Fine-grained Heat-affected Zone Research Articles

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.

Physical Simulation and Numerical Simulation of Flash Butt Welding for Innovative Dual Phase Steel DP590: A Comparative Study.

In this study, the microstructure and performance of newly designed dual-phase steel (DP590) after joining by flash butt welding (FBW) for vehicle wheel rims was analysed and compared by two simulations, i.e., physical simulation and numerical simulation, due to the high acceptance of these two methodologies. Physical simulation is regarded as a thermal-mechanical solution conducted by the Gleeble 3500 simulator and which can distribute the heat-affected zone (HAZ) of the obtained weld joint into four typical HAZs. These are coarse-grained HAZ, fine-grained HAZ, inter-critical HAZ and sub-critical HAZ. A combination of ferrite and tempered martensite leads to the softening behaviour at the sub-critical HAZ of DP590, which is verified to be the weakest area, and influences the final performance due to ~9% reduction of hardness and tensile strength. The numerical simulation, relying on finite element method (FEM) analysis, can distinguish the temperature distribution, which helps us to understand the relationship between the temperature distribution and real microstructure/performance. Based on this study, the combination of physical and numerical simulations can be used to optimise the flash butt welding parameters (flash and butt processes) from the points of temperature distribution (varied areas), microstructure and performance, which are guidelines for the investigation of flash butt welding for innovative materials.

Microstructure and crystallographic texture of high frequency electric resistance welded X65 pipeline steel

Microstructure and crystallographic texture and their correlation with impact toughness of high-frequency electric resistance welded (HF-ERW) X65 Grade pipeline steel have been investigated. X65 base metal after HF-ERW has formed a typical hourglass-shaped weld joint with four different regions, including the thermomechanical-affected zone (TMAZ), fine-grained heat affected zone (FGHAZ), coarse-grained heat affected zone (CGHAZ), and bondline (Weld Zone). X65 base metal shows prominent (113) [110] and (112) [110] texture components due to thermomechanical-controlled processing. TMAZ depicted random texture with a minor intensity of Cube component (001)[110] due to the partial recrystallization during welding. In the FGHAZ and CGHAZ, near the bondline, the base metal texture has been converted to rotated Goss (110) [110], Goss (110) [001], and rotated cube (001) [110] due to the recrystallization of the austenite and the shear deformation in the austenite temperature range. A high density of {100} and {110} cleavage planes is observed in the CGHAZ, which is often found to be the fracture location for the impact toughness testing.

Stress corrosion cracking of X80 steel heat-affected zone in a near-neutral pH solution containing Bacillus cereus

Bacillus cereus (B. cereus) is observed to have varying effects on the stress corrosion cracking (SCC) sensitivity of different microstructures in the simulated heat-affected zone (HAZ) of X80 steel. At open circuit potential (OCP), the SCC sensitivity of different microstructures increased from 3.40–7.49% in an abiotic medium to 10.22–15.17% in a biotic medium. At −0.9 V (SCE), it increased from 22.81–26.51% to 35.76–39.60%. The increment in SCC sensitivity upon exposure to B. cereus was highest in the coarse-grained HAZ (7.68 and 16.79% at OCP and −0.9 V, respectively), followed by the intercritical and fine-grained HAZs. Owing to differences in the phase composition, grain boundary type, dislocation density, and surface volta potential, the initial adhesion number and position of B. cereus in the microstructure of the HAZ were differed, resulting in different sensitivities to SCC.

Investigation of microstructure, and mechanical properties of dissimilar high and ultra-high steel welded joints: application for extreme climate conditions

The paper focuses on the technical challenges of producing high-quality welds in modern extreme climate conditions structures, as welds are typically the weakest part of welded structures. Welding is particularly difficult with high-strength and ultra-high-strength steels (HSS-UHSS), which are used in structures to reduce weight. The microstructural compositions and mechanical properties of dissimilar high-strength and ultra-high-strength steels were investigated in this study, which was performed with three different heat inputs (0.8, 1.2, and 1.8 kJ/mm). There was a 2.3Cr, 0.4Si, and 2.8Mn increase on the FGHAZ microstructure of the S960QC side, confirming the temperature increase in that zone. Microhardness results show softening (160 HV5) in the E500 side's fine grain heat-affected zone (FGHAZ). Bending test results show that when the maximum force applied was 4000N, the fracture angle was close to 149°, and that the fracture zone was oriented exclusively in the FGHAZ, which had the higher softening zone. Tensile results show the fracture zone, which was oriented in the E500 side's FGHAZ. It was suggested that a heat input of 1.2 kJ/mm be applied to the weld dissimilar joint of TMCP E500-S960QC, which will be beneficial for extreme climate conditions.  

