Two test samples were made to validate the proposed method; one was with aluminium alloy 2024, the other steel fig.3 shows the geometry of the samples and Fig.4 is the experimental set-up. (W 115) (1)

 Test sample = Amostra de teste

Welded samples produced during the test are sent to an independent test house for testing. Ten test specimens are taken from each welded sample with five being tested in shear and five in peel. It is required that the test samples fail in the parent material. (W 459) (2)

Welded sample = Amostra soldada

Table 4 presents the residual stress measurement results obtained on the surfaces of the pipe sample. The maximum principal stress, the angle of the maximum principal stress to the pipe axis, the axial and hoop stresses are all presented in the table. (W 38) (3)

Pipe sample = Tubo de amostragem

(1) Deformation pattern based digital image correlation method and its application to residual stress measurement

Jianxin Gao* and Haixia Shang 

*Corresponding author

Paper published in Applied Optics, vol.48. issue 7, 2009. pp.1371 – 1381.

(2) Environmental lining systems – raising the standards

Ian D Froment

Presented at: ANTEC 2001, Dallas, Texas, USA, 6-10 May 2001.

(3) Measurement and modelling of residual stresses in offshore circumferential welds

Yan-Hui Zhang, Simon Smith, Liwu Wei and Carol Johnston 

TWI Ltd 

Cambridge, United Kingdom

Alexander Stacey 

Health & Safety Executive London, United Kingdom

Paper presented at Proceedings 32nd International Conference on Ocean, Offshore and Arctic Engineering (OMAE 2013) June 9-14, 2013, Nantes, France.

In general, TSA offered protection to the underlying or exposed steel by cathodically polarizing it and forming a calcareous deposit in synthetic seawater. (W 58) (1)

Synthetic seawater = Água do mar sintética

….This project is currently investigating the influence on corrosion resistance in chlorinated seawater (at up to 60°C), brine with CO 2 and some O 2, and a sour environment with H 2S and CO 2. (W 527) (2)

Chlorinated seawater = Água do mar clorada

The paper includes the results of constant load, step load and slow strain rate tests on tensile specimens, with and without notches, and slow strain rate fracture mechanics tests on notched bend specimens, all under cathodic charging in simulated seawater. (W 163) (3)

Simulated seawater = Água do mar simulada

(1) Improved Coatings for Extended Design Life of 22%Cr Duplex Stainless Steel in Marine Environments

S Paul,* C M Lee, M D F Harvey 

TWI, Cambridge, United Kingdom

Paper presented at ITSC 2012 International Thermal Spray Conference, Houston USA, 21-24 May 2012, and published in Journal of Thermal Spray Technology.

(2) TWI: Corrosion, welds & pipelines – An update 2000

Stuart Bond

New information about TWI Corrosion Services Expertise and Failure Assessment and our current activities in corrosion, welds and pipelines.

Based on paper published in ‘Anti-Corrosion Methods & Materials’, 1999, No.2, March/April 

Updated in June 2000.

(3) Resistance of dissimilar joints between steel and nickel alloys to hydrogen-assisted cracking

M F Gittos

Paper presented at Corrosion 2008, NACE, New Orleans, March 2008, paper 08095.

Table 1 compares film, imaging plates and flat panels with such properties as IQI sensitivity and pixel-pitch. Film and Amexposure. This orphous Selenium are capable of achieving high sensitivity over a range of energies. (W 328) (1)

IQI sensitivity = Sensibilidade ao IQI

As far as scanning sensitivity is concerned, ASME requires scanning at a level at least 6dB above the reference sensitivity, plus there are recommendations for scanning to be up to 14dB higher than the reference sensitivity level. (W 45) (2)

Scanning sensitivity = Sensibilidade à varredura

The temper bead technique was devised to generate a fine-grained HAZ in low alloy (Cr-Mo-V) steels which suffered reheat cracking sensitivity. (W 258) (3)

Cracking sensitivity = Sensibilidde à rachadura

(1) Digital radiography – is it for you?

Bruce Blakeley

Paper published in Insight, July 2004

Keywords: Computed Radiography, Imaging Plates.

