Coarse-grained Heat-affected Zone Research Articles

Effect of Carbon on Stress-Relief Cracking Susceptibility of T23 Steel

The coarse-grained heat-affected zone (CGHAZ) samples were prepared from T23 steel with three different carbon contents on a thermal simulator, then isothermal slow strain rate tensile tests were carried out at 500° ~ 750°C, and the effect of carbon content on the stress-relief cracking (SRC) sensitivity of T23 steel was evaluated according to fracture ductility. The microstructure evolution of the CGHAZs in the process of SRC was observed by optical microscopy, structural equation modeling energy-dispersive spectroscopy, and transmission electron microscopy energy-dispersive spectroscopy/selected area electron diffraction to reveal the mechanism of SRC. Finally, the feasibility of adjusting carbon content to prevent SRC was discussed. The results showed the classical theory of intragranular precipitation hardening cannot explain the cause of SRC, and a new viewpoint was put forward that the precipitation of M23C6 at the grain boundary was the main reason for SRC. The precipitation of M23C6 carbide cannot only provide a preferred site for void nucleation but also leads to the depletion of alloy elements in the matrix near the grain boundary. The interaction of these two aspects leads to the direct weakening of grain boundaries. Moreover, the SRC of T23 steel could be inhibited when the carbon content was determined to be close to the ASME standard lower limit of 0.04 wt-%. In summary, reducing the carbon content can inhibit the SRC sensitivity of T23 steel, which is not due to reducing the relative weakening of the grain boundary by reducing the precipitation hardening in the grain interior but to inhibiting the direct weakening of the grain boundary by reducing the precipitation of M23C6 at the grain boundary.

Effect of Heat Input on Microstructure and Corrosion Resistance of X80 Laser Welded Joints

Using fiber laser welding technology, X80 pipeline steel welded joints with different welding heat inputs were obtained. Their microstructure, mechanical properties, and corrosion resistance (in NACEA solution saturated with hydrogen sulfide) were studied. Findings indicated that with the increase in heat input, the proportion of ferrite, strength, elongation, and corrosion resistance increased within a certain range and the sum of the proportion of martensite and bainite and hardness decreased. The heat input has a greater effect on the microstructure of weld metal (WM) and coarse-grained heat-affected zone (CGHAZ), while that of fine-grained heat-affected zone (FGHAZ) is basically unchanged. Obvious differences are also found in the corrosion resistance of different regions of the welded joints, among which FGHAZ has the strongest corrosion resistance, followed by WM and CGHAZ. The heat input mainly affects the microstructure type of the welded joint to affect the corrosion resistance. Therefore, we model the heat input as a function of Rct and icorr from this relationship. In addition, the corrosion products film produced by the long-term immersion of the welded joint in the saturated H2S NACEA solution can hinder the development of corrosion and enhance the corrosion resistance to a certain extent.

A Study on the Microstructure and Mechanical Properties of the Coarse Grain Heat Affected Zone in EH40 Grade High Strength Structural Steels

In this paper, the effect of the electro gas arc welding (EGW) process with a heat input of 600 kJ/cm on the microstructural and mechanical characteristics was investigated for two types of EH40 high strength hull structural steels, containing Ti and Nb. The coarse grain heat affected zone (CGHAZ), with a peak temperature of 1450 °C, was simulated for both alloys using a material thermal cycle simulator. Tensile and Charpy impact toughness tests were performed to determine the mechanical properties of the CGHAZ, and microstructural analysis was performed using scanning electron microscopy and transmission electron microscopy. Both alloys exhibited a significant loss of impact toughness because of the welding thermal cycle, causing the formation of a brittle phase and the growth of precipitates. The experimental results indicated that although the addition of Ti and Nb had several benefits on mechanical properties, this might be unsuitable for the EGW process owing to the resulting deterioration in impact toughness.

Effect of Post-Weld Heat Treatment on Microstructure and Fracture Toughness of X80 Pipeline Steel Welded Joint.

