Filler Wire Research Articles

Stable production of dissimilar steel joints in construction machinery by narrow gap oscillating laser welding

Narrow gap oscillating laser welding with filler wire is a promising technique for joining high-strength steels in construction machinery. In order to investigate the influence of beam oscillation on the surface morphology and microstructure of weld joints of two types of commonly-used high-strength steels, a comparative study between oscillation welding and non-oscillation welding was conducted. High-speed photography technique was employed to reveal the microstructure and mechanical properties of the dissimilar joints. The results showed that laser beam oscillation produces two effects: one was to enlarge the heated surface of molten pool, while the other was to stir the liquid metal in molten pool periodically. Under the first effect, the fusion between sidewall and weld bead layers was promoted, while under the latter, coarse columnar grains ceased to appear, but finer grains were formed. The weld joints between Q355 and 35 steels exhibited excellent tensile impact bending performance, which was attributed to the grain refinement effect. The results also demonstrated that the oscillation welding with a contact angle less than 50° could avoid lack of fusion in multi-pass wire-filling laser welding. The influence of the oscillation welding process on the quality of welding was further discussed.

Experimental and numerical investigation on cold cracking susceptibility of naval grade high strength steel welds for lightweight shipbuilding structures

In this study the cold cracking (CC) susceptibility of naval grade high strength steel (HSS) welds developed using flux core wires of different yield strength levels was analyzed for lightweight shipbuilding structures. The steel plates of the PCE500 TM grade were welded in T-joint configuration using automatic flux core arc welding under the shielding gas. The CC susceptibility of weld metals was evaluated using Tekken weldability test. The microstructure of weld metal and the hardness of welded joint were analyzed using optical microscope and Vickers microhardness tester, respectively. Software package Sysweld was used for finite element simulation of CC susceptibility of weld metals. Results showed that the probability of CC increases with increase in the strength of filler wires, especially under conditions of limited welding deformations and exposure to low temperatures. The maximum resistance to the formation of cold cracks (CCs) in microstructure of the weld metal is observed in the presence acicular ferrite of at least 60%. To assess the structural strength of T-joint with soft welds, a calculation method has been developed, which allows ranking various structural and technological solutions of the T-joint from the condition of resistance to various types of fracture. Numerical calculation showed that the margin for brittle fracture at 11–23% and the gain in fatigue durability at 40% for welded joint with soft weld greater than for a welded joint with an equally strong weld. The use of low strength filler wires for welding thick plates of HSSs can successfully resolve the problem of CCs and ensure structural strength of joints.

Исследование изменения геометрических параметров образцов, наплавленных методом GMAW при воздействии на электрическую дугу продольного магнитного поля

Introduction. The paper presents the results of research of additive manufacturing process by electric arc with axial feeding of steel filler wire in protective gas environment (GMAW technology) with additional influence of external longitudinal magnetic field on electric arc. Purpose of work: an experimental study of the effect of a longitudinal magnetic field during additive manufacturing by an electric arc with axial feed of filler wire made of structural steels in a protective gas environment on the change in the geometrical characteristics of the layers being surfaced. Research Methods. The manufacturing of specimens was carried out on a 5-axis additive machine based on a CNC machine. Surfacing was carried out in the following modes: voltage 17.5 V; current 55–65 A; wire diameter 1.2 mm; wire material Sv-08G2S; wire feed rate 2,267 mm/min; approximate roll diameter 3.0 mm; roll length 50 mm; number of wires per one roll 312.5 mm; number of layers when surfacing the wall 5; magnet operation mode: alternating current with frequency 50 Hz, voltage 30 V; measured magnetic induction 5.7 mTl; initial height of the magnet above the substrate 10 mm; electrode stickout 10 mm; shielding gas: welding mixture CO2-Ar; gas pressure (flow rate) 0.15 MPa. Results and discussion. The conducted experimental study showed that the effect of longitudinal magnetic field had a statistically significant effect on the change in the dimensions of the singular, namely an increase in the width of the layers being surfaced by 34.1 %, with a calculated significance index close to zero, and a decrease in height by 20.2 %, with a calculated significance index equal to 2.7105. The effect of longitudinal magnetic field had a statistically significant effect on the change of the overall dimensions of the specimens consisting of five layers, namely, the width of the specimens increased by 11.2 % with a calculated significance index of 4.3103, and the height of the specimens decreased by 10.3 % with a calculated significance index of 6.3105. The effect of longitudinal magnetic field had no statistically significant effect on the change of the vertical deviation from straightness for the side walls of the specimens, with a calculated significance index of 0.3277, and had no statistically significant effect on the change of the error of the width of the walls of the specimens, with a significance index of 0.098.

