Fine-grained Heat-affected Zone Research Articles

Microstructural evolution and mechanical performance of friction stir spot welded ultrafine carbide-free bainitic steel: Role of dwell time

This study focuses on unraveling the role of dwell time on microstructural evolution, mechanical performance, and failure characteristics of friction stir spot welded ultrafine carbide-free bainitic steel. Results clarify that the microstructures of the different weld zones exhibit a receptive behavior to extended dwell time, by which not only coarser martensite is acquired within the stir zone (SZ), thermo-mechanically affected zone (TMAZ), and fine-grain heat affected zone (FGHAZ) but also sub-critical heat affected zone (SCHAZ) experiences a more pronounced tempering. Applying a dwell time of 3 s is sufficient to make an ample bonding width containing refined martensite, being effective in retarding the crack propagation, and in turn, delivering a joint with the highest load-bearing capacity. However, enlarging the bonding width at dwell times beyond 3 s fails to provide higher peak loads owing to the formation of coarse martensite within the SZ. The failure modes of the welds are classified into two distinct modes: interfacial and partial pullout. The reduced upper sheet thickness (∼685 μm) paves the way for crack propagation along the thickness direction, allowing for partial pullout failure to occur.

Eliminating heat-affected zone of nuclear heat-resistant steel joint via low-temperature friction stir welding

Ferritic/martensitic (F/M) heat-resistant steels are one of the most promising candidate materials applied in core fuel assemblies such as cladding and packaging in nuclear reactors, but their weldments with high performance especially the creep properties were difficult to obtain by conventional welding methods due to the formation of heat-affected zone (HAZ) and rapid dissolution of precipitates. Here we successfully averted the formation of HAZ by reducing the heat input during welding to improve the structure-property synergy of a 12Cr-F/M steel joint via a low-temperature friction stir welding (FSW) technology. Complex microstructure regions consisting of stirred zone (SZ), fine-grained HAZ and inter-critical HAZ were generated in the traditional FSW joint with a high heat input, while only SZ and thermo-mechanically affected zone were found in the low-temperature FSW joint with a peak temperature between the Ac3 and Ac1 temperature. Under dynamic recrystallization at the α+γ two-phase region, ultrafine ferrite and martensite were generated and large amounts of precipitates were retained, giving rise to the greatly improved microhardness and superior tensile strength and impact toughness on par with that of the base metal. This work recommends a feasible technique to produce high-performance heat-resistant steel joints for lengthening the service life of nuclear reactors.

Crystallographic Study of Transformation Products of Heat-Affected Zone and Correlation with Properties of FH690 Heavy-Gauge Marine Steel by Multi-Pass Submerged Arc Welding

In this work, the microstructure–property relationship of the heat-affected zone (HAZ) of a FH690 ultra-heavy marine steel plate was investigated based on insight of microstructure and crystallographic features. After multi-pass welding with a heat input of ~30 kJ/cm, an ~8 mm wide HAZ was obtained with a coarse grain HAZ (CGHAZ) of ~3.8 mm, fine grain HAZ (FGHAZ) of ~3.4 mm, and intercritical HAZ (ICHAZ) of ~1 mm. High impact toughness values of ~120 and 140 J at -60 °C were obtained for coarse grain HAZ and fine grain HAZ, respectively. The microstructure of the CGHAZ and FGHAZ was fine lath bainite. Although the average prior austenite grain size for the CGHAZ was ~75 μm, which was five times that of the FGHAZ (15 μm), a high density of high-angle grain boundaries (HAGBs) with misorientation higher than 45° was obtained in the CGHAZ. This is the underlying reason for the excellent low-temperature toughness of the HAZ. Thermo-dynamic calculations indicated that the high density of HAGBs in the CGHAZ was attributed to the decreased bainitic transformation temperature due to the reduced phase transformation driving force via the high nickel addition, leading to weak variant selection. In addition, the high nickel addition offered high hardenability for high hardness in the FGHAZ. The outcome of this study could provide an experimental and fundamental basis for designing high-strength ultra-heavy steel plates with excellent weldability.