In the current study, post-weld heat treatment (PWHT 580 °C) was used for an X80 pipeline steel-welded joint, and the fracture toughness of the welded joint was investigated using a crack tip opening displacement (CTOD) test. The relationship between microstructure evolution and fracture toughness is also discussed in this study. The results showed that the weld center mainly consisted of acicular ferrite (AF). The subcritical heat-affected zone (SCHAZ) consisted of a large amount of fine polygonal ferrite and some AF, and it maintained the rolling state of the base metal. The microstructure of the coarse-grained heat-affected zone (CGHAZ) was composed of granular bainite (GB) and M/A constituents, the latter of which decreased after the PWHT. The CTOD values of the weld center were in the range of 0.18–0.27 mm, while those of the CGHAZ were in the range of 0.02–0.65 mm. A brittle fracture occurred in the CGHAZ for both the as-welded and PWHT samples; the CTOD values were 0.042 mm and 0.026 mm, respectively. The CTOD values of the SCHAZ’s location were in the range of 0.8–0.9 mm. The PWHT did not deteriorate the microstructure of the CGHAZ and had little influence on the fracture toughness of the X80 pipeline steel-welded joint; it ensured the fracture toughness of the welded joints and reduced the welding residual stress.

Effect of Microstructure on Impact Toughness and Fatigue Performance in Coarse-Grained Heat-Affected Zone of Bainitic Steel Welds

Effect of Microstructure on Impact Toughness and Fatigue Performance in Coarse-Grained Heat-Affected Zone of Bainitic Steel Welds

Crystallographic study on microstructure and impact toughness of coarse grained heat affected zone of ultra-high strength steel

The significant effect of welding heat input on microstructure evolution and toughness of coarse grained heat affected zone (CGHAZ) in ultra-high strength steel was studied from the aspect of crystallography. Charpy impact test confirmed the optimum toughness of CGHAZ was obtained at the heat input of 20 kJ/cm, which was related to the cumulative contribution of its well-refined bainitic structure and the highest density of high angle grain boundaries (HAGBs). Analysis on crystallography shows that the weakest variant selection occurs at the nose temperature of bainite transformation curve, inducing the staggered configuration of different Bain groups, and thus obtaining the highest density of HAGBs, especially the block boundary dominated by V1/V2 variant pair. From the establishment of the relationship between impact toughness and crystallographic structure, the variation in toughness of CGHAZ is primarily correlated to the block size.

Local microstructure and mechanical characteristics of HAZ and tensile behavior of laser welded QP980 joints

Microstructural evolution of the heat-affected zone (HAZ) seriously affects the mechanical properties of the welded joints. In this paper, QP980 steels were butt-welded by fiber laser. The thermocouple and Gleeble1500 system were used to achieve the thermal simulated HAZ specimens of laser welded joints, which solved the problem that it was difficult to evaluate the mechanical properties due to the narrow HAZ of the laser welding. Large amounts of granular carbides were precipitated in the block martensite of the sub-critical HAZ (SCHAZ). Carbides were not found in lath martensite, but there were dislocation tangles in the lath martensite of the SCHAZ. In addition, the number of dislocations in the ferrite of the SCHAZ was significantly reduced. The SCHAZ had the lowest strength but the highest elongation owing to the tempering. The fine-grain strengthening resulted in the highest tensile strength in the fine-grained HAZ (FGHAZ). The tensile fracture morphologies indicated a brittle fracture mechanism in coarse-grained HAZ (CGHAZ) and FGHAZ, and exhibited a ductile fracture mechanism in the inter-critical HAZ (ICHAZ) and SCHAZ. According to the overview of the joint and the local mechanical characteristics of HAZ, the numerical model of the tensile test was performed by ABAQUS. And the simulation results showed good agreement with the experimental results, which both illuminated the constraint effect of SCHAZ and made the strain concentration transferred from SCHAZ to the BM with the increase of stress.

Strengthening and toughening mechanism of coarse-grained heat-affected zone for the Cr-/Mo-free Cu-bearing HSLA steel under high heat input welding conditions

Strengthening and toughening mechanism of coarse-grained heat-affected zone for the Cr-/Mo-free Cu-bearing HSLA steel under high heat input welding conditions

Metallurgical Factors Affecting the Tensile Properties of Weld Heat-Affected Zone in Medium Mn Transformation-Induced Plasticity Steel

The role of retained austenite in the mechanical property changes in the medium Mn transformation-induced plasticity (TRIP) steel heat-affected zone (HAZ) was elucidated throug a comparison with conventional TRIP steel. The two steel grades had similar microstructures consisting of ferritic phases with a high fraction of retained austenite in the as-received state; however, the difference in properties after welding was significant. The microstructures of both steels were dramatically changed to a martensitic matrix in the coarse-grained HAZ region. The medium Mn TRIP steel HAZ can have a higher retained austenite fraction than the conventional one; hence, an excellent combination of tensile strength and elongation can be obtained. The decisive difference between the two steels was determined in terms of austenite stability and the initial grain size.

