Interdendritic Areas Research Articles

Effect of cast part size on the microstructure and mechanical properties of a bainitic High-Carbon and High-Silicon Cast Steel

This study aims at assessing the impact of casting size on the bainitic transformation, resulting microstructures, and tensile properties of a high-carbon, high-silicon steel austempered at different temperatures. The casting size was analyzed by using Y blocks of two different thicknesses. The microsegregation, a common occurrence in cast parts, leads to different bainitic transformation rates at the microscopic scale. Specifically, interdendritic areas with higher alloying contents exhibit a slower transformation, resulting in a lower degree of transformation and a higher amount of blocky austenite. Despite differences in solidification structure and distribution of alloying elements, samples obtained from the thinner and thicker Y blocks yield comparable transformation times and mechanical properties, leading to enhanced uniformity in the mechanical behavior of the entire component. However, it is essential to ensure that the bainitic transformation is completed to minimize the detrimental effects of microsegregation in these cast steel components. The presence of very fine microstructures results in ultra-high strength with low ductility cast steel.

Tribological behavior and characteristics of TIG surface cladded AlCoCrFeNi high-entropy alloy on 304L stainless steel

The present study examines the tribological properties of AlCoCrFeNi high-entropy alloy (HEA) surface cladded on 304L stainless steel via a Tungsten Inert Gas (TIG) heat source. Commercially pure powders of aluminum, cobalt, chromium, and nickel were ball-milled, mixed in specific ratios, and applied onto the substrate with polyvinyl alcohol as a binder. Cladding was performed with optimized parameters to create layers of HEA. Microstructural and EDS analysis revealed equiaxial dendrites rich in aluminum and nickel in dendritic (DI) areas, and rich in iron, chromium, and cobalt in interdendritic (ID) areas. Mixing entropy was calculated by consideration of EDS analysis of the cladding and based on the initial definition of a high-entropy alloy, the high-entropy nature of the cladding was confirmed. XRD analysis showed the presence of FCC, A2/B2, and hard σ phases. Surface alloyed material exhibited higher hardness compared to the base material, with an average of 540 HV versus 200 HV. A pin-on-disc wear test machine was used to assess tribological properties under different loads of 10, 20, and 40 N. The wear rates of the high-entropy cladded material were 36 and 50 % less than those of the 304L stainless steel under applied loads of 10 and 40 N, respectively, while their wear rates were almost similar at 20 N. Friction coefficients of HEA pins were notably lower than 304L at 10 and 20 N, with smoother profiles. Wear mechanisms of the HEA material varied with load: oxidative wear at 10 and 20 N due to the formation of an oxide layer, and abrasion and spallation at 40 N, resulting in a threefold increase in wear rate at this load. Overall, the study highlights the effectiveness of HEA cladding in improving tribological properties, especially under high applied load.

Role of micro‐constituents on the fatigue deformation micro‐mechanisms of IN 713 C alloy

AbstractThe cast IN 713 C alloy is extensively used in the aerospace and automobile industries. Even with improved casting methods, the inhomogeneity in the microstructure is still inevitable and causes strain localizations during cyclic loading. So far, the effect of microstructural variables on the low cycle fatigue (LCF) deformation behavior of IN 713 C alloy has rarely been studied. In this study, IN 713 C alloy is LCF tested at 650°C and 750°C for strain amplitudes of 0.35% to 0.6%. The results showed that the deformation heterogeneity resulted from carbides, γ′ precipitates, and γ–γ′ eutectics distribution, governing the LCF failure micro‐mechanisms. The principle fatigue cracks were seen to be initiated from the precipitate‐free zone and oxidized‐surface carbides. It is corroborated that the higher GNDs were observed at carbide/matrix, eutectic/matrix, γ′/matrix interfaces, and in the interdendritic areas where voids and cracks formed. The higher GNDs at these sites facilitate crack initiation and propagation.

How the multi-phase microstructure of a novel tool steel determines its corrosion behaviour in sulphuric acids

The corrosion behaviour of a Fe81Cr15V3C1 steel was analysed compared to commercial X90CrMoV18 (1.4112) in 0.01–1 mol/L H2SO4 solutions. The rapidly cooled steel comprises martensite dendrites, carbide networks (M7C3, MC) and austenite interdendritic areas. Electrochemical measurements with surface analysis (SEM, EDX, AES, GD-OES) revealed the phase impact on corrosion. Active corrosion of austenite occurs at martensite-carbide boundaries leading to narrow bands. A unique oxidation between passivity and transpassivity with dissolution along lamellar carbides and vanadyl(IV) cation release enhances with increasing acid concentration. Both steels exhibit similar corrosion resistance, a superior mechanical performance of Fe81Cr15V3C1 explains its potential for tool manufacturing.