(2) Comparison between ASME and RCC-M requirements for welding and NDT

Marcello Consonni and Peter Mudge 

TWI Ltd.

Cambridge, UK

Paper presented at 20th International Conference on Nuclear Engineering. 30 Jul – 3 Aug 2012, Anaheim, CA, USA. Paper No. ICONE20POWER2012-54190.

(3) Advanced joining processes for repair in nuclear power plants

Fred Delany, William Lucas, Wayne Thomas, Dave Howse, David Abson, Steve Mulligan and Colin Bird 

Paper presented at 2005 International Forum on Welding Technologies in Energy Engineering September 21 – 23 Shanghai, China.

The temperature sensor showed a step decrease in the area with added solder and a step increase in areas with applied grease. The temperature sensor was also sensitive to variations in laser focus position and changes in laser beam position on the stiffener plate (caused incomplete penetration and lack of root fusion in welds). (W 188) (1)

Temperature sensor = Sensor de temperatura

…the responses from the plasma sensor to some of the engineered anomalies were different to those from the temperature sensor in terms of the magnitude of variation in recorded intensity, with respect to the signals from the reference weld. (W 188) (2)

Plasma sensor = Sensor de plasma

At the heart of the Crack-First system is a fatigue sensor which, when installed on welded steel structure, indicates the portion of the design life that’s been consumed and enables engineers to estimate its remaining life. (Welding 376) (3)

Fatigue sensor = Sensor de fadiga

(1) In-process weld quality monitoring of laser and hybrid laser-arc fillet welds in 6-12mm C-Mn steel

G. Shi, P. Hilton and G. Verhaeghe

Paper presented at Proceedings of the Fourth International WLT-Conference on Lasers in Manufacturing 2007 (LIM2007) , Munich, 18 – 22 June 2007.

(2) In-process weld quality monitoring of laser and hybrid laser-arc fillet welds in 6-12mm C-Mn steel

G. Shi, P. Hilton and G. Verhaeghe

Paper presented at Proceedings of the Fourth International WLT-Conference on Lasers in Manufacturing 2007 (LIM2007) , Munich, 18 – 22 June 2007.

(3) Case Study

www.twi-global.com/…/crackfirst-a-new-sensor-system-to-assist-in-structural-health-monitoring-339/ – 2014-05-06.

The use of argon, helium or helium-argon mixtures (up to 50% argon) is recommended for laser welding aluminium sheet. (W 484) (1)

Aluminium sheet = Folha de alumínio

Welding of steel sheet can easily be done without shielding gas, but the appearance of the top and under-bead may not be as smooth and some porosity might be present in the weld. Argon is probably the most commonly used gas, but helium, nitrogen, CO 2 or gas mixtures can also be used, depending on requirements such as plasma suppression, penetration, hardness, porosity, etc. (W 484) (2)

Steel sheet = Chapa de aço

Previous studies by Christner et al.,have highlighted the importance of proper fit-up, sheet thickness tolerance, bottom sheet deformation and adequate depth of penetration of the probe into the lapped sheet to ensure good quality welds are made. (W 334) (3)

Lapped sheet = Folha revestida (de sobreposição)

(1) Laser welding automotive steel and aluminium

G Verhaeghe

Make It With LASERS TM Workshop, July 2000

Paper presented at meeting on ‘Lasers in the automotive and sheet metal industries’, TWI, Great Abington, UK on 13 July 2000.

(2) Laser welding automotive steel and aluminium

G Verhaeghe

Make It With LASERS TM Workshop, July 2000

Paper presented at meeting on ‘Lasers in the automotive and sheet metal industries’, TWI, Great Abington, UK on 13 July 2000.

(3) FSW Process Variants and Mechanical Properties

by W. Thomas, D. Nicholas, D. Staines, P J Tubby and M F Gittos

TWI Ltd 

(III-1293-04)

Published on the Internet June 17, 2004 

Presented at the IIW Meeting on FSW in Nagoya 2004, Nagoya University, Japan, 9th July 2004.