Effect of post-heat treatment on microstructure and properties of EH47 steel CGHAZ

To clarify the effect of post-heat treatment on the microstructure and mechanical properties of the coarse-grained heat-affected zone (CGHAZ) for EH47 steel, simulated CGHAZ specimens were subjected to post-heat treatment at 250°C for 1.0 h. The results showed that the microstructure of CGHAZ was composed of granular bainite (GB) and lath bainite (LB), and a large number of iron-carbon particles (∼81 nm) were precipitated after post-heat treatment. The relationship between dislocations, low-angle grain boundaries and iron-carbon particles was revealed by KAM values. The iron-carbon particles hindered the movement of sub-grain boundaries and dislocations, thereby increased the yield strength (∼120 MPa). The precipitation of iron-carbon particles caused the cracking of bainite ferrite and reducing the fracture toughness of CGHAZ.

Study on Corrosion Resistance and Hydrogen Permeation Behavior in Inter-Critically Reheated Coarse-Grained Heat-Affected Zone of X80 Pipeline Steel

We studied the effects of peak temperature and cooling rate in the secondary welding thermal cycles on the martensite/austenite (M/A) constituents’ characteristics (including fraction, average size and distribution), corrosion resistance and hydrogen permeation behaviors in the inter-critically reheated coarse-grained heat-affected zone (ICCGHAZ) of X80 pipeline steel. We observed that the M/A constituents’ characteristics mainly depend on the secondary peak temperature and cooling rates, while the microstructure style and prior austenite grain size are dependent on the first peak temperature. In addition, the variations in the M/A constituents’ characteristics result in different corrosion resistance and hydrogen permeation behaviors by changing the micro-galvanic effect and the number of hydrogen trapping sites. The high fraction and coarse grain size of M/A constituents are against the corrosion resistance and hydrogen permeation in ICCGHAZs, and their functional relationships are established. Moreover, the effects of the fraction of M/A constituents on the corrosion resistance and hydrogen permeation behaviors are much greater than those of the average size.

Effect of Heat Input on Microstructure and Impact Toughness in the Simulated Coarse-Grained Heat-Affected Zones of X90 Pipeline Steel

Effect of Heat Input on Microstructure and Impact Toughness in the Simulated Coarse-Grained Heat-Affected Zones of X90 Pipeline Steel

Welding heat input for synergistic improvement in toughness and stress corrosion resistance of X65 pipeline steel with pre-strain

The microstructure, hydrogen embrittlement sensitivity, fracture toughness, and influence of pre-strain on the sulfide stress corrosion cracking (SSCC) sensitivity of the coarse-grained heat-affected zone of X65 pipeline steel with large deformation were studied to determine the optimal welding heat input in an acidic H2S environment. After pre-straining, the microstructures of the specimens changed insignificantly, but their ductility decreased. The acicular ferrite microstructure obtained under a low heat input demonstrated the synergistic improvement in the SSCC resistance and fracture toughness under pre-strain, especially at t8/5 = 20 s. The M/A constituents interface potentially causes microcrack initiation and interconnection under pre-strain.

Characterization of the cyclic deformation behavior of simulated HAZs and other constituent microstructural regions of P91 steel weldment

Low cycle fatigue tests were conducted on theweld metal, coarse grain heat-affected zone (CGHAZ), fine grain heat-affected zone (FGHAZ), inter-critical heat-affected zone (ICHAZ), base metaland the actual weldmentof P91 steelat 550 °C using different strain amplitudes.The P91 weldment and its constituent microstructural regions exhibited typical continuous cyclic softening behavior. In the HAZs, the FGHAZ exhibited better fatigue behavior. The CGHAZ and ICHAZ showed higher fatigue lives at the lower and higher strain amplitudes, respectively. An empirical relationship was established for predicting the fatigue life of the weldment using weighted factors of all the constituent regions.