Influence of microstructure on the micro-region fracture toughness of the 30Cr2Ni4MoV turbine rotor welded joint

The fracture toughness of each micro-region in 30Cr2Ni4MoV steam turbine rotor welded joint was studied, including the central zone of the SAW bead (SAW-C), the overlapping zone of the SAW bead (SAW-Z), and the central zone of the TIG weld metal (TIG), coarse-grained heating affected zone (CGHAZ), fine-grained HAZ (FGHAZ) and base metal (BM). The microstructure, fracture morphologies and cracking paths were observed by OM and SEM microscope, and the influence of microstructure on fracture toughness was analyzed. The research results show that the fracture toughness of the weld metal is lower than that of BM and HAZ, and the fracture toughness of the weld metal is non-uniform. TIG and SAW-C are composed of columnar tempered bainite, intergranular tempered lath martensite and carbides, and the fracture toughness is the worst. SAW-Z is zigzag columnar tempered bainite and equiaxed granular tempered bainite between weld passes, which has good fracture toughness. CGHAZ and FGHAZ are equiaxed tempered martensite with the best fracture toughness. By observing the fracture morphology and cracking path, SAW-C and TIG are dominated by brittle cleavage fracture mode, and SAW-Z, FGHAZ, CGHAZ and BM are in the ductile fracture mode. The straight columnar grains of SAW-C and TIG are prone to crack propagation, but the tempered bainite acts as a bridge. SAW-Z has a zigzag tempered bainite grains, and the crack propagation path is tortuous. For FGHAZ, CGHAZ and BM with equiaxed grains, the fracture toughness is related to the grain size and the dimple size around the crack tip. The crack propagation process is that the dimples are first formed in a certain range around the crack tip, but only the dimples in the lower strength micro-regions grow and merge preferentially, and rapidly form new cracks.

Different ways for HAZ microstructure preparation and testing on high alloy steel

The heat-affected zone (HAZ) is the part of the weld that is affected by the heat generated by the welding process during welding. The microstructure of the HAZ is very heterogeneous and consists of different zones such as the coarse-grained HAZ, the fine-grained HAZ, the intercritical HAZ, and the over-tempred HAZ [1]. All these zones are very narrow and their properties are slightly different. These properties affect the integrity of the entire weld, so in many cases the HAZ may be the worst part of the weld. Another challenge is determining the properties of the individual HAZ regions, since the entire HAZ is very narrow and inhomogeneous. For this reason, many properties cannot be determined accurately, with the exception of a few, such as hardness, for which only a small region is sufficient for measurement. Therefore, it is important to know how to produce the individual microstructure of a HAZ in a wider range of the material in order to determine the actual properties of such a HAZ. One of the ways is to measure the welding parameters during welding to determine the actual influence of the thermal cycle on the formation of the invidual microstructure of HAZ in the weld. Moreover, it is crucial to repeat this weld thermal cycle in an unaffected base metal on a thermal welding simulator to obtain a suitable microstructure of the HAZ [1,2]. The second option is to prepare the microstructure in the furnace by slow heating which is followed by rapid cooling [1,3]. Both processes must be precise and accurate to obtain suitable HAZ microstructures. This article addresses the challenges of producing HAZ microstructures on the high-alloy steel CT781, which is widely used in the automotive industry for parts subjected to high dynamic loads.

Microstructure and Mechanical Properties of the Ternary Gas Shielded Narrow-Gap GMA Welded Joint of High-Strength Steel

An 80%Ar-10%CO2-10%He ternary gas mixture was used as the shielding gas during the narrow-gap welding of thick Q690E high-strength steel plates. Complete and defect-free welded joints were obtained, and the microstructure and mechanical properties of the welded joint were investigated. The weld zone consists of a solidification area and interlayer zone, and the heat-affected zone consists of a coarse-grain heat-affected zone (CG-HAZ) and a fine-grain heat-affected zone (FG-HAZ). The microstructures of the weld zone are mainly lath bainite (LB), acicular ferrite (AF), and granular bainite (GB). The microstructure of the CG-HAZ is lath martensite (LM) and the microstructure of FG-HAZ is GB. Methods with different heat inputs were used to study their effects on the mechanical properties of the welded joint. It was found that the microstructure and mechanical properties of the welded joints are better with lower heat input. With tandem wire narrow-gap GMA welding, the tensile strength of the joints declined from 795.3 to 718.3 MPa and the impact toughness at −40 °C resulted in a weak position in the weld zone, which declined from 76~81 J to 55~69 J, when the welding speed reduced from 350 to 250 mm/min. With oscillating-arc narrow-gap GMA welding, the tensile strength achieved 853.4 MPa and the impact toughness at −40 °C was around 69~87 J. The results indicated that, under the appropriate heat input, the tensile strength of the joint exceeds 770 MPa and the low temperature impact toughness at −40 °C exceeds 69 J. A 155 mm-thick Q690E steel welded joint was obtained and the mechanical properties of the welded joint meets the requirements of the offshore drilling platforms.