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Module 8
COMIMSA
Module 8
1. Introduction
Metallurgy Is the science that deals with the internal structure of metals and the relationship between those structures and the properties exhibited by metals.
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Energy (-) Atoms in a fixed position Each atom has a specific home held in place by the attracting and repelling forces The atomic configuration determines their physical, mechanical, and electrical properties
COMIMSA
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COMIMSA
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The atoms are not however stationary in this positions. In reality they tend to vibrate about an equilibrium position to maintain a balanced spacing.
Any attempt to force to force the atoms closer together will be counteracted by repulsive forces which increase as the atoms are pushed closer together.
Similary, any attempt to pull the atoms further apart will result in a counteracting attractive force. These attractive forces, however, tend to decrease as the atoms are pulled further apart
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Basic Metal Structures The atoms exhibit a very specific spacing at given temperture. The internal energy of a metal is increased when its temperature is raised. The atoms to vibrate more which increases their interatomic spacing
The metal to expand,,, if heat is elevated the vibration and spacing continue increase,, the solid metal then transforms into a liquid
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The portion heated expands and is restrained by the portion no heated, the bar tend to bend
Residual stresses
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Basic Metal Structures Crystal Structures The smallest number of atoms that can completely describe their orderly arrangement is referred as a unit celd When a metal solidifies, it always does so in a crystalline pattern. The most common crystal structures, or phases are:
1)
Body Centered Cubic (bcc) iron, carbon steels, Cr, Mo, W Face Centered Cubic (fcc) Al, Cu, Ni, austenitic SS. Hexagonal close packed (hcp) Zn, Cd, Mg -
2)
3)
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Basic Metal Structures Alloying The proprieties of metallic elements can be altered by the addition of other elements, wich may be or not metallic Example; metallic zinc + metal cooper = the alloy brass Nonmetal carbon is one of the alloying elements added to iron to form the alloy steel
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COMIMSA
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Basic Metal Structures Microestructural Constituents of Carbon Steel Welds Under the Microscope Steel exist in several phases, typically Austenite, ferrite, perlite, bainite, and martensite. See, Figures 7.5 7.7.
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of steel
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The
critical
cooling
rate is governed by the carbon content, and for their alloy steels, by
additional
chemical composition.
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Normalize
Oil Quench
Water Quench
Quenching the steel results in a martensitic structure. Slow cooling forms Ferrite and Perlite. Faster cooling forms Bainite
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COMIMSA
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COMIMSA
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Welding Chemistry of Specific Base Metals When the carbon content increases, weldability decreases 0.15 to 0.30 %C - Easily Weldable About above 0.30 %C - More difficult to weld and may require: Weldability also decreases with alloying elements such as Cr, Mo, Ni, may require the use of: Preheat Interpass temperature control PWHT
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CE= %C + %Mn + %Si + %Cr + %Mo + %Ni +%Cu 6 5 15 CE >0.40 Preheat 200 400 F (93 204 C) Low Hydrogen Electrodes CE >0.60 Preheat 400 700 F (204 - 370 C) Low Hydrogen Electrodes
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Heat Input, Joules/in = Welding current x Welding Voltage x 60 travel speed, in/min As the heat input increase the cooling rate decreases.
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Carbono equivalente
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There are three methods of removing weld stresses: 1) 2) 3) Thermal Treatment Peening Vibratory Stress Relief Approved by Code
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Mechanical distortion of the weld bead trough mechanical means Usually when the metal is still hot Only on the intermediate layers Should not be done on the root pass (crack) nor final pass of a weld (interfere with later VI)
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Martensitic Grades More difficult to weld and often require special preheating and PWHT.
PH Stainless Steels Weldable, but attention must be given to the changes in mechanical properties caused by welding.
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Alternating current is used. Reformation of oxide film is avoided by shielding with He, or Ar gas.
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Welding softens the cold worked material One of the major problems when welding cooper and its alloys is due to their relative low melt point and very high metal conductivity. Considerable heat must be applied to the metal to overcome its loss through conductivity, and the relatively low melting point often results in the metal melting earlier than expected and flowing out of the weld joint.