Microstructure, mechanical and corrosion study of friction stir processed Inconel 625 additive layers deposited via wire arc direct energy deposition

This study explores the application of friction stir processing (FSP) as an effective post-deposition surface treatment technique for improving the mechanical and corrosion properties of wire arc direct energy deposited (WA-DED) Inconel 625 additive layers. The coarse and cube-oriented microstructure observed in as-built Inconel 625 components results in anisotropic mechanical properties. The non-equilibrium solidification in WA-DED Inconel 625 leads to severe micro-segregation of alloying elements, forming large Nb and Mo-rich Laves and carbide phases in the inter-dendritic areas. This causes a heterogeneous distribution of vital alloying elements within the γ-Ni matrix of the material, adversely affecting its mechanical properties and corrosion resistance, thereby restricting the utility of this manufacturing technique in critical applications. The incorporation of FSP has been observed to successfully eradicate the presence of typical coarse and highly oriented microstructure through grain refinement, achieving a more uniform microstructure. Through severe plastic deformation (SPD), coarse eutectic phases are broken down and redistributed within the γ-Ni matrix, enhancing the uniformity of material properties. The research thoroughly investigates the changes in microstructure, mechanical performance, and corrosion resistance of both WA-DED and FSP-enhanced WA-DED Inconel 625 samples. A Thermo-Calc simulation using the classical Scheil model was conducted to understand the solidification pathway and the formation mechanism of the Laves phase in the WA-DED sample. The grain size was significantly reduced by 98.23%, from 138 µm in the WA-DED sample to 2.44 µm in the stir zone (SZ) of the FSP-treated area, due to dynamic recrystallization (DRX), particle-stimulated nucleation (PSN), and the Zener pinning effect. This grain refinement led to remarkable enhancements in the yield strength (YS) by approximately 113%, ultimate tensile strength (UTS) by about 37% and micro-hardness by around 60% compared to the WA-DED sample. In a 3.5 wt% NaCl solution, the FSP-treated sample demonstrated superior corrosion resistance by forming a stable, thicker passive film than the as-built sample. The results of this study will offer valuable insights into utilizing the FSP technique as post-weld surface treatment of WA-DED deposited IN625 superalloy.

Investigation of the precipitation behavior and its role on creep deformation and failure mechanisms at high temperatures for a turbine disk alloy

The creep deformation behavior of a turbine disk alloy at high temperatures was studied, and the role of the multi-scale precipitates on the creep deformation and failure mechanisms was revealed. The turbine disk alloy shows a typical microstructure with the micron-scale MC carbides, submicron delta phase, together with nanoscale γ″ and γ' precipitates distributed in the matrix after hot working and aging treatment. The MC carbides are mostly formed from the solidification process due to enrichment of Nb in the inter-dendritic areas. The creep life decreases from 763.5 h to 5.7 h when the creep temperature increases from 953 K to 1023 K at 500 MPa. The fracture surfaces exhibit a transgranular fracture pattern accompanied with the formation of substantial microvoids. Slipping occurs in both unidirectional and bidirectional modes during deformation. The microvoids along the grain boundaries are generated through decohesion of δ precipitates from the matrix or the interaction between slip traces and grain boundaries. When the intragranular MC carbides interact with the slip traces, microcracks can be formed by particle fracturing. The dense distribution of particles along the grain boundaries will result in a significantly higher critical stress required for microvoid nucleation, whereas the non-coherent particles inside the grains, particularly the large size MC carbides, can decrease the critical shear stress for microcrack formation to as low as 88.9 MPa, thereby contributing to alloy rupture. For the coherent precipitates, a comprehensive strengthening effect of 389.12 MPa is achievable by the synergistic precipitation of γ″ and γ', which primarily serve to enhance and coordinate intragranular deformation during creep.

Corrosion Behavior of Zn-Al-Mg-Si Coatings in Sulfur Dioxide-Containing Environment

Zn-Al-Mg-Si coatings are an excellent alternative to conventional hot-dip galvanizing coatings. Their high corrosion resistance in corrosive environments containing chlorides and CO2 is well recognized. But sulfur dioxide is also an important stimulator of corrosion in the atmospheric environment. This article presents the results of microstructure (SEM/EDS/XRD) and corrosion behavior tests of Zn-Al-Mg-Si coatings obtained by a double hot-dip method on HSLA steel. The corrosion resistance of the coatings was determined in the sulfur dioxide test with general condensation of moisture (EN ISO 6988). In the corrosion test, Zn-Al-Mg-Si coatings showed twofold smaller weight loss compared to conventional hot-dip zinc coatings. It was found that the corrosion behavior of coatings was influenced by the structural components revealed in the outer layer: Al-rich dendritic and interdendritic areas with Zn/MgZn2 eutectic, MgZn2 intermetallic and Si precipitates and their electrochemical nature. The increase in corrosion resistance was caused by the formation of beneficial corrosion products: layered double hydroxides (LDHs) based on divalent Mg2+ and Zn2+ cations, trivalent Al3+ cations and SO42− anions, and zinc hydroxysulfate—Zn4SO4(OH)6∙5H2O. The presence of Si precipitates could cause pitting corrosion of coatings.