Insights into microstructure evolution and fracture mechanisms of welded joints of high strength steel patchwork components

The hot roll bending patchwork components of B1500HS uncoated ultra-high strength steel processed at industrial scale were welded with filler wire. The microstructure, grain orientation, mechanical properties and fracture behavior of the joint were investigated. The results showed that the weld metal (WM) was mainly composed of lath martensite and lower bainite (LB). Various microstructure appeared in different positions of the HAZ, among which martensite-austenite (M-A) constituents in the incompletely quenched zone and tempered martensite (TM) in the tempered zone were the key factors determining the performance of the joint. The welded joint exhibited complex structure and anisotropic mechanical response due to the decarburization and rolling texture of the original base material (BM). In the tempered zone, lath merge and boundaries disappear lead to the annihilation of dislocations, carbide precipitation leads to reduction of mobile dislocations, and recrystallization and recovery eliminate work hardening. The reduction of the effect of dislocation strengthening results in the formation of a softening belt at 6 mm from the center of the weld, with a minimum hardness of 266 HV. The tensile strength of the joint in the rolling direction (RD) was 983 MPa, and the fracture occurred in the softening belt. Both brittle and ductile fracture features were observed. The reason why the fracture occurs in the high temperature tempered zone instead of the incompletely quenched zone was the difference in the effect of “constraint strengthening”. Fracture occurred through delamination cracking along the “weak interface” owing to precipitated high-hardness cementite particles and the unfavorably oriented ferrite cleavage planes.

Effect of Cr on the high-temperature corrosion of dissimilar AISI 904L and Inconel 625 joints employed in the coal-fired thermal power plant tubes

ABSTRACT The hot corrosion behaviours of 5-mm-thick plates of dissimilar AISI 904L and Inconel 625 weldments produced by continuous current gas tungsten arc welding process using Ni-Cr-Mo-enriched filler wires (ERNiCrMo-4 and ERNiCrCoMo-1) were investigated. Optical microscopy was used to examine the microstructure of these weldments. The corrosion performance of the weldments and base metals was determined in the mixture of K2SO4 + 60% NaCl molten salt (MS) and air oxidation conditions at 700°C for 50 cycles. The thermogravimetric plots derived the corrosion kinetics of the weldments. The microstructure and the elemental analysis of the scales formed on the corroded samples were evaluated by scanning electron microscopy and energy-dispersive spectroscopy. The phases developed on the oxide layers during the corrosion were analysed using X-ray diffraction. The fusion zones of ERNiCrCoMo-1 weldment and AISI 904L base metal were vulnerable to degradation in the MS environment, causing severe cracks and spallation compared to ERNiCrCoMo-1 weldment.

Improving the Formation and Quality of Weld Joints on Aluminium Alloys during TIG Welding Using Flux Backing Tape

This work aimed to compare the quality and properties of the welded joints of AMg6 aluminium alloy produced via conventional TIG welding with the properties of those produced with flux backing tape. This study focussed on the relative length of oxide inclusions (Δoi) and the amount of the excess root penetration (hroot) of the AMg6 alloy weld beads. The results show the influence of the thickness of the flux layer of the backing tape on the formation and quality on the AMg6 alloy welds, along with the effect of flux backing tape and edge preparation on the mechanical properties of the 6 and 8 mm thick welded plates. In accordance with the results obtained, the joints produced by means of TIG welding with flux back backing tape and without edge preparation have higher mechanical properties. Moreover, the TIG welding of AMg6 alloy using flux backing tape reduces the total welding time by 55%, reduces filler wire consumption by 35%, reduces shielding gas consumption by 43% and electricity consumption by 60% per 1 linear meter of the weld line.

