A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process

Mohamed Abu-Aesh; Mohamed Taha; Ahmed Salem El–Sabbagh; Lutz Dorn

doi:doi:10.11648/j.eas.20210605.12

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A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process

Mohamed Abu-Aesh, Mohamed Taha, Ahmed Salem El–Sabbagh, Lutz Dorn

Published in Engineering and Applied Sciences (Volume 6, Issue 5)

Received: 21 August 2021 Accepted: 8 September 2021 Published: 15 September 2021

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Abstract

Solidification cracking is a significant problem during the welding of fully austenitic stainless steels. The present work is considered as the first trial to investigate and propose a mechanism of hot cracking formation when welding the Fan-shaped cracking test specimen, using the pulsed current gas tungsten arc welding process (PCGTAW). The specimen lateral expansions perpendicular to welding line due to thermal effects, plus the transverse expansion due to crack opening are sensed and recorded to detect the crack behavior with time. The stages of crack formation are filmed by a high-speed photography of the weld pool and solidification process at a speed of about 1000 fps. Additionally, some microscopic examinations using Scanning Electron Microscope (SEM) and Electron Probe Micro-Analyzer (EPMA) are performed on the welds. The results helped in establishing a proposed mechanism for the formation of hot cracks in full–austenitic stainless steel welds done on a Fan-shaped test specimen. The proposed mechanism suggests three stages during hot cracking formation; the crack initiation, propagation, and ceasing. The occurrence of a hot crack during welding mainly depends on the way by which the molten zone solidifies, and which solid phase will primarily solidify. This affects, in turn, the segregation of the chemical elements, which found to have a great role in crack initiation. Moreover, the weld metal structure type, together with the thermal stresses in conjunction with the applied strains on the weld joint play a great role in the crack expansion and ceasing. The present work is considered the first trial done to propose a mechanism of hot-cracking formation during welding the Fan-Shaped test specimen using Pulsed-Current Gas Tungsten Arc welding process.

Published in	Engineering and Applied Sciences (Volume 6, Issue 5)
DOI	10.11648/j.eas.20210605.12
Page(s)	86-104
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Proposed Hot Cracking Mechanism, Full-Austenitic Stainless Steel, Pulsed-Current Gas Tungsten Arc Welding, Fan-Shaped Testing Specimen, High-Speed Photography, Electron Probe Micro-Analyzer

References

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APA Style

Mohamed Abu-Aesh, Mohamed Taha, Ahmed Salem El–Sabbagh, Lutz Dorn. (2021). A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Engineering and Applied Sciences, 6(5), 86-104. https://doi.org/10.11648/j.eas.20210605.12

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ACS Style

Mohamed Abu-Aesh; Mohamed Taha; Ahmed Salem El–Sabbagh; Lutz Dorn. A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Eng. Appl. Sci. 2021, 6(5), 86-104. doi: 10.11648/j.eas.20210605.12

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AMA Style

Mohamed Abu-Aesh, Mohamed Taha, Ahmed Salem El–Sabbagh, Lutz Dorn. A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Eng Appl Sci. 2021;6(5):86-104. doi: 10.11648/j.eas.20210605.12

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@article{10.11648/j.eas.20210605.12,
  author = {Mohamed Abu-Aesh and Mohamed Taha and Ahmed Salem El–Sabbagh and Lutz Dorn},
  title = {A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process},
  journal = {Engineering and Applied Sciences},
  volume = {6},
  number = {5},
  pages = {86-104},
  doi = {10.11648/j.eas.20210605.12},
  url = {https://doi.org/10.11648/j.eas.20210605.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.eas.20210605.12},
  abstract = {Solidification cracking is a significant problem during the welding of fully austenitic stainless steels. The present work is considered as the first trial to investigate and propose a mechanism of hot cracking formation when welding the Fan-shaped cracking test specimen, using the pulsed current gas tungsten arc welding process (PCGTAW). The specimen lateral expansions perpendicular to welding line due to thermal effects, plus the transverse expansion due to crack opening are sensed and recorded to detect the crack behavior with time. The stages of crack formation are filmed by a high-speed photography of the weld pool and solidification process at a speed of about 1000 fps. Additionally, some microscopic examinations using Scanning Electron Microscope (SEM) and Electron Probe Micro-Analyzer (EPMA) are performed on the welds. The results helped in establishing a proposed mechanism for the formation of hot cracks in full–austenitic stainless steel welds done on a Fan-shaped test specimen. The proposed mechanism suggests three stages during hot cracking formation; the crack initiation, propagation, and ceasing. The occurrence of a hot crack during welding mainly depends on the way by which the molten zone solidifies, and which solid phase will primarily solidify. This affects, in turn, the segregation of the chemical elements, which found to have a great role in crack initiation. Moreover, the weld metal structure type, together with the thermal stresses in conjunction with the applied strains on the weld joint play a great role in the crack expansion and ceasing. The present work is considered the first trial done to propose a mechanism of hot-cracking formation during welding the Fan-Shaped test specimen using Pulsed-Current Gas Tungsten Arc welding process.},
 year = {2021}
}

