Mechanical characteristics and stretch-bend failure analysis on ultra high frequency pulsed gas tungsten arc welded thin FSS 409/430 dissimilar joints

Abstract

The Mechanical and Stretch-Bend Failure studies on Ultra High Frequency Pulsed Gas Tungsten Arc Welded dissimilar joints of AISI409-AISI430 Ferritic Stainless Steels were conducted. Welding was conducted with 5 ultra high frequencies (50 Hz, 150 Hz, 250 Hz, 350 Hz, 450 Hz). Mechanical characteristics evaluation on the joints included tensile strength, microhardness variations across the welds and creep. Microstructural and metallurgical investigations included weld cross section evaluation, comparing grain variations in high, medium and low thermal heat affected zones, weld zones and base material region. Stretch bend failure studies included studies on angular distortion, fracture limit strain, and coefficient of friction. Tests revealed that joints welded at 350 Hz was better, compared to other joints. Dissimilar AISI409-AISI430 joint fabricated at 350 Hz exhibited 267 ± 3 MPa as yield and 409 ± 6 MPa and as ultimate tensile strength. Its creep fracture duration was 72.7 min (highest among the joints). Microstructural studies revealed grain growth, partially coarse and partially fine grains in heat affected zones. Depending on the difference in grain sizes, on both sides of the welds, heat affected regions were identified as three distinct zones. In AISI430 side; high temperature austenitic, martensitic, delta ferrites and in AISI409 side; needle like martensitic structures, mixture of ferritic-austenitic, δ-ferrite with carbide precipitation were found in high, medium and low thermal heat affected zones, respectively. On increasing the ultra high frequency pulses, angular distortion increased, fractures changed from tensile/shear type to mixed type. In shear bend tests, on increasing the ratio of radius: thickness, fracture limit strain on outer surface, across sheet thickness, due to stretching increased.