1. THE HEAT AFFECTED ZONE Nick Kostrikin Liz Lehman

2. Objectives: Analyze the heat affected zone (HAZ) created by 3 types of welding and 2 different cooling rates Identify any changes in the properties of the material characteristic of each type of welding Identify any changes in the properties of the material based on the method of cooling used after welding

3. Parent metal: Low carbon steel ASTM 569 Easy to form and weld Max carbon content of 0.15 wt% 0.30 – 0.60 wt% Mg Max phosphorous content of 0.04 wt% 55,000 psi tensile strength 30,000 psi yield strength 30% elongation

4. TIG welding: Non-consumable tungsten electrode is used to create an arc Inert gas used to shield the weld zone from contaminants Temperature of electric arc exceeds 6500º F The intense heat is focused on a very small area The process is quick, clean, and free of slag and sputter

5. A look at TIG welding…

6. MIG welding: A consumable wire is used to establish an arc and as a filler material in the weld zone Can be used with inert gas or flux cored filler wire to shield the weld zone from contaminates As with TIG welding, an intensely hot electric arc is created with the filler wire As with TIG welding, a minimum amount of material is necessary to produce a weld of maximum strength

7. MIG welding 101…

8. More MIG…

9. Gas welding: Brazing is a process of gas welding Oxygen and acetylene are burned at correct proportions to create a flame ranging from 5800º to 6300º F An alloy of a lower melting temperature is used to join the parts of the base metal Brazing typically takes longer to weld than either TIG or MIG The flame is not as intense or focused as an electric arc Because of the inherently lower tensile strength of brass, a proportionately larger amount of brass must be used in the weld to provide sufficient strength

10. Ancientand modern forms of gas welding…

11. …alternative forms of gas welding

12. Getting the Right flame …

13. Procedure: Weld 2 sets of metal samples with TIG, MIG and BRAZING One set is to be AIR COOLED at room temperature The other set is to be WATER QUENCHED Conduct laboratory experimentation: –Rockwell hardness measurements at 2mm increments. –Fatigue testing by bending the sample at the joint 60º in both directions Collect and analyze data Discussion of results

14. Examples of some TIG welds…

15. Our TIG welded samples…

16. Hardness plot of the TIG welded sample Water quenched sample 97 cycles to failure, crack at 10mm Air cooled sample 116 cycles to failure, crack at 18mm

17. Our MIG welded samples…

18. Water quenched sample 72 cycles to failure, crack at 6mm Air cooled sample 85 cycles to failure, crack at 16mm Hardness plot of the MIG welded sample

19. Our Brazed welded sample…

20. Air cooled sample 6 cycles to failure, crack at welded joint Water cooled sample 4 cycles to failure, crack at welded joint Inconclusive Results !!

21. Hardness comparison of TIG and MIG welding…

22. Effects of different types of welding: TIG welding created a very strong weld with good hardness and ductility MIG welding created a similarly strong weld with slightly greater hardness values, less ductility, and a smaller heat affected zone than TIG Gas welding with brass created a weld of insufficient strength hence its strength and ductility could not be compared to the two types of arc welding

23. Effects of different methods of cooling: Typically the grain structure adjacent to the weld has relatively lower hardness and greater ductility associated with a coarse grain size. Water quenching decreases the size of the grain structure, thus raising the hardness. The next zone consists of a band of finer grains at the critical temperature. This zone is relatively harder and less ductile than the first zone and is more prone to cracking. Water quenching tends to harden this zone and causes cracks to occur closer to the weld than air cooled samples. The third zone consists of a normal grain structure resembling those of the parent metal and is furthest from the weld.

24. Effects of bending and fatigue testing: TIG & MIG Welded Samples When subjecting the samples to a bending action, the location where the bending occurred corresponded to the area where there was a drop in the minimum hardness Subsequent folding at this ductile location resulted in work hardening which led to the formation of a crack In general, material failure occurred within the weld zone where the material has undergone changes in its physical properties Braze Welded Samples No conclusion from fatigue testing can be made –Insufficient amount of material deposited –Low tensile strength of brass

25. THE END