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TY  - JOUR
T1  - A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process
AU  - Mohamed Abu-Aesh
AU  - Mohamed Taha
AU  - Ahmed Salem El–Sabbagh
AU  - Lutz Dorn
Y1  - 2021/09/15
PY  - 2021
N1  - https://doi.org/10.11648/j.eas.20210605.12
DO  - 10.11648/j.eas.20210605.12
T2  - Engineering and Applied Sciences
JF  - Engineering and Applied Sciences
JO  - Engineering and Applied Sciences
SP  - 86
EP  - 104
PB  - Science Publishing Group
SN  - 2575-1468
UR  - https://doi.org/10.11648/j.eas.20210605.12
AB  - Solidification cracking is a significant problem during the welding of fully austenitic stainless steels. The present work is considered as the first trial to investigate and propose a mechanism of hot cracking formation when welding the Fan-shaped cracking test specimen, using the pulsed current gas tungsten arc welding process (PCGTAW). The specimen lateral expansions perpendicular to welding line due to thermal effects, plus the transverse expansion due to crack opening are sensed and recorded to detect the crack behavior with time. The stages of crack formation are filmed by a high-speed photography of the weld pool and solidification process at a speed of about 1000 fps. Additionally, some microscopic examinations using Scanning Electron Microscope (SEM) and Electron Probe Micro-Analyzer (EPMA) are performed on the welds. The results helped in establishing a proposed mechanism for the formation of hot cracks in full–austenitic stainless steel welds done on a Fan-shaped test specimen. The proposed mechanism suggests three stages during hot cracking formation; the crack initiation, propagation, and ceasing. The occurrence of a hot crack during welding mainly depends on the way by which the molten zone solidifies, and which solid phase will primarily solidify. This affects, in turn, the segregation of the chemical elements, which found to have a great role in crack initiation. Moreover, the weld metal structure type, together with the thermal stresses in conjunction with the applied strains on the weld joint play a great role in the crack expansion and ceasing. The present work is considered the first trial done to propose a mechanism of hot-cracking formation during welding the Fan-Shaped test specimen using Pulsed-Current Gas Tungsten Arc welding process.
VL  - 6
IS  - 5
ER  -

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Author Information

Mohamed Abu-Aesh

Mechanical Engineering Department, University of Bahrain, Manama, Kingdom of Bahrain
Mohamed Taha

Design and Production Engineering Department, Ain-Shams University, Cairo, Egypt
Ahmed Salem El–Sabbagh

Design and Production Engineering Department, Ain-Shams University, Cairo, Egypt
Lutz Dorn

Department of Forging and Welding Techniques, Technical University, Berlin, Germany

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Mohamed Abu-Aesh, Mohamed Taha, Ahmed Salem El–Sabbagh, Lutz Dorn. (2021). A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Engineering and Applied Sciences, 6(5), 86-104. https://doi.org/10.11648/j.eas.20210605.12

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ACS Style

Mohamed Abu-Aesh; Mohamed Taha; Ahmed Salem El–Sabbagh; Lutz Dorn. A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Eng. Appl. Sci. 2021, 6(5), 86-104. doi: 10.11648/j.eas.20210605.12

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AMA Style

Mohamed Abu-Aesh, Mohamed Taha, Ahmed Salem El–Sabbagh, Lutz Dorn. A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Eng Appl Sci. 2021;6(5):86-104. doi: 10.11648/j.eas.20210605.12