A new method for refinement of Ti-6Al-4 V prior-β grain structure in the alternating magnetic field assisted narrow gap gas tungsten arc welding (AMF-GTAW) via filler wire oscillation

This study presents a new method for refining Ti-6Al-4 V prior-β grain in the alternating magnetic field assisted narrow gap gas tungsten arc welding (AMF-GTAW) process by stirring the molten pool, which is accomplished directly through the use of an oscillating filler wire. The wire feed rate can be increased from 1.8 m/min to 2.2 m/min by filler wire oscillation in the traditional AMF-GTAW process with minimal heat input. This method greatly increases welding efficiency by efficiently utilizing the energy of the arc and molten pool. Using a high-speed camera, the flow behavior of the molten pool was investigated under different filler wire oscillating amplitudes. The results showed that the oscillation of the filler wire can cause a violent stir in the molten pool. By increasing the oscillating amplitude of filler wire, one can refine the columnar prior-β grain structure and attain a morphology of the upper layer of the welded joint that is nearly equiaxed with crystallographic texture, all while maintaining a fixed heat input. This is because the wire's insertion into the molten pool also creates a negative thermal gradient and the filler wire's high-frequency and high-amplitude oscillation creates an intense convection that prevents randomly oriented nuclei and/or dendrite fragments from remelting and promotes nucleation activation. The oscillating amplitude of 6 mm and the oscillating frequency of 100 Hz are the ideal values for this effect.

Microstructural evolution and high-temperature oxidation behavior of oxide dispersion strengthened Inconel 625 superalloy fabricated by directed energy deposition

In the present study, wire arc-directed energy deposition (DED) technology was developed to fabricate the Oxide dispersion strengthened (ODS) Ni-based superalloy employing an Inconel 625 flux-cored wire including nano-La2O3 oxides. The microstructural evolution, mechanical properties and high-temperature oxidation behavior were systematically investigated. The results indicate that the melting and decomposition of La2O3 are thought to take place within the melt pool, followed by rapidly combining with Ti to re-precipitate as La2Ti2O7 oxides during DED. These oxides can serve as a highly effective nucleation site according to edge-to-edge matching calculation, resulting in the columnar-to-equiaxed transition and the refinement of grains. However, it is found that plenty of La elements are absorbed by the molten flux in the filler wire, resulting in the formation of slag and the loss of La. Consequently, the strength increases slightly due to the combined effects of precipitation strengthening and grain boundary strengthening. Furthermore, The ODS Inconel 625 sample can achieve a higher oxidation resistance after high-temperature oxidation at 900 °C for 150 h. The fine microstructure promotes the rapid formation of dense Cr2O3 oxide scales. On the other hand, the precipitation of La-rich oxides retards the outward transport of cation such as Ni, Fe and Nb, leading to the formation of a protective δ-Ni3Nb layer beneath the Cr2O3 layer to prevent the oxidation of matrix.

Modelling the Evolution of Phases during Laser Beam Welding of Stainless Steel with Low Transformation Temperature Combining Dilatometry Study and FEM

In this study, the evolution of volume fractions during laser beam welding (LBW) of stainless steel, with a specific focus on incorporating the low transformation temperature (LTT) effect using the dilatometer, has been proposed. The LTT effect refers to the phase transformations that occur at lower temperatures and lead to the formation of a martensitic microstructure, which will significantly influence the residual stresses and distortion of the welded joints. In this research, the LTT conditions are achieved by varying the Cr and Ni content in the weld seam by varying the weld parameter, including laser power, welding speed and filler wire speed. The dilatometer analysis technique is employed to simulate the thermal conditions encountered during LBW. By subjecting the stainless steel samples to controlled heating and cooling cycles, the kinetics of the volume fractions can be measured using the lever rule and empirical method (KOP and Lee). The phase transformation simulation model is computed by integrating the thermal and metallurgical effects to predict the volume fractions in LBW joints and has been validated using dilatometer results. This provides valuable insight into the relationship between welding parameters and phase transformations in stainless steel with the LTT effect during laser beam welding. Using this relationship, the weld quality can be improved by reducing the residual stresses and distortion.