Creep rupture properties of dissimilar welded joint of ferritic/martensitic P92 steel and Inconel 617 alloy

The dissimilar welded joint (DWJ) comprising P92 steel and Inconel 617 (IN617) is frequently utilized in advanced ultra-supercritical (AUSC) boilers. In present work the creep rupture behaviour, rupture mechanism and microstructure evolution of DWJ of P92 steel and IN617 with Ni-based ERNiCrCoMo-1 filler, were examined at 650 °C under the stress range of 120–200 MPa. The results of the creep test indicated that the location of creep rupture varied across different testing conditions, encompassing areas such as P92 base metal and the fine-grained heat-affected zone (FGHAZ). The creep tested specimens within the stress range of 180–200 MPa exhibited failure originating from P92 base metal, predominantly influenced by plastic deformation. The failure manifested in a transgranular mode, driven by the formation, growth, and eventually coalescence of microvoids. The creep tested specimens within the stress range of 120–150 MPa displayed the characteristic ofType IV failure, primarily attributed to matrix softening and the absence of adequate precipitates to pin the PAGBs. Microstructural characterization unveiled the presence of microvoids along the PAGBs, facilitating microvoid nucleation primarily owing to the existence of the coarse brittle carbide phase. The growth of these microvoids over a period of time during tertiary stage of creep which lead to their coalescence and the formation of microcracks, ultimately resulting in premature intergranular failure. The specimen creep exposed at 650 °C under the lower stress of 120 MPa exhibited higher creep rupture life for 432 h. The SEM/EDS study of the crept sample of 120 MPa is also confirmed the presence of intermetallic laves phases in regions near the fracture tip and in the heat-affected zones (HAZs). Although the creep tested specimens at 150 MPa and 120 MPa exhibited failure in the FGHAZ and their elemental SEM/EDS analysis confirmed the presence of an oxide layer and notch formation near the interface of P92 base metal and ErNiCrCoMo-1 filler weld. The FESEM study revealed the growth of the oxide layer in the notch region, and it also showed the presence of multiple cracks and microvoids in the oxide layer. The formation and propagation of the oxide notch mainly led to the interfacial failure. The crept specimens subjected to 180 MPa and 200 MPa did not exhibit any cracks or microvoids in HAZs. However, specimens that failed under applied stresses of 120 MPa and 150 MPa revealed the presence of a high density of microvoids in the FGHAZ, inter-critical heat-affected zone (ICHAZ), and in the region of the coarse-grained heat-affected zone (CGHAZ) adjacent to the interface attached with an oxide layer.

Stress-Corrosion-Cracking Sensitivity of the Sub-Zones in X80 Steel Welded Joints at Different Potentials.

X80 steel plays a pivotal role in the development of oil and gas pipelines; however, its welded joints, particularly the heat-affected zone (HAZ), are susceptible to stress corrosion cracking (SCC) due to their complex microstructures. This study investigates the SCC initiation mechanisms of X80 steel welded joints under practical pipeline conditions with varying levels of cathodic protection. The SCC behaviors were analyzed through electrochemical measurements, hydrogen permeation tests, and interrupted slow strain rate tensile tests (SSRTs) conducted in a near-neutral pH environment under different potential conditions (OCP, -1.1 VSCE, -1.2 VSCE). These behaviors were influenced by microstructure type, grain size, martensite/austenite (M/A) constituents, and dislocation density. The sub-zones of the weld exhibited differing SCC resistance, with the fine-grain (FG) HAZ, base metal (zone), welded metal (WM) zone, and coarse-grain (CG) HAZ in descending order. In particular, the presence of coarse grains, low dislocation density, and extensive M/A islands collectively increased corrosion susceptibility and SCC sensitivity in the CGHAZ compared to other sub-zones. The SCC initiation mechanisms of the sub-zones within the X80-steel welded joint were primarily anodic dissolution (AD) under open-circuit potential (OCP) condition, shifting to either hydrogen-enhanced local plasticity (HELP) or hydrogen embrittlement (HE) mechanisms at -1.1 VSCE or -1.2 VSCE, respectively.