Copy | Download

@article{10.11648/j.eas.20210605.12,
  author = {Mohamed Abu-Aesh and Mohamed Taha and Ahmed Salem El–Sabbagh and Lutz Dorn},
  title = {A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process},
  journal = {Engineering and Applied Sciences},
  volume = {6},
  number = {5},
  pages = {86-104},
  doi = {10.11648/j.eas.20210605.12},
  url = {https://doi.org/10.11648/j.eas.20210605.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.eas.20210605.12},
  abstract = {Solidification cracking is a significant problem during the welding of fully austenitic stainless steels. The present work is considered as the first trial to investigate and propose a mechanism of hot cracking formation when welding the Fan-shaped cracking test specimen, using the pulsed current gas tungsten arc welding process (PCGTAW). The specimen lateral expansions perpendicular to welding line due to thermal effects, plus the transverse expansion due to crack opening are sensed and recorded to detect the crack behavior with time. The stages of crack formation are filmed by a high-speed photography of the weld pool and solidification process at a speed of about 1000 fps. Additionally, some microscopic examinations using Scanning Electron Microscope (SEM) and Electron Probe Micro-Analyzer (EPMA) are performed on the welds. The results helped in establishing a proposed mechanism for the formation of hot cracks in full–austenitic stainless steel welds done on a Fan-shaped test specimen. The proposed mechanism suggests three stages during hot cracking formation; the crack initiation, propagation, and ceasing. The occurrence of a hot crack during welding mainly depends on the way by which the molten zone solidifies, and which solid phase will primarily solidify. This affects, in turn, the segregation of the chemical elements, which found to have a great role in crack initiation. Moreover, the weld metal structure type, together with the thermal stresses in conjunction with the applied strains on the weld joint play a great role in the crack expansion and ceasing. The present work is considered the first trial done to propose a mechanism of hot-cracking formation during welding the Fan-Shaped test specimen using Pulsed-Current Gas Tungsten Arc welding process.},
 year = {2021}
}

Copy | Download

TY  - JOUR
T1  - A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process
AU  - Mohamed Abu-Aesh
AU  - Mohamed Taha
AU  - Ahmed Salem El–Sabbagh
AU  - Lutz Dorn
Y1  - 2021/09/15
PY  - 2021
N1  - https://doi.org/10.11648/j.eas.20210605.12
DO  - 10.11648/j.eas.20210605.12
T2  - Engineering and Applied Sciences
JF  - Engineering and Applied Sciences
JO  - Engineering and Applied Sciences
SP  - 86
EP  - 104
PB  - Science Publishing Group
SN  - 2575-1468
UR  - https://doi.org/10.11648/j.eas.20210605.12
AB  - Solidification cracking is a significant problem during the welding of fully austenitic stainless steels. The present work is considered as the first trial to investigate and propose a mechanism of hot cracking formation when welding the Fan-shaped cracking test specimen, using the pulsed current gas tungsten arc welding process (PCGTAW). The specimen lateral expansions perpendicular to welding line due to thermal effects, plus the transverse expansion due to crack opening are sensed and recorded to detect the crack behavior with time. The stages of crack formation are filmed by a high-speed photography of the weld pool and solidification process at a speed of about 1000 fps. Additionally, some microscopic examinations using Scanning Electron Microscope (SEM) and Electron Probe Micro-Analyzer (EPMA) are performed on the welds. The results helped in establishing a proposed mechanism for the formation of hot cracks in full–austenitic stainless steel welds done on a Fan-shaped test specimen. The proposed mechanism suggests three stages during hot cracking formation; the crack initiation, propagation, and ceasing. The occurrence of a hot crack during welding mainly depends on the way by which the molten zone solidifies, and which solid phase will primarily solidify. This affects, in turn, the segregation of the chemical elements, which found to have a great role in crack initiation. Moreover, the weld metal structure type, together with the thermal stresses in conjunction with the applied strains on the weld joint play a great role in the crack expansion and ceasing. The present work is considered the first trial done to propose a mechanism of hot-cracking formation during welding the Fan-Shaped test specimen using Pulsed-Current Gas Tungsten Arc welding process.
VL  - 6
IS  - 5
ER  -

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