Materials Science Books

Guide to Submitting your Proposal

The information you provide will help us to evaluate your proposal. Please provide as
much detail as possible.

1. Title (and subtitle) of your proposed book:

Life assessment of weldments in metallic structures

2. Author(s) or Editor(s) with Affiliation(s):

Dr. Abdel Salam Hamdy Makhlouf
Full Professor: Central Metallurgical Research and Development Institute, CMRDI, Cairo, Egypt
Materials/Metallurgical Engineering Consultant: ORC International Expert Service, USA

Dr. Khaled Hafez

Full Professor: Welding Department, Central Metallurgical Research and Development Institute,
CMRDI, Cairo, Egypt

3. Please indicate whether your proposal is for an authored or contributed

(edited) book

It will be contributed (edited) book and we will author some chapters as well.

4. Description:
i. One-Line Description:

Remaining life assessment assignments and relevant non-destructive tests for welded structures.

ii. Detailed Description: Please provide a 200-word description of your proposed

book.
For large complex structures such as power stations, refineries, and other petrochemical plants,
the safety and cost-effective operation is essential. All these metallic components are fabricated
by welding. The welded structure of a component is expected to perform specific functions for a
minimum specified duration of time. Failures of welding components without prior warning can
have serious consequences for personnel, environment and the metallic structures in general and
be extremely expensive in terms of both losses in generating revenue, environmental spoils,
unplanned shut-down and repair costs. Therefore, remaining life assessment is crucial in the
operation of most metallic constructions. It helps to plan maintenance, repair, and avoid
unexpected failures. This book will set the subject into context by describing the lifetime
assessment. It will also explore several approaches such as assessing the lifetime of a welded
joint in relation to fatigue, creep or estimating the time before an interior welding defect will
reach a criticality that entails risk of failure. Lifetime assessment may also depend on the
expected corrosion rate compared to the actual corrosion rate in the (spectrum of) environments
to which the construction is exposed.

5. Audience: For whom is this book primarily intended and at what level? Is it for
academics, or professionals, or both? How would you ensure the content meets the
needs of the readership?
This book is intended to be suitable for practicing engineers, metallurgists, materials scientists
and researchers who are involved in the design and operation or maintenance of welded
components. The book will be useful for graduate-level students who want to explore this new
field of research. With content relevant to both academic and industrial (commercial) viewpoints,
the book will interest researchers and postgraduates as well as consultants and industrial
engineers.

6. Benefits to audience
What problems will this help the intended reader solve for its readers?
- This book provides the necessary knowledge of the procedures involved in making
integrity assessments of welded components which may contain defects initially or
develop cracks during use.
- It will solve the high cost and risks associated with unplanned shut down.
- It helps to plan maintenance, repair, and avoid unexpected failures.
- It will discuss the challenges welded materials failure analysis in many strategic
industries including oil and gas, petrochemical power stations, and many more.
- It will also explore the factors affecting the lifetime of a welded joint in relation to
corrosion, fatigue, creep, etc.

7. Table of Contents
Please include (target) contributor name/s and affiliations (if available), chapter
titles, and main sub-headings if possible at this stage.

Target Contributors: The following table provides some examples of the book contents with
possible authors and their affiliations.

No. Proposed title Contributor Affiliation Sub-headings

name Contact
details
1 Introduction to welding  Fusion welding
and metallurgy of  Heat flow
welded joints  Fusion zone and Weld Metal
Solidification
 Partially melted zone
 Heat affected zone
2 Weld Discontinuities  Imperfect Shape
and Defects  Cracks
 Cavities
 Lack of Fusion/Penetration
 Inclusions
 Miscellaneous
3 Failures Related to  Failure due to faulty design or
Welding misapplication of material.
 Failure due to improper processing
or improper workmanship.
 Failure due to deterioration during
service.
4 Introduction to life  Definition
 assessment  Why conduct a life assessment?
 Life assessment as standard
procedure
 life assessment tools and support
structures
5 Fracture mechanics    The Complex Stress State in the
assessment of welded Notch
joints  Theoretical Notch Coefficient
 The Fictitious Radius of the
Welding Notch
 The Notch Coefficient with the Use
of the Fictitious Notch Radius
6 Health monitoring of  In Service Inspection (ISI)
weld joints  Various Inspection Methods of ISI
 Application of the impedance
technique to weldments
7 Assessment of fatigue
in welded joints
8 Creep life assessment
of welded joints
9 Assessment of
corrosion in welded
joints
10 Environment
Conditions and its
effect on lifetime of
welded joints
11
12
13
14 Statics and Economic Economic evaluations
evaluations of the life
assessment
15 Future trends and Future trends and outlook
outlook

8. Length
Please indicate how many printed pages you estimate the book will be? We can fit
roughly 350 words per printed page. How many illustrations (estimated) will there
be?
It may include 15-20 chapters. Each chapter will be in 20-25 pages with 5-10 illustrations.

9. Competition:
i. What is the major competing work(s) to the proposed Work?
1. Ibrahim, Raouf A. Handbook of Structural Life Assessment. John Wiley & Sons, 2017.
2. Webster, George A., and Robert A. Ainsworth. High temperature component life
assessment. Springer Science & Business Media, 2013.
 3. Lagoda, Tadeusz. Lifetime estimation of welded joints. Springer Science & Business
Media, 2008.
-

ii. How does the proposed Work differ from this?

- The first book is dealing with lifetime assessment of metallic structure in general. The
coverage about weldment is very limited.

- The second book is dealing with estimating the lifetime of welded joints operating within
creep range at high temperatures. There is a significant lack of information about the
lifetime assessment at other moderate and regular temperatures.

- The third book presents the estimation of the lifetime of welded joints only under fatigue
loading, without explaining other factors such as crawling or corrosion.

-
- Our book is unique, as it will focus on the welded joints as the weakest points in most of
the metallic structures. The factors affecting the weldments performance and their
impacts on the life assessment will be discussed in detail

10. Delivery
When would you plan to deliver the completed manuscript?

The expected time for deliver will be June 2021 or before.