Effect of impurity elements on the creep rupture strength of Gr. 91 steel welded joints at 650 °C

The upper limits for Sb, As, and Sn in Gr. 91 steel are set by the recent standardized Gr. 91 Type 2 specification. To clarify how the three impurities impact the microstructures and creep rupture strength of Gr. 91 welded joints, two types of steel with varying impurity concentrations were prepared. The first contained high impurity concentrations (Steel 1), while the other had low impurity concentrations (Steel 2). The results of the creep tests on the welded joints showed that Steel 1 had lower creep rupture strength compared to Steel 2, indicating premature failure caused by the impurities. Comparing the microstructures in the as-welded joints, it was observed that Steel 1 had more M23C6 particles in the fine-grained heat affected zone (FGHAZ) than Steel 2. This finding indicates that M23C6 dissolution during the welding process was hindered in Steel 1. It is believed that M23C6 dissolution was reduced due to the segregation of impurities at the grain boundaries or the interface between the matrix and M23C6 particles. Consequently, the microstructure in FGHAZ of Steel 1 showed lower creep resistance because the pinning force by M23C6 was decreased due to the reduction of re-precipitation on the grain boundaries during post weld heat treatment. The degradation in the creep rupture strength due to the impurities was attributed to the earlier progression of recovery process in FGHAZ during creep, leading to premature creep void formation.

Improving creep strength of the fine-grained heat-affected zone of novel 9Cr martensitic heat-resistant steel via modified thermo-mechanical treatment

Improving creep strength of the fine-grained heat-affected zone of novel 9Cr martensitic heat-resistant steel via modified thermo-mechanical treatment

Galvanic Corrosion Behavior of the X80 Steel Welded Joint

Wire beam electrode techniques and classical electrochemical techniques were used to investigate the effect of the area ratio of each part of the welded joint on the galvanic corrosion behavior. The results showed that the order of the corrosion current density of the different regions in the simulated X80 steel welded joint was as follows: coarse-grained heat-affected zone > fine-grained heat-affected zone > intercritical heat-affected zone > base metal > weld metal. As the area ratio of weld metal increased, the galvanic potential shifted positively, the maximum anode galvanic current density increased and the main anode galvanic effect increased. On the other hand, as the area ratio of the base metal and the heat-affected zone decreased, the coupled potential shifted negatively and the maximum anode galvanic current density decreased. The galvanic corrosion intensity of the simulated X80 steel welded joint increased as the area ratio of the weld metal decreased and increased as the area ratio of the heat-affected zone and base metal increased. To enhance corrosion resistance, it is advisable to choose a shape with a larger groove to increase the WM area in the welded joint. Additionally, selecting a welding method with lower heat input and a higher energy density can help reduce the HAZ area in the welded joint.

Creep-fatigue life estimation of circumferential welds in thermal high energy piping systems

ABSTRACT To prevent accidents in high energy piping systems of thermal power plants, it may be important to accurately estimate the creep-fatigue life of circumferential piping welds. The main failure mode in the damage cases was Type IV damage which was creep-dominated damage occured at the fine-grained HAZ(FGHAZ). The damege mode is considered to change from longitudinal failure at the base metal to circumferential Type IV failure when the ratio of axial stress to hoop stress exceeds a certain value. The allowable thermal expansion stress in the design, the stress relaxation property of the material, and the creep rupture strength of welded joints are investigated, as factors affecting creep damage of circumferential piping welds. Fundamental creep-fatigue tests were perfomed using cross-weld specimens and their lives were estimated by a linear damage summation rule. In the life estimation, it seems necessary to consider elastic follow-up phenomena where strain transfers to the HAZ.