Influence of environmental pressure on the energy coupling and droplet transition behavior in laser welding with filler wire

The influence of environmental pressure on droplet behavior and weld formation in laser welding with filler wire for 304 stainless steel was investigated and the energy coupling behavior was analyzed. As ambient pressure increases from 5 kPa to 700 kPa, the weld depth decreases by 77 %, the variance of the weld width increases approximately 5 times, and the continuity of the weld surface formation deteriorates. During the welding process, a high-speed camera was employed to observe the melt pool, plasma, and melt drop transition behavior. With an increase in the ambient pressure followed by an increase in the metal evaporation temperature, the effects of shielding of the plasma and its internal metal vapor particles on the laser beam lead to a reduction in the depth of the melt. The inverse bremsstrahlung absorption of laser by plasma increased by approximately 36.3 times at 700 kPa compared with that at atmospheric pressure. The number of metal vapor particles at 700 kPa is approximately 3.58 times higher than that at 101 kPa, and the average particle diameter is approximately 0.4 times higher, causing enhanced absorption of laser light by the metal vapor particles. An increase in gas density at elevated ambient pressures resulted in a significant increase in the resistance to droplet descent and decrease in the drive force, leading to an increase in the droplet transition period. This change shifts from a liquid bridge transition to a particle transition, which is the main cause of the deterioration of weld surface formation at high pressures.

Effect of post-weld heat-treatment and solid-state thermomechanical treatment on the properties of the AA6082 MIG welded joints

Post-weld heat treatment (PWHT) and solid-state thermomechanical treatment (TMT) via friction stir processing (FSP) have been shown to enhance the mechanical properties of aluminum alloys. The current work investigates the effects of PWHT and TMT on the microstructure and mechanical performance of AA6082-T6 welded butt joints welded using the MIG process. The 5 mm thick AA 6082-T6 plates were joined in butt configuration using MIG welding with ER 5356 filler wire, 120 A current, 0.3 mm/s weld speed, and argon shielding gas at 15 L/min flow rate. PWHT was performed on the MIG welds per the T6 temper procedure. TMT was implemented via FSP using a pinless tool rotating at 800 rpm and traversing speed at 200 mm/min with a 3° tilt angle. Microstructural analysis, hardness mapping, tensile testing, and fracture surface evaluation were utilized to characterize the as-welded, PWHT, and TMT samples. The results demonstrate that both PWHT and TMT significantly refine and homogenize the microstructures of the welded joints. However, the TMT samples displayed superior hardness and tensile strength compared to the as-welded and PWHT conditions. The TMT-processed welds achieved approximately 99% joint efficiency versus only 69% and 85% for the as-welded and PWHT samples. In summary, PWHT and especially TMT via FSP are effective at enhancing the mechanical properties of MIG welded AA6082-T6.

Weldability and Joining of Dissimilar Metal Welding between Low Carbon Steel and Ferritic Stainless Steel

This paper is to study weldability and joining characteristics of dissimilar metal welding between low carbon steel and ferritic stainless steel using ER308L and ER309L filler wires. Weldability and welded joints were evaluated by microstructure analysis and bend test. It was observed that the microstructure of the fusion zone and the bend test of the welded joint were significantly affected by welding parameters and filler wire. A welded joint prepared with high heat input using the ER309L filler wire exhibited a significant delta ferrite and austenite microstructure. In contrast, when employing the ER308L filler wire with a high intensity welding current, martensite, and carbide formed at the fusion zone. The bend property was acceptable for all the specimens, and there was no evidence of solidification cracking.