This analysis was conducted for a welding residual stress field as a result of a welding simulation rather than for a residual stress field due to a prescribed temperature distribution as considered by the majority of previous investigations. (W 65) (1)

Welding simulation = Simulação de soldagem

….This work is concerned with the GCHAZ of a multi-pass weld. Cleavage tests are therefore carried out on several SENB specimens that have previously undergone a thermal simulation of the welding process. (W 412) (2)

Thermal simulation = Simulação térmica

POD curves could be generated more rapidly and more cost-effectively if theoretical simulation of PODs were shown to be sufficiently representative of actual inspection performance. (W 43) (3)

Theoretical simulation = Simulação teórica

(1) The effects of loadings on welding residual stresses and assessment of fracture parameters in a welding residual stress field

Liwu Wei, Weijing He and Simon Smith 

TWI Ltd

Paper presented at the ASME 2011 Pressure Vessels & Piping Division Conference, Baltimore, Maryland, USA, July 17-21, 2011, PVP2011-57518.

(2) Local approach predictions of fracture toughness behaviour in real multi pass welds using thermal simulation specimens

Annette D. Karstensen (1), Anthony Horn (2) and Martin Goldthorpe (1)

(1)TWI, Cambridge, UK 

(2)Corus, UK

Paper presented at 2nd International Symposium on High Strength Steel (PRESS), Stiklestad, Verdal, Norway, 23-24 April, 2002.

(3) Estimation of probability of detection curves based on theoretical simulation of the inspection process

Charles R A Schneider, Ruth M Sanderson, Capucine Carpentier, Lu Zhao and Channa Nageswaran 

TWI Ltd Cambridge, UK

Paper presented at BINDT Annual Conference 2012.

The engineered factors included addition of metal debris (a small piece of silver solder wire) in the joint. (W 188) (1)

Silver solder = Solda de prata

The Young’s modulus of SAC387 is much higher than that of the eutectic solder joint therefore it has stronger resistance to deformation. (W 139) (2)

Eutectic solder = Solda eutética

Zbrzezny, Agia, Lam, Ghorbani, 2004. ‘Accelerated thermal fatigue of lead-free solder joints as a function of reflow cooling rate’, Journal of Electronic Materials, 33(12), pp.1497. 1506. (W 139) (3)

Lead-free solder = Solda sem chumbo

(1) In-process weld quality monitoring of laser and hybrid laser-arc fillet welds in 6-12mm C-Mn steel

G. Shi, P. Hilton and G. Verhaeghe

Paper presented at Proceedings of the Fourth International WLT-Conference on Lasers in Manufacturing 2007 (LIM2007), Munich, 18 – 22 June 2007.

(2) Thermal stresses measurement of solder joints in BGA packages: theoretical and experimental

H X Shang, J X Gao and P I Nicholson 

Paper presented at 2008 ASME International Mechanical Engineering Conference and Exposition, November 2-6, 2008, Boston, Massachusetts, USA. Paper no. IMECE2008-66417.

(3) Thermal stresses measurement of solder joints in BGA packages: theoretical and experimental

H X Shang, J X Gao and P I Nicholson 

Paper presented at 2008 ASME International Mechanical Engineering Conference and Exposition, November 2-6, 2008, Boston, Massachusetts, USA. Paper no. IMECE2008-66417.

Closer examination of the holiday area from the coated specimens did not show any sign of corrosion on the exposed steel surface. The exposed holiday surface was fully protected and appeared unaffected due to immersion in the test solution, except that the machined surface had lost its glossy appearance due to a thin film build-up on the exposed steel surface. (W 262) (1)

Test solution = Solução de teste

The bulk 316 alloy shows the expected behaviour for this alloy in a chloride solution. (W 422) (2)

Chloride solution = Solução de cloreto

Loss of strength can occur as a consequence of fusion welding. The properties of the welded joint will be very dependent on the condition of the material (as cast, annealed, work hardened, solid solution hardened, precipitation hardened) before welding. (W 238) (3)

Solid solution = Solução sólida

(1) Characteristics and electrochemical corrosion behaviour of thermal sprayed aluminium (TSA) coatings prepared by various wire thermal spray processes.

S. Shrestha and A. Sturgeon

TWI Ltd

E-mail: suman.shrestha@twi.co.uk

Paper published in EUROCORR 2005 Lisbon, Portugal, 4-8 September 2005.