Characterization of As-Welded Microstructure in a P91 Steel

The microstructure of the heat affected zone (HAZ) and fusion zone (FZ) in the as-welded condition of a single-pass weld performed by the flux-cored arc welding (FCAW) process was studied in a P91 steel using microhardness measurements, field-emission scanning electron microscopy, transmission electron microscopy, and x-ray diffraction. The evolution of precipitates in each region of the single-pass weld was analyzed, and particular attention was paid to the presence of retained austenite (RA). Experimental observations indicated that M23 C6 carbide played a major role in the thermal cycle associated with the weldment. On one hand, the dissolution of M23 C6 led to the precipitation of spherical NbCN in the finegrained HAZ (FGHAZ) near the coarse-grained HAZ (CGHAZ). On the other hand, the total or partial dissolution of M23 C6 carbides changed the chemical composition of the initially formed austenite. In the regions where the M23 C6 carbides were completely dissolved (i.e., the CGHAZ and FZ), retained austenite was observed as a thin, continuous film along primary austenite grains and lath boundaries. Instead, a shell of retained austenite was observed around some partially dissolved M23 C6 of the intercritical HAZ (ICHAZ) and FGHAZ.

Type IV cracking of P92 steel welded joint used in China power plants

ABSTRACT P92 (9Cr-1.8W–0.5Mo-NbV) martensite steel is widely used in high-temperature pipes of ultra-supercritical boilers in China. During high-temperature operation, microstructural evolution of the heat affected zone (HAZ) across welded joint leads to type IV cracking failure. In this article, microstructural evolution and type IV cracking of P92 steel welded joint in an actual 605℃ supercritical boiler were analysed. The results show the cracking appeared in the fine-grained heat affected zone (FGHAZ). Laves phase and M23C6 phase clustered around the cavity. Their precipitation and coarsening promote the nucleation and growth of cavities. The Z phase was also observed in the heated affected zone. Compared with other zones, FGHAZ has lower dislocation density and more degeneration of tempered martensite lath, the coarsening of Laves phase and M23C6 phase is more severer in FGHAZ. These factors led to the deterioration of the creep properties and type IV cracking.

Effect of aging on microstructure and mechanical properties of dissimilar steel welded joints between G115 and Sanicro25 steel

This paper studied the high-temperature stability of dissimilar steel welded joints between G115 and Sanicro25 steel. The joints were exposed to 700 °C for time up to 2000h. The microstructure evolution of base metal (BM) and fine-grain heat-affected zone (FGHAZ) were analyzed. Tensile, microhardness, and impact experiments were conducted on the joints, and the explanations for the changes in mechanical performance are derived from the microstructure. The results showed that the Laves phase were precipitated after aging for 100 h, which has two nucleation methods. Nucleation adjacent to M23C6 is the main way in this research. Laves phase mainly grows up to consume M23C6. The microstructure in BM and FGHAZ is obviously different after aging. After aging for 1000 h, mechanical properties such as tensile strength, Vickers hardness, impact energy, elongation and area reduction are reduced, except for the yield strength. The softening caused by the microstructure evolution of FGHAZ is the main reason for the joint fracture in FGHAZ.

Creep–Fatigue Life Estimation of Gr.91 Steel and Its Welded Joints

A series of creep–fatigue tests of Gr.91 steel were performed at 600 °C. Fatigue life was reduced by tensile strain holding. The minimum life reduction factor was approximately 0.3. The creep–fatigue life could not be estimated properly via the conventional linear summation rule of the fatigue damage and creep damage. Since this material is considered to have a large creep–fatigue interaction, it was proposed that the creep–fatigue life should be estimated using the improved linear summation rule of the fatigue damage, the creep damage and the creep–fatigue interaction damage. In the future, it will be necessary to clarify the creep–fatigue interaction mechanism and define its damage value. On the other hand, a series of creep–fatigue tests for Gr.91 steel welded joints were also performed in the strain range of 0.5% at 600 °C. Again, the fatigue life was shortened by the tensile strain holding. The minimum fatigue life reduction factor was approximately 0.2. All the test pieces fractured in the fine-grained HAZ of the welded joints. The creep–fatigue life could not be estimated properly using the linear summation rule of the fatigue damage and creep damage in the HAZ. One possible reason was thought to be the effects of the elastic follow-up phenomena peculiar to welded joints. The creep strain of the HAZ might increase due to the transfer of the elastic strain from both the base metal and the weld metal, according to the elastic follow-up phenomena during strain holding. In the future, it will be important to quantitatively estimate the effects of the elastic follow-up phenomena.

