Influence of fusion zone size and failure mode on mechanical performance of dissimilar resistance spot welds of AISI 1008 low carbon steel and DP600 advanced high strength steel

The work here addresses the investigation of the effect of the welding parameters (welding time, welding current and electrode force) on the overload failure mode and mechanical performance of dissimilar resistance spot welds between drawing quality special killed AISI 1008 low carbon steel and DP600 dual phase steel. Mechanical properties of spot welds are described in terms of failure mode, peak load and energy absorption during the quasi-static tensile-shear test. Three distinct failure modes were observed during the tensile-shear test: interfacial, pullout and partial thickness–partial pullout failure modes. Correlations among failure mode, welding parameters, weld physical attributes and weld mechanical performance are analyzed. Effect of expulsion on mechanical performance of welds is also investigated.     

Resistance Spot Welding of Quenching and Partitioning (Q&P) Third-Generation Advanced High-Strength Steel: Process–Microstructure–Performance

Metallurgical and Materials Transactions A - This paper investigates process–microstructure–performance relationships in Q&P980 third-generation advanced high-strength steel...     

Projection friction stir spot welding: a pathway to produce strong keyhole-free welds

ABSTRACT

This paper introduces a novel facile method, called projection friction stir spot welding, to produce a keyhole-free friction stir welds based on a pinless tool method involving using a specially designed projection on the surface of the backing anvil. The projection plays two key roles contributing to the bonding mechanism and the joint strength: (i) encouraging the material flow perpendicular to the joint interface and (ii) bending the joint interface at the edge of the projection. The process enables pathway to produce keyhole-free welds with superior mechanical performance in steel sheets compared to the other spot welding techniques.     

Dissimilar Spot Welds of AISI 304/AISI 1008: Metallurgical and Mechanical Characterization

This paper aims at investigating structure‐properties relationships in dissimilar resistance spot welding of AISI 304 austenitic stainless steel (SS) and AISI 1008 low carbon steel (CS). Microstructural characterization, microhardness test and the tensile‐ shear test were conducted. It was shown that the shape of the SS/CS fusion zone (FZ) is unsymmetrical and the final fusion line shifts from sheet/sheet interface into the higher resistivity side (i.e. AISI 304). FZ microstructure was ranged from ferrite‐austenite to full martensite depending on the dilution ratio of the base metals. The variation of SS/CS dissimilar welds failure mode was explained in terms of hardness/microstructure characteristics. It was concluded that to ensure pullout failure mode, welding parameters needed to adjust so that the FZ size is sufficiently large and dilution is sufficiently high to produce a martensite FZ. Fusion zone size at CS side proved to be the most important controlling factor of SS/CS peak load and energy absorption. Finally, the mechanical properties of SS/CS dissimilar welds were compared with SS/SS and CS/CS similar welds.     

Diffusion induced isothermal solidification during transient liquid phase bonding of cast IN718 superalloy

In transient liquid phase (TLP) bonding for commercial applications, one of the important key parameters is the holding time required for complete isothermal solidification t_IS, which is a prerequisite for obtaining a proper bond microstructure. The objective of the study is to analyse the isothermal solidification kinetics during TLP bonding of cast IN718 nickel based superalloy. Experiments for TLP bonding were carried out using a Ni–7Cr–4·5Si–3Fe–3·2B (wt-%) amorphous interlayer at several bonding temperatures (1273–1373 K). The time required to obtain TLP joints free from centreline eutectic microconstituents was experimentally determined. Considering the solidification behaviour of residual liquid, t_IS could be predicted by a mathematical solution of the time dependent diffusion equation based on Fick’s second law.

Dans la brasure en phase liquide transitoire (TLP) pour applications commerciales, l’un des paramètres clés importants est le temps de maintien requis pour la solidification isotherme complète (t_IS), qui est une condition requise pour l’obtention d’une microstructure adéquate du lien. L’objectif de cette étude est d’analyser la cinétique de la solidification isotherme lors de la brasure TLP du superalliage coulé à base de nickel, IN718. On a effectué les expériences de brasage de TLP en utilisant une couche de liaison amorphe de Ni–7Cr–4·5Si–3Fe–3·2B (% en poids) à plusieurs températures de brasage (1273–1373 K). On a déterminé expérimentalement le temps requis pour l’obtention de joints TLP libres de micro constituants eutectiques à la ligne centrale. En considérant le comportement de solidification du liquide résiduel, on pouvait prédire t_IS au moyen d’une solution mathématique de l’équation de diffusion dépendante du temps basée sur la seconde loi de Fick.     