(2) Improved corrosion resistant coatings prepared using a modified diamond jet HVOF spraying system

A J Sturgeon, Cambridge/UK

Paper 171 presented at ITSC 2002 International Thermal Spray Conference, 4-6 March 2002, Essen, Germany.

(3) Making the link – Effective joining technology for aluminium in the 21st Century

C N D Peters 

TWI Ltd, Granta Park, Gt. Abington, Cambridge, UK CB21 6AL

Paper published in Aluminium surface science and technology conference, Beaune, France, 14-18 May 2006.

All the deposition tasks were performed onto cylindrical substrate articles of a known material. Following experimentation TWI produce a welding-procedure specification for the clients’ approval. TWI was able to conclude to the client’s satisfaction that the additional equipment was successfully installed and commissioned. (Welding 459) (1)

Welding-procedure specification = Especificação do procedimento de soldagem

One furnace was found to have tubes which had been running at temperatures in excess of the design specification. The cumulative life fraction calculation for this tubing was large compared to the other components assessed, indeed, it exceeded unity, indicating that failure would have occurred if the material had been ‘lower bound’ in its creep resistance. (Welding 187) (2)

Design specification = Especificação de design

Medical devices, whether temporary or permanent, used externally or inside the body, are becoming more complex and sophisticated both in terms of their performance specification and structural complexity. As a consequence many devices in current use are multi-component and require assembly in production. Joining is one of the key issues in many manufacturing industries and the medical industry is no exception. (W 286) (3)

Performance specification = Especificação de desempenho

(1) Laser direct metal deposition for shaft refurbishment

Case Study

www.twi-global.com/…/case-studies/laser-direct-metal-deposition-for-shaft-refurbishment-470/ – 2014-12-08.

(2) Moth-balled naphtha plant

Case Study

www.twi-global.com/news-events/case-studies/moth-balled-naphtha-plant-189/ – 2013-05-29.

(3) A review of adhesive bonding techniques for joining medical materials

S M Tavakoli, D A Pullen and S B Dunkerton

TWI Ltd

Paper published in Assembly Automation, Jun 2005 Volume: 25 Issue: 2 Page: 100 – 105.

On a plot of creep rupture stress versus duration, an inflection is observed for cross-weld specimens. This inflection occurs at a threshold stress level for a given temperature and material. (W 22) (1)

Cross-weld specimens = Espécimes de solda cruzada

Data derived from tests using deeply-cracked specimens may result in non-conservative life predictions. (W 152)  (2)

Deeply-cracked specimens = Espécimes rachados profundamente

The testing conditions in this study were very severe, and the investigators pointed out that SCC tests repeated on U-bend specimens did not reveal any susceptibility. (W 190) (3)

U-bend specimens = Espécimes um U

(1) Review of type IV cracking of weldments in 9– 12%Cr creep strength enhanced ferritic steels

D. J. Abson and J. S. Rothwell* 

TWI Ltd

International Materials Reviews, November 2013, 58(8), 437-473.

(2) Corrosion fatigue of simulated C-mn steel HAZs in sour produced fluids

R I Hammond and D P Baxter 

Paper presented at OMAE 2008 27th international Conference on Offshore Mechanics and Arctic Engineering, Estoril, Portugal, 15 – 20 June 2008. Paper OMAE 2008 – 57149.

(3) Friction stir welding of aluminium ships

Fred Delany, Stephan W Kallee and Mike J Russell

TWI China, Baliqiaobei Chaoyang District, P O Box 863, 100024 Beijing, P.R. China

Tel: +86 (0)10 8570 3255, enquiries@twichina.com

Paper presented at 2007 International Forum on Welding Technologies in the Shipping Industry (IFWT) Held in conjunction with the Beijing Essen Welding and Cutting Fair in Shanghai, 16-19 June 2007.