Effect of PWHT on metallurgical and mechanical characterization of dissimilar welded joint of P91 and P92 steels

P91 and P92 steels are widely used in nuclear and thermal power plant’s high-temperature (650–700 °C) operating components. The welding procedure, base plate composition, filler material composition, and post-weld heat treatment (PWHT) significantly affect the metallurgical characterization of weldments at room temperature. This work focuses on joining P91 and P92 steel by the TIG welding with filler ER90S-B9. The study analyzes the materialization of coarse-grained HAZ (CGHAZ), inter-critical HAZ (ICHAZ), and fine grained HAZ (FGHAZ) under welded and PWHT. PWHT was conducted at 840 °C for 2, 4 and 6h. An optical microscopic (OM) scanning electron microscope (SEM) was employed to characterize the welded and PWHT samples. It was perceived that the tensile strength of PWHT increased as the heat treatment times increased from 2 to 6 h, while the hardness value decreased accordingly. The maximum tensile strength (594.71 MPa) was observed in PWHT_6 h, while the minimum tensile strength (537.52 MPa) was perceived in the as-welded sample. The PWHT_6h reveals the minimum hardness values (271.12 HV) at the fusion zone among all the conditions. The WFZ consisted of an untampered lath martensitic grain structure, demonstrating an average hardness value of 314.15 HV in the PWHT_2h condition. The hardness value in CGHAZ samples for as-welded, PWHT_2h, PWHT_4h, and PWHT_6h was observed at 456.85, 436.81, 368.63, and 327.41 HV, respectively.

Deformation behavior, microstructure evolution, and rupture mechanism of the novel G115 steel welded joint during creep

To promote the wide application of the G115 steel in ultra-supercritical (USC) power plants, creep deformation, microstructure evolution and rupture mechanism of the G115 welded joint were systematically investigated. The fabricated G115 welded joint exhibits superior creep strength to the P92 or MARBN steels. The deformation behaviors are analyzed by the Norton's power law, proving that the deformation mechanism is closely associated with the stress levels. During short-term creep under higher stress, the weld metal (WM) and heat-affected zone (HAZ) exhibit outstanding microstructure stability, and the rupture occurs within the base metal (BM) due to the lath fracture. While, during long-term creep under lower stress, the brittle Type IV cracking occurs within the inter-critical heat-affected zone (ICHAZ) or fine-grained heat-affected zone (FGHAZ) due to the formed micro-voids along boundaries, obviously deteriorating the creep strength. The weld strength reduction factors are calculated under different stresses, and prove that synergistic action of back stress and dislocation motion can enhance the creep resistance of the G115 welded joint. Additionally, the allowable service stress of G115 weldments should be designed according to the creep strength of the welded joints under expected performance life.

The creep-fatigue fracture behavior of heat-resistant steel welded joint under different tensile and compressive holding

The stress-controlled creep-fatigue test was conducted to investigate the damage mechanism for the CrMoV steel welded joint by introducing tensile holding and tensile-compressive holding respectively. It was found that the final fracture mode changed from creep void-induced fracture inside the over-tempered zone (OTZ) to fatigue crack-induced fracture in the fine-grain heat-affected zone (FGHAZ) as the stress amplitude decreased to 250 MPa and compressive holding of 180 s was introduced. Simulation results based on the local miniature tensile test indicated that the strain mainly concentrated inside the OTZ because of the low strength, while the stress concentrated on the surface of the FGHAZ and inside the OTZ due to the constraint of high-strength weld metal (WM) on the radial deformation. The distribution of strain and stress demonstrated the competitive failure between OTZ and FGHAZ with different modes of damage. The crack initiation on the surface of FGHAZ was promoted in the oxide due to compressive holding, then the sharpened tip of cracks induced sufficient propagation during numerous cycles under low stress amplitude, resulting in the fracture of fatigue crack-induced mode.