Microstructural characteristics of a cast IN718 superalloy bonded by isothermal solidification

Isothermal solidification is a key feature of transient liquid phase bonding which prevents the formation of deleterious intermetallic phases in the joint centerline and results in bonds with improved mechanical performance. This paper discusses the metallurgical characteristics and mechanical properties of an as-cast IN718 superalloy bonded by diffusion-induced isothermal solidification of Ni-7Cr-4.5Si-3.2B-3Fe (wt%) filler metal. After transient liquid phase bonding of as-cast IN718 at 1000 °C for 60 min, a bond exhibiting a solid solution microstructure with joint efficiency of 72% in terms of shear strength was obtained. The joining process was effectively able to prevent the formation of hard and brittle nickel and chromium borides, which typically lead to critical problems in brazing. The formation of Nb-rich Laves phase, which is well known as a major issue in the fusion welding of IN718, was not observed. The bonding time, which governs the extent of isothermal solidification, was a critical parameter for controlling the mechanical properties of the joints in terms of shear strength and hardness distribution across the bond.     

Role of base-metal composition in isothermal solidification during diffusion brazing of nickel-based superalloys

The key feature of diffusion brazing, also referred to as transient liquid phase bonding, is isothermal solidification which precludes the formation of intermetallic in the joint centreline. Analysing the available data published in the literature showed that the composition of the nickel-based superalloys plays a strong role in determining the required time for obtaining intermetallic-free joint during diffusion brazing. This effect is not predictable by the standard conventional models. It is proposed that increasing the boride-forming elements in the base superalloy which promotes in situ boride precipitation at the diffusion-affected zone can accelerate the diffusion flux of the boron into the base superalloy, leading to faster isothermal solidification. The higher the Cr?+?Mo?+?Nb?+?Ta?+?W content in base superalloy, the shorter the isothermal solidification time.     

On the weldability of grey cast iron using nickel based filler metal

Shielded metal arc welding process using nickel based filler metal was used to join grey cast iron. The effect of post weld heat treatment (PWHT) on the microstructure and hardness was studied. PWHT included heating up to 870 °C, holding for 1 h at 870 °C and then furnace cooling. By using nickel based filler metal, formation of hard brittle phase (e.g. carbides and martensite) in the fusion zone is prevented. Before PWHT, heat affected zone exhibited martensitic structure and partially melted zone exhibited white cast iron structure plus martensite. Applied PWHT resulted in the dissolution of martensite in heat affected zone and graphitization and in turn the reduction of partially melted zone hardness. Results showed that welding of grey cast iron with nickel based filler metal and applying PWHT can serve as a solution for cast iron welding problems.     

On the failure of low carbon steel resistance spot welds in quasi-static tensile–shear loading

Failure behavior of low carbon steel resistance spot welds in quasi-static tensile–shear test is investigated. Microstructure, hardness profile and mechanical performance of the spot welds were studied. Results showed that spot welds are failed in two distinct failure modes: double-pullout and interfacial failure modes. There is a critical fusion zone size beyond which, pullout failure mode is guaranteed. Metallographic examination showed that failure is a competitive process between shear plastic deformation of weld nugget and necking of the base metal. In pullout failure mode, only the grain pattern of the base metal changes significantly and that of the fusion zone and heat affected zone remains unchanged. Strain localization was occurred in the base metal due to its low hardness. Moreover, the experimental results showed that increasing the holding time which increases the hardness of the fusion zone did not affect the peak load. It was concluded that in the pullout failure mode, the strength of the spot welds is not affected by the fusion zone strength. Fusion zone size proved to be the most important controlling factor for the spot welds’ mechanical performance in terms of peak load and energy absorption.     

Wire-Based Friction Stir Processing as a Novel Pathway for Solid-State Surface Alloying of Magnesium

Wire-based friction stir processing is introduced as a solid-state surface alloying strategy for surface alloying of AZ31 magnesium alloy with aluminum, as a key alloying element in magnesium alloys. This technique enables the formation of a defect-free, grain refined and alloyed surface with the increased volume fraction of Mg-Al second phase, and thus, enhanced surface hardness. This simple technique provides a solid-state surface alloying pathway to improve the surface properties of the metallic materials.