Effect of Nb on inclusions and phase transformation in simulated high heat input coarse-grain HAZ of Nb/Ti low carbon microalloyed steel

In this paper, two groups of Nb/Ti low carbon microalloyed steels (Nb-bearing and Nb-free) were obtained through laboratorial methods. The evolution and effect of Nb/Ti-containing complex inclusions were characterised and analysed after being subjected to high heat input thermal simulation of 100 kJ/cm. The results showed that the prior austenite grain size in the coarse grain heat-affected zone (CGHAZ) was not affected by 0.045 wt% Nb addition. However, the acicular ferrite nucleation, induced by effective micron-level inclusions, was inhibited. Nb tended to converge towards the interfaces between the micron-level inclusions and matrix, which had a negative effect on the nucleation potential of acicular ferrite. The re-precipitation behaviour of nano-level inclusions satisfied the dynamic conditions during the high heat input thermal cycle, under which the dislocation movement was inhibited due to the pinning effect of re-precipitation particles. Besides, the size, morphology and composition of nano-level precipitates were changed by Nb (0.045 wt%) addition. In general, the evolution and effect of inclusions in simulated high heat input CGHAZ provide theoretical references for the study of welding performance in Nb/Ti low carbon microalloyed steels. • Nb segregation at the interface between micron inclusion and matrix affects the nucleation of acicular ferrite. • The acicular ferrite nucleation induced by effective inclusions is inhibited by a certain amount of Nb. • The size, morphology and even composition of the nano-level inclusions in CGHAZ are changed by 0.045wt%Nb addition.

Microstructure anomaly upon high temperature exposure and its influence on the mechanical properties of a modified 9Cr-1Mo steel weld

The present work evaluates the microstructure stability of modified 9Cr-1Mo steel welds when subjected to high temperature exposure (HTE) at 775 °C for different times (5, 100, 500, and 1000 h). Prior to HTE, a post weld heat treatment (PWHT) at 760 °C for 2 h was performed. Upon HTE, the individual weld zones viz., weld metal (WM), coarse-grain heat affected zone (CGHAZ) and fine-grain heat affected zone (FGHAZ) demonstrate distinct microstructural variations in terms of precipitate size, grain size and substructure (lath/block/packet boundaries) fractions. The least- and the highest-microstructure stability are respectively seen in FGHAZ and WM after HTE. A detailed investigation involving electron backscattered diffraction (EBSD) and high-resolution transmission electron microscopy (HR-TEM) confirm that a pronounced recovery of the substructure in FGHAZ happens due to enhanced diffusion along the higher fraction of prior-austenite grain boundaries (PAGBs), leading to M23C6 precipitate coarsening and substantial grain growth. The microstructure degradation upon HTE for 1000 h had eventually resulted in deterioration of mechanical properties, where the hardness reduced the most for FGHAZ (~34%), while the least for WM (~7%). Similarly, after HTE, the tensile strength and toughness had deteriorated by ~67% and ~57%, respectively, from the PWHT condition. Fractography further confirms the pronounced degradation after HTE as they result in failure from FGHAZ.

Microstructure anomaly during welding and its influence on the mechanical properties of dissimilar weldments of P92 martensitic steel and AISI 304L austenitic stainless steel