The cold spray process is used for coating applications where lower thermal spray temperatures are beneficial. The main advantages over conventional thermal spraying include: the powder remains in the solid phase, lower substrate surface temperatures, less oxidation of the powder and the substrate material, no metallurgical transformations and reduced residual stress formation. (Welding 510) (1)

Thermal spraying = Pulverização térmica

Coating process – coatings were applied by a variety of thermal spraying processes including conventional arc spraying, inert gas shrouded arc spraying and high velocity oxy-fuel spraying (HVOF). Powder or wire consumable is heated by oxy-fuel combustion (flame & HVOF) or electrically (arc & plasma) until molten or soft, and projected at speed onto a substrate to form a coating. (W 109) (2)

Arc spraying = Pulverização do arco

Free-burning flames generate the highest concentrations of NO and NO2, and the risk of over-exposure is also highest. Caution should be exercised during activities such as flame heating, flame straightening, flame brazing, flame spraying, etc – particularly as emissions from these processes are difficult to control. The flame should be extinguished when not in use. (W 226) (3)

Flame spraying = Pulverização da chama

(1) Cold spray enables welding of crack-sensitive alloys

Case Study

www.twi-global.com/…/case-studies/cold-spray-enables-welding-of-crack-sensitive-alloys-521/ – 2017-01-24.

(2) Corrosion mitigation in biomass combustion plant using thermal spray coatings

M A Riley and M D F Harvey 

Paper presented at COAL-GEN Europe, Katowice, Poland, 1-4 Sept. 2009.

(3) Welding Fume – Do you know your WEL?

Paper published in Health & Safety International, July 2006; (also in Welding & Cutting, No 4 2007).

Dr Dave McKeown, Manager, Corporate Projects at TWI Ltd, the Research and Technology Organisation focussed on joining, reviews the generation and control of hazards from welding and cutting.

Welding Fume – Do you know your WEL?

Paper published in Health & Safety International, July 2006; (also in Welding & Cutting, No 4 2007).

Dr Dave McKeown, Manager, Corporate Projects at TWI Ltd, the Research and Technology Organisation focussed on joining, reviews the generation and control of hazards from welding and cutting.

The Dawes approach [12] which combined separate elastic and plastic components of the crack tip opening displacement was that which was ultimately adopted by the British Standard, and in the early editions of ASTM E1290.(W 24) (1)

British standard = Norma britânica

The European Standard was selected because it is specific to laser welding of aluminium, whereas the American standard and the internal standard were chosen because they are specific to fusion welding for aerospace applications. (W 327) (2)

European standard = Norma europeia

In the field of non-destructive testing (NDT) there is a European and an International Standard[6,7] that deal with the independent certification of NDT personnel. These standards have not resulted in the harmonised approach to NDT like the one that has been adopted in the international welding community.  (W 126) (3)

International standard = Norma internacional

(1) CTOD and pipelines – the past, present and future

Dr Philippa Moore and Dr Henryk Pisarski 

TWI Ltd, Cambridge, UK

Paper presented at the 6th International Pipeline Technology Conference (Rudi’s Pipeline Conference), 6-9 October 2013, Ostend, Belgium.

(2) Laser Welding of Low-Porosity Aerospace Aluminium Alloy

Geert Verhaeghe and Paul Hilton

Paper presented at 34th International MATADOR Conference, 7th – 9th July 2004, UMIST, Manchester, UK.

(3) The special importance of personnel competence in welding fabrication

Eur Ing Jessop, Tim, and Eady, Chris 

TWI Ltd

Paper presented at Seventh European Congress on Joining Technology (EUROJOIN 7) on behalf of the European Federation for Welding, Joining and Cutting, 21 – 22 May, 2009 in Venice (Italy), organised by the Istituto Italiano della Saldatura (Italian Welding Institute).

Table 1 shows FSW simulations matrix on stainless steel with numbers identifying the weld parameters. (W 35) (1)

Stainless steel = Aço inoxidável

…In tests extending to more than 104 h, the cross-weld strength fell more than 20% below that of the parent steel. (W 22) (2)

Parent steel = Aço de origem

The (CRA) layer, typically a few millimetres thick, has different ultrasonic properties from the carbon steel.(W 67) (3)

Carbon steel = Aço carbono

(1) Numerical investigations of friction stir welding of high temperature materials.

