Assignment 2

• Identify a journal article related to the experimental fusion welding process

(with microstructures).
• Last date: 22/10/2023
**Mechanisms of Weld Metal Nucleation:**

There are three primary mechanisms of weld metal nucleation:

1. **Heterogeneous nucleation:** This mechanism involves the formation of new grains on existing surfaces or particles within the weld pool. These surfaces or particles act as nucleation sites, providing a preferential location for atoms to
arrange themselves into a new grain structure.
2. **Homogeneous nucleation:** This mechanism involves the formation of new grains without the presence of pre-existing surfaces or particles. It requires a high degree of undercooling, meaning the temperature of the liquid metal is
significantly lower than its equilibrium melting point.
3. **Dendrite fragmentation:** This mechanism involves the breaking up of existing dendrites, which are elongated grains that form during solidification. The fragments of these dendrites can act as nucleation sites for new grains.

**Factors Affecting Weld Metal Nucleation:**

Several factors can influence the type and extent of nucleation in the weld pool:
* **Temperature gradient:** A higher temperature gradient promotes heterogeneous nucleation at the fusion boundary between the weld pool and the base metal.
* **Cooling rate:** A faster cooling rate increases the degree of undercooling, favoring homogeneous nucleation.
* **Solute content:** The presence of solute atoms can either promote or hinder nucleation depending on their chemical affinity for the base metal.
* **Inclusions:** The presence of inclusions, such as oxides or nitrides, can provide heterogeneous nucleation sites.
* **Welding parameters:** Welding parameters such as heat input, travel speed, and welding current can indirectly affect nucleation by influencing the temperature gradient, cooling rate, and solute distribution.

**Importance of Weld Metal Nucleation:**

Weld metal nucleation plays a crucial role in determining the microstructure and properties of the weld metal. A fine-grained microstructure, with a large number of small grains, generally exhibits improved strength, toughness, and ductility
compared to a coarse-grained microstructure.
**Controlling Weld Metal Nucleation:**
Several techniques can be employed to control weld metal nucleation and achieve the desired microstructure:
* **Grain refinement:** This involves adding grain refining elements, such as titanium or zirconium, to the weld pool. These elements provide potent heterogeneous nucleation sites, resulting in a fine-grained microstructure.
* **Controlled cooling:** This involves slowing down the cooling rate of the weld pool, allowing for more time for diffusion and nucleation. This technique favors the formation of an equiaxed microstructure.
* **Ultrasonic stirring:** This involves introducing ultrasonic waves into the weld pool to agitate the molten metal. This agitation can enhance nucleation by providing additional nucleation sites and promoting grain fragmentation.

By understanding and controlling weld metal nucleation, it is possible to tailor the microstructure and properties of welds to meet specific engineering requirements.
Weld metal nucleation mechanisms
Heterogeneous Nucleation: This Mechanism Involves The Formation Of New Grains On Pre-Existing Surfaces Or Particles Within The Liquid Or Solid Phase. These
Surfaces Or Particles Act As Nucleation Sites, Providing A Preferential Location For Atoms To Arrange Themselves Into A New Grain Structure. The Energy Barrier For
Heterogeneous Nucleation Is Typically Lower Than That For Homogeneous Nucleation, Making It The More Prevalent Mechanism.

Homogeneous Nucleation: This Mechanism Involves The Formation Of New Grains Without The Presence Of Pre-Existing Surfaces Or Particles. It Requires A High
Degree Of Undercooling, Meaning The Temperature Of The Liquid Or Solid Phase Is Significantly Lower Than Its Equilibrium Melting Point. Homogeneous Nucleation Is
Less Common Than Heterogeneous Nucleation Due To The Higher Energy Barrier Involved.
Effect of Welding Parameters on Heterogeneous Nucleation
Grain structure control
Solidification modes
Effect of welding parameters
Microstructure refinement
Solidification Cracking
Houldcroft test Varestraint test
Factors affecting solidification cracking
Mechanical factors
LIQUATION
LIQUATION MECHANISMS