In this investigation, microstructural characteristics, mechanical properties, and residual stress magnitude of dissimilar weld joints (DWJs) between creep strength enhanced ferritic-martensitic (CSEF) P92 steel and austenitic stainless steel (ASS) 304L has been investigated. The Thermanit MTS 616 (P92 filler) filler metal was employed to prepare P92/304L SS DWJs. The groove geometry also plays a crucial role in DWJs, so the conventional V-groove and narrow shape groove geometry was adopted for P92/304L SS DWJs. The microstructure characterization was performed using optical microscope (OM), scanning electron microscope (SEM), and filed emission SEM (FESEM). The microstructural examination showed the formation of the δ-ferrite grains and unmixed zone (UZ) at the weld interface. The martensitic microstructure produced after welding is brittle due to quenched martensite and the dissolution of precipitates. Thus, the post-weld heat treatment (PWHT) known as tempering was carried out at 760 °C for the period of 2 h to get tempered martensitic microstructure. The ultimate tensile strength (UTS) of the as-weld (AW) and PWHT tensile specimen of the P92/304L SS DWJs was 660 MPa and 643 MPa, respectively for V-groove geometry specimens and 640 MPa and 609 MPa, respectively for narrow groove geometry specimens. The tensile fracture was experienced at 304L base metal, and the UTS value of DWJs was very close to the UTS of the 304L SS. The average microhardness value of the martensitic weld metal (352HV0.5) and coarse-grain heat-affected zone (CGHAZ, 366HV0.5), fine grain HAZ (FGHAZ, 320HV0.5) in the AW state was beyond the maximum permissible hardness value of 265HV0.5, as per the A335/A335M − 15a standard. The hardness value beyond 265HV0.5 indicates the undesirable brittle martensitic microstructure. After PWHT, the micro-hardness value of the CGHAZ (235HV0.5), FGHAZ (215HV0.5), and inter-critical HAZ (ICHAZ, 201HV0.5) was below the maximum allowable value of 265HV0.5 for P92 material because of the tempering of the quenched martensite. However, the Charpy test result concluded that the problem associated with the martensitic P92 filler is to obtain an acceptable value of the impact toughness of weld metal in AW state. The Charpy impact toughness of weld metal for P92/304L SS DWJs in AW condition was 10 J (V-groove geometry) and 37 J (narrow groove geometry), while for PWHT condition, it was 188 J (V-groove geometry) and 150 J (narrow groove geometry). The impact toughness of the P92 filler weld was below the minimum requirement of 47 J (EN ISO 3580:2017) in AW state. However, the impact toughness of the welds made by using P92 filler metal met the minimum requirement of 47 J (EN ISO 3580:2017) after PWHT due to the tempering of the martensite. The residual stress analysis using deep hole drilling (DHD) technique revealed the existence of the compressive residual stresses in the weld metal and P92 HAZ in as-weld and PWHT condition. The compressive stress was dominant because of the martensitic phase transformation.

Effect of H2S Corrosion on the Fracture Toughness of the X80 Pipeline Steel Welded Joint.

To analyze the causes and mechanisms affecting the fracture toughness of X80 pipeline steel welded joints against H2S, the fracture toughness of different zones of X80 pipeline steel welded joints in both air and saturated H2S solution was investigated. The fracture toughness of welded joints degraded significantly in the saturated H2S solution, where the crack tip opening displacement (CTOD) characteristic value in the coarse grain heat-affected zone (CGHAZ) and weld metal (WM) was only 8% and 12% of that in air, respectively. However, the sub-critical grain heat-affected zone (SCHAZ) showed better resistance to H2S corrosion, with the CTOD characteristic value reaching 42% of that in air. The resistance of the welded joint to H2S corrosion was sensitive to microstructures. The grain boundary ferrite (GBF) presented in WM, and the angle of grain boundary orientation in CGHAZ was not conducive to hindering crack propagation. Moreover, the formation of the resultant hydrogen cracks owing to the H2S corrosion also reduced the fracture toughness of the welded joint.

Wire-based electron beam additive manufacturing of tungsten

In present study, the feasibility of wire-based additive manufacturing of commercially pure tungsten using electron beam technique could be demonstrated. Three different representative volumetric AM structures were built and subsequently characterized. The parts show a sound visual appearance with the absence of macroscopic cracks or severe distortion. The fabricated parts exhibit high density and the value depends on the welding sequence applied; while the thin- and medium-walled structure has a relative density of ~100% and 99.875%, the measured relative density of the volumetric structure is slightly reduced to ~99.131% due to the smaller periodic bonding defects. However, a higher density could be achieved compared to powder-based processes on refractory metal. The mean hardness value of the fabricated AM structures is approx. 366–380 HV1 and is in the range of approx. 89–93% of the conventionally fabricated substrate of 410 ± 39 HV1. A coarsening of the grains from the bottom to the top and a change in morphology can be noted for all AM structures. While the coarsening is quite severe for the thin-walled structure, it is moderate for the volumetric AM structures due to the change of the thermal boundary conditions. Caused by the deposition process, the microstructure in the substrate also changes and exhibits a coarse-grained heat-affected zone. Nevertheless, the grain size is still smaller compared to the AM bulk material.

Favorable Impact Toughness of High Heat Input Coarse-Grained HAZ in an Ultra-Low Carbon High-Strength Microalloyed Steel

Favorable Impact Toughness of High Heat Input Coarse-Grained HAZ in an Ultra-Low Carbon High-Strength Microalloyed Steel