A. Elbanhawy, E. Chevallier, K. Domin 

TWI Ltd, Structural Integrity Technology Group  

Presenter: Dr Amr Elbanhawy, Project Leader at TWI Ltd, Granta Park, Cambridge, CB21 6AL, UK 

NAFEMS world congress, Salzburg, Austria, 9-12 June 2013.

(2) Review of type IV cracking of weldments in 9– 12%Cr creep strength enhanced ferritic steels.

D.J. Abson and J. S. Rothwell* 

TWI Ltd

International Materials Reviews, November 2013, 58(8), 437-473.

(3) New approaches to assuring the integrity of pipelines and risers

Geoff Booth, Henryk Pisarski, Channa Nageswaran and Peter Mudge 

Joining, Cutting and Surfacing Technology, Chennai, 17-22 TWI Ltd Cambridge, UK

Paper presented at IIW International Conference on Global Trends 2011 in July.

Figure 12 shows typical contour plots for the equivalent plastic strain in the ligaments adjacent to an embedded flaw. (W 105) (1)

Plastic strain = Tensão plástica

In the model, design pressure was applied first and then axial strain. The results were used to generate an axial stress-strain response for the material. (W 230) (2)

Axial strain = Tensão axial

Recent literature presenting uniaxial creep and crack growth tests indicate that some materials show lower failure strains during longer term laboratory tests. (W 30) (3)

Failure strain = Tensão de falha

(1) Approaches for Determining Limit Load and Reference Stress for Circumferential Embedded Flaws in Pipe Girth Welds

Mohamad J Cheaitani 

TWI Ltd Granta Park, Great Abington, Cambridge CB21 6AL, UK

Pipeline Technology Conference, Ostend, Belgium 2009.

(2) Fracture mechanics assessment of flaws in pipeline girth welds

Henryk Pisarski, Guang Xu and Simon Smith

Proceedings of HSLP-IAP2006: International Seminar on Application of High Strength Line Pipe And Integrity Assessment of Pipeline 2006, June 15-16, 2006, Xi’an, China.

(3) Creep Crack Growth Prediction of Very Long Term P91 Steel Using Extrapolated Short-Term Uniaxial Creep Data.

S. Maleki 

TWI Ltd.

A. Mehmanparast, K. M. Nikbin 

Imperial College London

Paper presented at the 2013 ASME Pressure Vessels and Piping Conference. Paris, France, 14-18 July 2013. 

The parent pipe had a yield strength of 568MPa and UTS of 615MPa. (W 7) (1)

Yield strength = Limite de elasticidade

The ultimate tensile strength (UTS) of the parent metal was between 584 and 586MPa, exceeding the specified minimum tensile strength value from API 5L X70 of 570MPa. (W 34) (2)

Tensile strength = Resistência à tração

The fatigue strength and fatigue limit of the plain material increase with increase in tensile strength whereas those for welded joints are independent of tensile strength. W (16) (3)

Fatigue strength = Teste de fadiga

(1) Optimisation of SENT test specimen design

Phillipa Moore 

TWI Ltd, Granta Park Great Abington, Cambridge, CB21 6AL, UK

Paper presented at Eurojoin 9. 20-22 May 2015. Bergen, Norway.

(2) The effect of inclusions on the fracture toughness of local brittle zones in the HAZ of girth welded line pipe

Philippa Moore and Joanna Nicholas 

TWI Ltd, 

Cambridge, UK.

Proceedings of the ASME 2013 32nd International Conference on Ocean, Offshore and Arctic Engineering 

June 9-14, 2013, Nantes, France

(3) Estimating long-endurance fatigue strength of girth-welded pipes using local stress approach

Yanhui Zhang and Steve J Maddox 

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK

Paper presented at Proceedings 33rd International Conference on Ocean, Offshore and Arctic Engineering (OMAE 2014) June 8-13, 2014, San Francisco, USA

Failure of welded structures due to the presence of flaws is typically driven by a mixture of applied and residual stresses, yet in most cases only the former are known accurately. (W 14) (1)

Residual stress = Estresse residual

The thickness effect discussed earlier will still exist even if fatigue strength is expressed in terms of the hot-spot stress. (W 341) (2)

Hot-spot stress = Estresse crucial, critico

A linear viscosity model has been developed based on a linear relationship between yield strength and temperature, and between yield stress and strain rate, where the viscosity is a function of the uniaxial stress and uniaxial strain rate. (W 35) (3)

Yield stress = Tensão de ruptura / limite de elasticidade

(1) Effects of Mechanical Loading on Residual Stress and Fracture: Part II: Validation of the BS 7910:2013 Rules
Isabel Hadley and Simon Smith
TWI Ltd Cambridge, UK
Presented at Proceedings of the ASME 2014 Pressure Vessels & Piping Conference (PVP2014), July 20-24, 2014, Anaheim, California, USA.

