Sindo Kou - Welding Metallurgy

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Third Edition

Sindo Kou

Department of Materials Science and Engineering University of Wisconsin Madison, Wisconsin

© 2021 John Wiley & Sons, Inc.

Edition History John Wiley & Sons, Inc. (1e, 1987)

John Wiley & Sons, Inc. (2e, 2003)

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Library of Congress Cataloging‐in‐Publication Data

Names: Kou, Sindo, author. Title: Welding metallurgy / by Sindo Kou, Professor Department of MaterialsScience and Engineering University of Wisconsin, Madison, Wisconsin. Description: Third edition. | Hoboken, NJ : John Wiley & Sons, Inc., 2021.| Includes bibliographical references and index. Identifiers: LCCN 2020004090 (print) | LCCN 2020004091 (ebook) | ISBN9781119524816 (hardback) | ISBN 9781119524854 (adobe pdf) | ISBN9781119524915 (epub) Subjects: LCSH: Welding. | Metallurgy. | Alloys. Classification: LCC TS227 .K649 2021 (print) | LCC TS227 (ebook) | DDC671.5/2–dc23 LC record available at https://lccn.loc.gov/2020004090LCebook record available at https://lccn.loc.gov/2020004091

Cover Design: Wiley

Cover Image: © ‐nelis‐/Getty Images

To Tina, Nancy, and Katharine

The 3rd edition of Welding Metallurgy includes updates and expands the 2nd edition that was published in 2003. About half of the 3rd edition has new content. It includes the significant new progress made in welding metallurgy since 2003. To help readers understand the subjects discussed, examples are provided in each chapter. To make it easier for readers to find cited articles or judge their relevance, the titles of the articles and the full names of the journals are provided.

In Part I, Introduction, Chapter 1has been expanded, which also includes topics on resistance spot welding and solid‐state welding (friction welding, friction stir welding, explosion welding, magnetic impulse welding, and diffusion welding). Chapter 3includes the significant effect of metal vapor in the arc on weld penetration. It also includes the new progress made at UW‐Madison on oscillatory Marangoni flow in the weld pool, weld‐pool‐surface deformation and oscillation, weld ripple formation, and how they are affected by the surface‐active agent. Chapter 4includes two new mechanisms proposed at UW‐Madison for spatter in gas–metal arc welding of Al and Mg alloys.

Part II, The Fusion Zone, has been restructured and expanded to include four new chapters: Chapters 10, 11, 12, and 14. Ternary alloy solidification, which is often difficult for students to understand, has been explained with the liquidus projections and solidification paths of example alloys. Part IIdiscusses more on the following new progress made at UW‐Madison. A liquid‐metal quenching technique to “freeze‐in” and reveal the elevated temperature microstructure during welding is demonstrated, which is useful for understanding phase transformations, nucleation mechanisms, microsegregation, diffusion, etc. Bending of growing columnar dendrites without breaking is shown to support thermal instead of mechanical, dendrite fragmentation. Identification of the grain refining mechanism is demonstrated. A statistically significant measurement of microsegregation used in casting is applied to welding. Base‐metal‐like “beaches,” “peninsulas,” and “islands” surrounded by the weld metal, often found in dissimilar filler welding and dissimilar metal welding, is explained. A simple index is proposed to predict the solidification cracking susceptibility of Al and Mg alloys and how effectively filler metals can reduce the susceptibility. A simple but improved new test for evaluating the solidification cracking susceptibility of various alloys and the filler metal effectiveness is demonstrated. New theories on the resistance of austenitic stainless steels to solidification cracking and ductility‐dip cracking are presented.