Welding of S1100 Ultra high‐Strength Steel Plates with Matching Metal‐Cored Filler Wire: Microstructure, Residual Stresses, and Mechanical Properties

This study investigates the relationship between the microstructure and the mechanical properties and the residual stresses of thermomechanically rolled, butt‐welded S1100MC ultra high‐strength steel plates. Matching metal‐cored filler wires are used for metal active gas welding of the plates in horizontal and vertical‐up positions. The effect of the heat input on the microstructures of both the weld metal (WM) and the heat‐affected zone (HAZ) is studied in detail. The microstructure of the WM consists of different types of ferrite, but the microstructure of the HAZ predominantly consists of fresh martensite at the top and bottom areas. Structure and size of the prior austenite grain boundaries are dependent on the welding positions and affect the impact toughness of the welds. HAZ of the weld produced in vertical‐up position is under intensive tensile residual stresses next to the fusion line. Even with matching filler wires, the strength of the welds is insufficient, and fracture of the weld metal occurs because the extended cooling time leads to the formation of acicular ferrite instead of martensite.

Metallurgical characteristics of AA6061 aluminium and AZ31B magnesium dissimilar joints by fusion welding technique.

Aluminium (Al) and magnesium (Mg) alloys are extensively used in the automobile sector because of their high strength-to-weight ratio, excellent castability low density and simplicity of recycling. Al-Mg structures used in the automotive sector can potentially reduce their weight. Although there is a significant opportunity for substantial cost reduction, the use of magnesium in aluminium structures remains restricted. This study aims to weld 3 mm-thick rolled sheets of AA6061 Al and AZ31B Mg alloy using the cold metal transfer (CMT) arc welding process. Three different filler wires (ER1100, ER4043, and ER5356) were used in the experiment. In this article, the mechanical and microstructure characteristics of Al/Mg dissimilar joints manufactured by CMT are evaluated and discussed in detail. Optical microscope (OM), scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDX), and x-ray diffraction (XRD) were used to analyze the CMT-welded Al/Mg dissimilar joints. Of the three filler wires used, ER4043 (Al-5%Si) filler wire yielded defect-free sound joints due to the presence of Si, which improves the flow ability of molten filler during welding. The presence of Mg-rich intermetallics-Al12Mg17)and Al-rich intermetallics-Al3Mg2 were observed. The fractured area of the CMT-welded Al/Mg dissimilar joints revealed the presence of the Mg-rich intermetallics (Al12Mg17), which is responsible for the decrease in tensile strength. The reduction of intermetallics, particularly of Mg-rich intermetallics (Al12Mg17) is important for improving joint strength. RESEARCH HIGHLIGHTS: Cold metal transfer (CMT) arc welding was used to control the Al-Mg-rich intermetallics in the Al/Mg dissimilar joints. The microstructure, morphology and phase composition of the welded joints were studied by OM, SEM, TEM, EDS and XRD. The weld metal and AL substrate bonded with a strong interface, while weld metal and Mg substrate were joined at the epitaxial solidification area where the intermetallic compounds of Mg2Al3, Mg17Al12 and Mg2Si are generated. The weld metal on the Mg side experienced brittle fracture, with a continuous distribution of Mg2Al3, Mg17Al12 and Mg2Si.

Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

PurposeThis study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire.Design/methodology/approachThe effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions.FindingsRSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations.Originality/valueThis modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.