Corrosion mechanisms of Al‐alloyed hot‐dipped zinc coatings in wet supercritical carbon dioxide

AbstractCommercial hot‐dip galvanized zinc (Zn‐0.2% Al), galfan (Zn‐5% Al), and galvalume (Zn‐55% Al) coatings were exposed to wet scCO2, followed by an assessment of microstructural changes in the coating structure. Zinc and galfan coatings showed similar surface activity with abundant zinc dissolution and uniform corrosion product deposition. The Al‐rich phases of the galfan coating were intact in the studied atmosphere and eventually became embedded within the deposits. The zinc dissolution ended for zinc and galfan coatings when the free metal surface was blocked from the surrounding medium by a uniform corrosion product layer. Galvalume showed scarce reactivity: dissolution of zinc in the Zn‐rich interdendritic areas proceeded slowly compared to zinc and galfan, and the Al‐rich dendrites (with nm‐scale Zn inclusions) remained intact. The ion beam milling technique combined with modern nm‐resolution energy‐dispersive spectroscopy analysis enabled previously unseen visualization of the discussed corrosion processes.

The Role of Microstructural Length Scale in Hydrogen Generation Features of an Al-Sn-Fe Alloy

The reaction of water with Al-based alloys presents a promising alternative for on-board hydrogen production. This method, free from carbon emissions, has the advantage of addressing issues related to hydrogen storage and logistics. Al-Sn-Fe alloys are potential candidates for this application. However, the current literature lacks an in-depth understanding of the role of microstructural evolution in the hydrogen generation performance of these alloys. The present work investigates the influence of the microstructural length scale on the hydrogen production behavior of an Al-9Sn-1Fe (wt.) alloy. Directionally solidified samples with different microstructural length scales were subjected to hydrogen evolution tests in a 1 M NaOH solution. The results revealed that the microstructure of the studied alloy comprised α-Al-phase dendrites with a plate-like morphology along with the presence of Sn-rich particles and Al13Fe4 intermetallic compounds (IMCs) in the interdendritic areas. In addition, the microstructural refinement induced a 56.25% rise in hydrogen production rate, increasing from 0.16 to 0.25 mL g–1 s–1, without affecting the hydrogen yield, which stayed around 88%. The corrosion process was observed to be stimulated by Sn-rich particles and Al13Fe4 IMCs at their interfaces with the α-Al phase, positively impacting the hydrogen production rate. An experimental equation based on the Hall–Petch relationship and multiple linear regression (MLR) is proposed to associate the hydrogen production rate with dendritic arm spacings.

INVESTIGATION OF THE MICROSTRUCTURE OF AISI 321 STAINLESS STEEL AFTER LASER SURFACE MELTING

The aim of the present paper is to investigate the microstructure of laser-melted surface layers of austenitic steel for biomedical applications. The surface of prismatic specimens from AISI 321 stainless steel was treated by continuous CO2 laser. Three modes of laser processing were used, ensuring surface melting. The microstructure was observed by OM and SEM, while the chemical composition was investigated by EDX analysis. It was found that the microstructure of as-delivered steel was two-phase and relatively inhomogeneous in morphology and chemical composition. It consisted of austenite with grain sizes between 20 - 150 μm, relatively large amount of striped δ-ferrite and spherical carbides along the grain boundaries. After laser melting, the microstructure remained two-phase (δ-ferrite and austenite), but became more homogeneous in morphology and composition. Different dendrites morphology in the particular regions of the molten layer was confirmed - fine equiaxed dendrites on the top surface and columnar at the bottom of the molten pool. Delta-ferrite is located in the interdendritic areas and in larger amounts in the transition zone between the molten.

Effect of Melt Superheating Treatment on the Microstructures and Purity of a Directionally Solidified Superalloy

In this paper, the effects and the mechanisms of melt superheating treatment (MST) on a directionally solidified alloy were investigated. The mass loss rate of the superalloy becomes severe as the MST temperature rises. The chromium, tantalum, and hafnium are the primary evaporation elements during MST. As the MST temperature increases from 1500 to 1600 °C, the secondary dendrite arm spacing is reduced by 13.3%, and the average size of γ′ particles are reduced by 11.5% and 18.2% in the dendrite core and inter-dendritic area, respectively. The content of oxygen and nitrogen gradually reduces with the increase in the MST temperature. However, the sulfur content is not significantly affected by the MST temperature. The essential cause of γ′ phases transition is supposed to be the MST-induced changes in solute distribution and the decomposition of atomic clusters. In addition, the nitrides and Ti (N, C)-type carbides are continuously dispersed as the MST temperature increases, which promotes the removal of nitrogen impurities.

