Toward Process-Based Quality through a Fundamental Understanding of Weld Microstructural Evolution

In this overview paper, the possibility of qualifying welded components by integrating software and hardware tools that are capable of describing physical processes that occur during welding is explored.The existing and emerging tools to define geometrical boundary conditions, process parameters, heat and mass transfer, solidification, solid-state transformation, plastic deformation, distortion, residual stress, and performance of welded components are reviewed.Existing challenges relevant to the fundamental understanding of complex alloying, processing environment, and transients in energy deposition are discussed with reference to microstructure evolution.Approaches to address these challenges were articulated with published case studies relevant to welding and additive manufacturing.