Welding Metallurgy: Sindo Kou
Welding Metallurgy: Sindo Kou
Welding Metallurgy: Sindo Kou
METALLURGY
SECOND EDITION
Sindo Kou
Professor and Chair
Department of Materials Science and Engineering
University of Wisconsin
Sindo Kou
Professor and Chair
Department of Materials Science and Engineering
University of Wisconsin
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10 9 8 7 6 5 4 3 2 1
To Warren F. Savage
for his outstanding contributions to welding metallurgy
CONTENTS
Preface xiii
I INTRODUCTION 1
Further Reading 95
Problems 95
References 195
Further Reading 197
Problems 197
Index 455
PREFACE
Since the publication of the first edition of this book in 1987, there has been
much new progress made in welding metallurgy. The purpose for the second
edition is to update and improve the first edition. Examples of improvements
include (1) much sharper photomicrographs and line drawings; (2) integration
of the phase diagram, thermal cycles, and kinetics with the microstructure to
explain microstructural development and defect formation in welds; and (3)
additional exercise problems. Specific revisions are as follows.
In Chapter 1 the illustrations for all welding processes have been re-
drawn to show both the overall process and the welding area. In Chapter
2 the heat source efficiency has been updated and the melting efficiency
added. Chapter 3 has been revised extensively, with the dissolution of
atomic nitrogen, oxygen, and hydrogen in the molten metal considered and
electrochemical reactions added. Chapter 4 has also been revised extensively,
with the arc added, and with flow visualization, arc plasma dragging, and
turbulence included in weld pool convection. Shot peening is added to
Chapter 5.
Chapter 6 has been revised extensively, with solute redistribution and
microsegregation expanded and the solidification path added. Chapter 7 now
includes nonepitaxial growth at the fusion boundary and formation of non-
dendritic equiaxed grains. In Chapter 8 solidification modes are explained with
more illustrations. Chapter 9 has been expanded significantly to add ferrite
formation mechanisms, new ferrite prediction methods, the effect of cooling
rate, and factors affecting the austenite–ferrite transformation. Chapter 10
now includes the effect of both solid-state diffusion and dendrite tip under-
cooling on microsegregation. Chapter 11 has been revised extensively to
include the effect of eutectic reactions, liquid distribution, and ductility of
the solidifying metal on solidification cracking and the calculation of fraction
of liquid in multicomponent alloys.
Chapter 12 has been rewritten completely to include six different liquation
mechanisms in the partially melted zone (PMZ), the direction and modes of
grain boundary (GB) solidification, and the resultant GB segregation. Chapter
13 has been revised extensively to include the mechanism of PMZ cracking
and the effect of the weld-metal composition on cracking.
Chapter 15 now includes the heat-affected zone (HAZ) in aluminum–
lithium–copper welds and friction stir welds and Chapter 16 the HAZ of
Inconel 718. Chapter 17 now includes the effect of multiple-pass welding on
xiii