, the steel was exposed to single and various double pulse RSW...

Elemental segregation during resistance spot welding of boron containing advanced high strength steels

The partitioning behaviour of carbon, phosphorous and boron during the solidification of a resistance spot weld pool was studied using experimental simulations and a phase field model. Steels with varying carbon, phosphorous and boron contents were designed and subjected to a range of resistant spot welding thermal cycles. Mechanical properties...

Accommodation of Plastic Deformation by Ultrasound-Induced Grain Rotation

Electron backscatter diffraction was used to investigate the softening effect in low-carbon steel [Fe-0.051C-0.002Si-0.224Mn-0.045Al (wt pct)] during tensile deformation with in situ ultrasonic treatment. A bimodal grain size distribution is observed with relatively small equiaxed grains with an average diameter of 10 ?m at the grain boundaries...

Keyhole behaviour during laser welding of zinc-coated steel

The production of consistent, high-quality laser welds on zinc-coated steels for the automotive industry remains a challenge. A simple overlap joint geometry is desirable in these applications but has been shown to be extremely detrimental to laser welding because the zinc vapour formed at the interface between the two sheets expands into the...

Quantitative Analysis of Microstructural Constituents in Welded Transformation-Induced-Plasticity Steels

A quantitative analysis of retained austenite and nonmetallic inclusions in gas tungsten arc (GTA)–welded aluminum-containing transformation-induced-plasticity (TRIP) steels is presented. The amount of retained austenite in the heat-affected and fusion zones of welded aluminum-containing TRIP steel with different base metal austenite fractions...

A stereo vision method for tracking particle flow on the weld pool surface

The oscillation of a weld pool surface makes the fluid flow motion quite complex. Two-dimensional results cannot reflect enough information to quantitatively describe the fluid flow in the weld pool; however, there are few direct three-dimensional results available. In this paper, we describe a three-dimensional reconstruction method to measure...

Laser beam welding of an Oxide Dispersion Strengthened super alloy

A Strategy for Modeling Microstructure in Macroscopic Simulations of Welded Material

With the increased precision in laser-welded structures, smaller and thinner parts can be joined. This magnifies the effect that microstructural changes due to the welding process have on the mechanical properties of the material. Although conventional welding processes are generally applied to work pieces of larger dimensions, the higher heat...