(2) Review of fatigue assessment procedures for welded aluminium structures
S J Maddox, TWI Ltd
Paper published in International Journal of Fatigue, Paper JIJF1005. vol. 25, no. 12, December 2003, pp.1359-1378 -available here

(3) Numerical investigations of friction stir welding of high temperature materials
A. Elbanhawy, E. Chevallier, K. Domin
TWI Ltd, Structural Integrity Technology Group
Presenter: Dr Amr Elbanhawy, Project Leader at TWI Ltd, Granta Park, Cambridge, CB21 6AL, UK
NAFEMS world congress, Salzburg, Austria, 9-12 June 2013.

Dr Pisarski(TWI)has managed projects applying fracture mechanics testing and assessment methods to a wide range of engineering structures including ships, offshore structures, subsea components, pipelines and pressure vessels. (W 24) (1)

Offshore structure = Estrutura offshore

A fine grain structure is an advantage, however the thermal cycles experienced during welding will lead to a reduction in mechanical properties, and a change in grain structure. (W 158) (2)

Grain structure = Estrutura da fibra

While beneficial, PMC applications for large hull structures have certain limitations in size and volume of seamless structural component without using joints. A hybrid hull that consists of both metal and composite structural members potentially enables desirable enhancements of structural efficiency, but robust joining between those heterogeneous structures must be employed. (W 123) (3)

Hull structure = Estrutura do casco

(1) CTOD and pipelines – the past, present and future

Dr Philippa Moore and Dr Henryk Pisarski 

TWI Ltd, Cambridge, UK

Paper presented at the 6th International Pipeline Technology Conference (Rudi’s Pipeline Conference), 6-9 October 2013, Ostend, Belgium. 

(2) Friction stir weld integrity and its importance to the rolling stock industry

Blignault C1, Kallee S W1, Thomas W M1, Russell M J1

Author details

1Friction and Forge Processes Department, TWI, Ltd., UK.

Paper presented at Southern African Institute of Welding (SAIW) conference, Integrity of Welded Structures in the Energy, Processing and Transport Industries in Southern Africa, Gold Reef City, 28-29 May 2008.

(3) Advanced hybrid joining technology

Vladimir M. Shkolnikov, Gabriel J. Hostetter, David K. McNamara, Joseph R. Pickens, Stanley P. Turcheck, Jr. 

Concurrent Technologies Corporation (CTC)

Johnstown, Pennsylvania 15904, U.S.A.

Bruce G. I. Dance 

Paper presented at ASME 28th International Conference on Ocean, Offshore and Arctic Engineering, OMAE 2009, Honolulu, Hawaii, 31 May – 5 June 2009. Paper #79769.

A very smooth ‘polished’ weld surface can be reliably produced for over 1m long weld runs… (W 199) (1)

Weld surface = Superfície de solda

Changes to the coating surfaces were recorded following periodic observations every 24 hours. (W 425) (2)

Coating surface = Superfície de revestimento

Examination of the fracture surfaces also revealed that failure had involved pulling a plug or button from the parent band material. (W 426) (3)

Fracture surface = Superfície de fratura

(1) Static shoulder friction stir welding of Ti-6Al-4V; process and evaluation.

M J Russell 1 , P L Threadgill 1 , M J Thomas 2 and B P Wynne 2

1 TWI Ltd

2 IMMPETUS (Institute for Microstructural and Mechanical Process Engineering: The University of Sheffield)

Paper presented at 11th World Conference on titanium (Ti-2007), (JIMIC – 5), Kyoto, Japan, 3-7 June, 2007. 