Correlation between the Coarse- and Fine-Grained HAZ Hardness of X70 Pipeline SMA Welded Girth Welds

This work confirmed that the locations of minimum and maximum HAZ hardness occurred within the FGHAZ and CGHAZ zones. CGHAZ and FGHAZ hardness data from different SMAW passes were compared to determine their correlation.

Effect of Post-Weld Heat Treatment Temperature on the Mechanical Properties and Microstructure of Weld Heat-Affected Zone of 2.25Cr-1Mo Steel

The effect of post-weld heat treatment (PWHT) temperature on the mechanical properties of the heat-affected zone (HAZ) of 2.25Cr-1Mo steels was investigated. SA-387 Gr. 22 Cl. 2 steel was employed, and the specimens taken from the steel were thermally cycled using Gleeble to simulate the coarse-grained HAZ (CGHAZ), fine-grained HAZ (FGHAZ), and intercritical HAZ (ICHAZ). Before the PWHT, the simulated HAZs exhibited poor impact toughness as compared with the base metal. The base metal and simulated HAZ specimens were heat treated in a furnace at 610, 650, 690, and 730℃ for 8 h; their impact toughness improved significantly irrespective of the PWHT temperature. The microstructural changes owing to the PWHT were observed using scanning electron microscopy and correlated with the mechanical properties.

Microstructural evolutions and impact toughness in simulated welding heat affected zones for a high-strength carbide-free bainitic rail steel

Systematic experimental investigations were conducted to study the microstructures and impact toughness of each heat affected zone (HAZ) formed during rail flash-butt welding. A high-strength carbide-free bainitic rail steel was subjected to different thermal simulation cycles to separately reproduce each HAZ subzone by tailoring the peak temperature (PT) with respect to 700, 850, 920, 1000 and 1350 °C, and hence to generate the corresponding microstructures by using Gleeble-3500 simulator. Results show that the HAZ subzones exhibit complicated microstructures depending on the PTs, and with increasing PT the dominant bainitic microstructure type evolves from polygonal bainitic ferrite (700 °C) to a mixture of fine bainitic ferrite and granular bainite (850–1000 °C), and finally to coarse bainitic ferrite and granular bainite (1350 °C). Impact tests demonstrate that the impact toughness initially increases significantly as the PT reaches 920 °C (i.e., fine-grained HAZ), beyond which the impact toughness starts to decrease. The fine-grained HAZ displays optimal impact toughness in HAZs, yet which is lower than the base metal. Moreover, the morphology and distribution of martensite-austenite (M-A) constituents is strongly dependent on the welding PT, and the high fraction blocky and coarse slender M-A constituents is considered to be detrimental for the impact toughness.

Crack tip fields effects on crack propagation through the heat affected zone in an overmatched welded joint

AbstractThe mismatching constraint effect on crack propagation through the heat‐affected zone (HAZ) in a welded joint is presented in this paper. It is shown that due to this effect, the fracture behavior of an overmatched welded joint depends on the mechanical properties and the size of the region of the crack tip location, as well as on the properties and the size of surrounding regions. The finite element analysis of high‐strength low‐alloyed (HSLA) steel welded joints with crack tips in the heat‐affected zone is performed based on previous experimental work. Two locations of the crack tip are analyzed: fine‐grained HAZ (FGHAZ) and coarse‐grained HAZ (CGHAZ). In both cases, after the initial propagation of the crack in FGHAZ or CGHAZ, its propagation is directed toward more ductile base metal, thus increasing the fracture resistance of a welded joint. Some new observations about the reasons for such behavior due to crack tip strain fields are presented as well.