Microstructural and mechanical properties of electron beam welded super duplex stainless steel

The electron beam welding of super duplex stainless steels is associated with challenges due to the concentrated heat input and the nitrogen loss that result in a predominantly ferritic structure after the solidification. This study presents an approach to overcome this issue by feeding nickel-based filler wire into the melt pool in welding of 2507 super duplex stainless steel. Results showed that the high-frequency beam oscillation combined with a multi-beam technique led a good mixing between the base metal and the filler wire, even at a large depth-to-width ratio. Additionally, the weld geometry was characterized by near-parallel fusion lines and a narrow heat-affected zone. The nickel addition resulted in a balanced microstructure in the weld metal with ferrite fractions of 35–55 %, despite a significant nitrogen loss, consequently leading to impact energy values of 215 ± 15 J and hardness values of 285 ± 15 HV. The findings of this investigation allow fabricators to effectively design electron beam welding processes for producing thick-walled super duplex stainless steel components.

Al4C3 formation and joint tensile properties of dual-beam laser butt welding SiCp/6005A composite with filler wires

SiC-reinforced aluminum metal matrix composite (SiC/Al MMC) is one of the most promising structural materials that provide excellent specific modulus and weight reduction for industrial applications. When fusion welding of SiC-reinforced Al MMC, however, mechanical properties of SiC/Al MMC were significantly deteriorated due to the formation of brittle Al4C3. In this paper, a dual-beam laser welding process was developed to laser weld SiCp/6005A Al composite with ER4043 and ER5356 filler wires. The morphology, microstructure, tensile properties, and fracture behaviors of the welded joints were investigated. Compared to ER5356 filler wire, the weld quality was improved by ER4043, including better surface quality, fewer weld defects, higher tensile strength and better ductility. By introducing the silicon element of ER4043 filler wire into the molten pool, the size and amount of brittle Al4C3 compounds and the porosities were reduced and the reaction between liquid Al and reinforced SiC particles was suppressed to some extent. Furthermore, the dual laser beam energy ratio was optimized to 90%:10% (90/10), the tensile strength of the joints produced with ER4043 was significantly improved to 209 MPa, reaching 70% of the ultimate strength of the base metal.

From Wire to Component: Aluminium Lithium Alloy Development for Wire and Arc Additive Manufacturing

The Innovative Aluminium filler Wires for Aircraft Structures (IAWAS) project aimed to demonstrate the potential of Wire Arc Additive Manufacture (WAAM) for the production of aluminium lithium components. Preliminary testing demonstrated the possibility of depositing an 2395 aluminium lithium filler wire using a plasma arc heat source and a local shielding device. The deposit had a low porosity level but also low ductility caused by long, vertical, segregated grain boundaries. Both chemical composition and deposition conditions are known to impact the deposit microstructure. In-situ alloying, an efficient technique to develop new material, was implemented using plasma arc as a heat source on aluminium lithium alloys. The results aligned with the literature review on the impact of copper on crack sensitivity and led to the design of a new alloy. Unfortunately, the composition selected yielded challenges during the drawing process, and the filler material quality was poor, leading to a low WAAM deposit quality. Machine hammer peening was implemented on the AA2395 alloy, resulting in a drastic increase in ductility and yield strength of 480 MPa after solution treatment and ageing. This alloy was used to manufacture an aluminium lithium demonstrator to showcase the potential of WAAM to produce real-life components.

Melt flow complexity in multi-spot laser welding of asymmetric T-joints

This study investigates melt flow dynamics in asymmetric T-joint laser welding, particularly with sheets inclined up to 45°. This complex scenario requires filler wire, accessible only from the flat sheet side. High-speed imaging at the top and root captures transient phenomena leading to weld imperfections. Research on stainless-steel involved the impact of first-order welding parameters on the weld quality. This included multi-spot laser welding with two beams. The analysis focused on melt pool dynamics under these challenging conditions. The asymmetric root side’s geometry necessitates proper melt flow to form a favorable root topology, avoiding defects like wavy roots and porosity. Key observations included intermittent keyhole openings, transient melt flow effects, and potential spatter ejection at the bottom. The findings offer a comprehensive understanding of 3D asymmetric melt flow, laying the analytical groundwork for enhancing the weld quality.

Question of cross impact of arcs under consumable electrode double-arc surfacing with current-carrying filler wire

Question of cross impact of arcs under consumable electrode double-arc surfacing with current-carrying filler wire