11.7 Troubleshooting Problems in the HAZ of Fusion Welds 186
References 187
Further Reading 188
12 Unaffected Base Metal Cracking Associated with Welding 189
12.1 Weld-Related Problems in the Unaffected Base Metal 189
12.2 Lamellar Tearing in Thick Steel Weldments 189
12.3 Corrosion Cracking Caused by Fusion Welding 192
12.4 Fatigue Cracking Outside Fusion Welds 195
12.5 Troubleshooting Weld-Related Problems in the Unaffected Base Metal 199
References 200
Further Reading 201
13 Discontinuities in Multi-pass Welds 203
13.1 Needs for Multi-pass Welding and Welds 203
13.2 Various Functions of Multi-pass Welding and Welds 205
13.3 Defects Found in Multi-pass Welds 207
13.4 Composition Adjustment with Multi-pass Welding 210
13.5 Property Alteration with Multi-pass Welding 213
13.6 Troubleshooting Problems in Multi-pass Welding and Welds 216
References 217
Further Reading 217
14 Problems with Non-fusion Welding and Non-fusion Welds 219
14.1 Non-fusion Welding Processes Versus Fusion Welding Processes 219
14.2 Overview of Non-fusion Processes 220
14.2.1 Pressure Welding Processes 222
14.2.2 Friction Welding Processes 222
14.2.3 Diffusion Welding Processes 222
14.2.4 Solid-State Deposition Welding 223
14.3 Problems with Non-fusion Welds and Non-fusion Welding Processes 223
14.4 Inspection and Repair Challenges with Non-fusion Welds 229
14.5 Troubleshooting Problems with Non-fusion Welds 230
References 230
Further Reading 231
Part III Material-Specific Weld-Related Problems 233
15 Embrittlement of Carbon and Low- and Medium-alloy Steels 235
15.1 The Importance of Steel 235
15.2 Four Causes of Embrittlement in Carbon and Low- and Medium-alloy Steels 238
15.3 Hydrogen Embrittlement: A Misnomer in Steels 239
15.4 Secondary Hardening in Steels 240
15.5 Ductile-to-Brittle Transition in Steels 241
15.6 Compromise of Fatigue and Impact Behavior by Residual Stresses in Steels 243
15.7 Troubleshooting Problems from Embrittlement of Steels by Welding 244
References 245
Further Reading 245
16 Sensitization or Weld Decay and Knife-line Attack in Stainless Steels 247
16.1 A Primer on the Metallurgy of Stainless Steels 247
16.2 Sensitization of Austenitic Stainless Steels by Welding 249
16.3 Sensitization of Other Grades of Stainless Steel 252
16.4 Knife-line Attack in Stabilized Austenitic Stainless Steels 252
16.5 Troubleshooting Problems from Sensitization or Knife-line Attack 254
References 255
Further Reading 255
17 Stress Relief Cracking of Precipitation-Hardening Alloys 257
17.1 Different Names, Same Phenomenon 257
17.2 Stress Relief Cracking in Ferritic Alloy Steels 260
17.3 Stress Relaxation Cracking in Stainless Steels 265
17.4 Strain-age Cracking in Ni-Based Superalloys 267
17.5 Troubleshooting Problems from Stress Relief or Strain-age Cracking 270
References 271
Further Reading 271
18 Loss of Properties in Cold-Worked Metals and Alloys 273
18.1 Cold Work, Recovery, Recrystallization, and Grain Growth 273
18.2 Cold-Worked Metals and Alloys in Engineering 278
18.3 Avoiding or Recovering Properties Loss from Fusion Welding 281
18.4 The Worked Zone in Pressure-Welded Metals and Alloys 284
18.5 Troubleshooting Welding Problems in Cold-Worked Metals and Alloys 285
References 285
Further Reading 286
19 Embrittlement with High-chromium Contents 287
19.1 Phase Formation and Structure 287
19.2 Adverse Effects of σ-Phase 291
19.3 Susceptible Alloys 291
19.4 Guidelines for Avoiding or Resolving Problems from σ-Phase 293
19.5 Troubleshooting Problems with σ-Phase Associated with Welding 294
References 295
Further Reading 295
20 Weld Dilution and Chemical Inhomogeneity 297
20.1 The Designer’s Druthers 297
20.2 Chemical Inhomogeneity in Welds 300
20.3 Weld Dilution 302
20.4 The Unmixed Zone in the Weld Metal 304
20.5 Impurities in the Weld Metal 307
20.6 Troubleshooting Problems from Weld Dilution and Chemical Inhomogeneity 307
References 308
Further Reading 308
21 Dissimilar Metal and Alloy Welding 309
21.1 Joining Dissimilar Materials 309
21.2 The Need for Welding Dissimilar Metals and Alloys 311
21.3 Chemical Incompatibility 311
21.4 Mechanical Incompatibility 315
21.5 Thermal Incompatibility 315
21.6 Troubleshooting Problems with Dissimilar Metal and Alloy Welding 318
References 318
Further Reading 319
Closing Thoughts 321
Index 323
As critically important as welding is to a wide spectrum of manufacturing, construction, and repair, it is not without its problems. Those dependent on welding know only too well how easy it is to find information on the host of available processes and on the essential metallurgy that can enable success, but how frustratingly difficult it can be to find guidance on solving problems that sooner or later arise with welding, welds, or weldments.
Here for the first time is the book those that practice and/or depend upon welding have needed and awaited. A Practical Guide to Welding Solutions addresses the numerous technical and material-specific issues that can interfere with success. Renowned industrial and academic welding expert and prolific author and speaker Robert W. Messler, Jr. guides readers to the solutions they seek with a well-organized search based on how a problem manifests itself (i.e., as distortion, defect, or appearance), where it appears (i.e., in the fusion zone heat-affected zone, or base metal), or it certain materials or situations. Show less -
About the Author Robert W. Messler, Jr., Ph.D., FASM, FAWS, is Emeritus Professor of Materials Science & Engineering at Rensselaer Polytechnic Institute, Troy, NY. His career spans more than four decades in diverse areas of advanced materials and processes in public and private industry and in academia, with unparalleled expertise in all aspects of joining. This "engineer who teaches" has authored more than a hundred technical papers and seven other engineering books. A Practical Guide to Welding Solutions being the logical complement to his renowned Principles of Welding, also by Wiley.