(2) Improved corrosion performance of AZ91D magnesium alloy coated with the KeroniteTM process

S Shrestha a, A Sturgeon a, P Shashkov b and A Shatrov b

aTWI Ltd

bKeronite Ltd

Paper presented at Magnesium Technology 2002, Seattle, WA, 17-21 February 2002 and published by TMS (The Minerals, Metals & Materials Society)

(3) Industrialisation of friction stir welding for aerospace structures

Stephan W. Kallee, E. Dave Nicholas and Wayne M. Thomas

TWI Ltd, Cambridge, United Kingdom

E-mail: friction@twi.co.uk

Paper presented at Structures and Technologies – Challenges for Future Launchers

Third European Conference, 11-14 December 2001, Strasbourg France.

Kasuya, Hashiba, Ohkita and Fuji (2001) indicate that for a consumable with a measured hydrogen content of 5ml/100g, the hydrogen level in the completed multi-pass weld will drop to approximately 0.4ml/100g after seven days. The significance of this was not considered in terms of crack susceptibility, but only in terms of hydrogen distribution. (W 62) (1)

Crack susceptibility = Susceptibilidade à fissura

Accelerated hydrogen cracking susceptibility testing without externally applied load – Accelerated hydrogen cracking test procedure.  Although the fracture mechanics tests show the resistance to propagation of a pre-existing crack, the fracture in this case is mechanically driven by the displacement of the cross-head. Alternatively, there is interest in looking at the nucleation and propagation of cracks from loss in toughness uniquely from the accumulation of hydrogen, as could happen after long service times. (W 79) (2)

Cracking susceptibility = Susceptibilidade à rachadura

Fig.3. Effect of as-deposited ferrite content (IIW Ref. Atlas) in the first-layer claddings (equal to or greater than 7mm in thickness) on disbonding susceptibility. (W 210) (3)

Disbonding susceptibility = Susceptibilidade à desagregação

(1) Novel Control of Weld Metal Hydrogen Cracking in the Welding of Thick Steels

Joanna Nicholas and Richard Pargeter

TWI Ltd, Granta Park, Great Abington, Cambridge, CB21 6AL

Paper presented at the International Steel and Hydrogen Conference

28 September 2011.

(2) Assessment of dissimilar metal interfaces for sub-sea application under cathodic protection

M. Milititsky, M. F. Gittos, S. E. Smith and V. Marques 

Paper presented at Materials Science & Technology 2010. Houston, Texas, USA, 17-21 October 2010.

Keywords: Dissimilar metal, cathodic protection, Hydrogen, sub-sea, fracture toughness.

(3) Disbonding of austenitic stainless steel cladding following high temperature hydrogen service

M F Gittos, J L Robinson and T G Gooch

IIW document Commission IX-2234-07. February 2007.

The gas-delivery system was purged for at least two minutes between subsequent welds. The welds were carried out on chemi-etched samples, with chemi-etched filler wire and using a twin-spot energy profile, based on the thus far accumulated experience. (W 354) (1)

Gas-delivery system = Sistema de saída de gás

This report evaluates a new high velocity flame-spray system that uses consumable in a wire form. (W 295) (2)

Flame-spray system = Sistema de pulverização de chama

To combat surface melting, further changes were made to the remote heating zone pattern using the deflection system. (W 225) (3)

Deflection system = Sistema de deflexão

(1) Achieving Low-Porosity Laser Welds in Aerospace Aluminium Alloy

G Verhaeghe and P Hilton 

TWI

S Barnes 

Warwick Manufacturing Group

Paper presented at 2003 Aerospace Manufacturing Technology Conference (AMTC), 8-12 September 2003, Montreal, Canada.

(2) Coatings for offshore applications by high velocity wire flame spraying

M D F Harvey, S Shrestha and A Sturgeon

Paper presented at NACE 2005 Houston, Texas, 3-7 April 2005.

(3) Electron beam welding of crack sensitive nickel super alloy MAR-M-002.

T. P. Mitchell, R. Sanderson, and B. G. I. Dance

TWI Ltd

Paper presented at the THERMEC 2006 conference in Vancouver, 4-8th July 2006.