Corrosion performance of wire arc additively manufactured NAB alloy

Nickel–aluminum bronzes (NAB) are vital alloys, known for biofouling resistance, crucial for marine and shipbuilding industries. This study examined corrosion performance of NAB samples fabricated by wire arc additive manufacturing (WAAM) in as-built and heat-treated conditions. Microstructural analysis revealed the WAAM-NAB parts primarily consisted of the α-phase (copper) and three types of κ-phases: κII (spherical Fe3Al), κIII (Ni–Al in lamellar shape) within the interdendritic areas, and iron-rich κIV particles dispersed throughout the matrix. In contrast, casting-produced NAB showed the formation of a rosette-like κI phase as well. Corrosion behavior comparisons between the two NAB fabrication methods were also assessed. The microstructural characterizations revealed a rise in the size of the κIV particles after heat-treated at 350 °C for 2 h (HT1). Heat treatment at 550 °C for 4 h (HT2) resulted in a needle-like κV, coarsening of κII, partial spheroidization of κIII, and reduced κIV precipitation. When heat-treated to 675 °C for 6 h (HT3), κII and κV were coarsened, κIII was completely spheroidized, and κIV precipitation was significantly reduced. These microstructural features in HT2 and HT3 conditions steeply decreased their corrosion resistance compared to the WAAM as-built part. The as-built WAAM sample showed superior corrosion resistance in chloride solution, attributed to fewer κ-intermetallic phases and a finer microstructure. The κ-phases, irrespective of morphology, act as the cathodic areas versus the α-dendritic matrix, fostering microgalvanic cell formation. Consequently, precipitation of all cathodic κ-phases draws a higher galvanic current of the anodic α-phase, meaning a lower corrosion resistance.

Design and development of porous CoCrFeNiMn high entropy alloy (Cantor alloy) with outstanding electrochemical properties

CoCrFeNiMn high entropy alloys are among the most well-studied high entropy alloys that exhibit reasonable strength and outstanding ductility. In the present study, porous CoCrFeNiMn foams have been developed by the addition of copper in the base high entropy alloy by arc melting followed by its removal through an electrochemical dealloying process. Microstructure characterization of the as-cast samples confirmed limited solubility of copper in the matrix while the majority of the copper was found to segregate to interdendritic areas. Removal of copper from the interdendritic areas was successfully carried out by an electrochemical dealloying process which resulted in the development of foams with interconnected porosity. CoCrFeNiMn foams with different levels of porosities were successfully developed by varying the amount of added copper in the base HEA and its removal by a dealloying process. The electrochemical performance of the developed foams was assessed by cyclic voltammetry (CV), galvanostatic charge-discharge (GCD), and electrochemical impedance spectroscopy (EIS). One of the developed foams was found to exhibit an areal capacitance of 1.56 F cm−2 at 2 mA cm−2 which is more than 2x times higher than the value reported for recently developed porous AlCoCrFeNi high entropy foam. Developed foam, besides showing excellent values of areal capacitance, demonstrated capacitance retention of 114.6% after 5000 cycles at 8 mA cm−2. The excellent electrochemical performance of the developed high entropy foams exhibits their potential to be used as electrode materials for supercapacitor applications and was attributed to the insertion of interconnected porosity in the base HEA.

The correlation between microstructure,mechanical and tribological propertiesin the alloys of Co-Cr protectors with microadditives Mo and W

The paper presents the results of tests of tribological wear of two Co-Cr-Mo alloys (Wironit LA) andCo-Cr-Mo-W (Colado CC) used to make skeletal prostheses, combined works, implants and metalframeworks for ceramics. The test samples were centrifugally cast using the lost wax method and subjected tohardness measurements, microscopic observations, and a quantitative description of the microstructure. SEMexaminations and EDS analysis of micro-areas on dendritic arms and interdendritic areas were performedtogether. The abrasive wear resistance tests with the use of a T-05 tester in the friction system roller-blockwere conducted in a dry sliding contact under the conditions of a metal-metal contact with the load of 100 Nand for two friction paths, 500 and 1000 m.

Hot isostatic pressing and heat treatments of LPBFed CoCuFeMnNiTi0.13 high-entropy alloy: microstructure and mechanical properties

The present work explores the possibility of processing a CoCuFeMnNiTi0.13 high-entropy alloy by laser powder bed fusion (LPBF). The alloy, produced under optimised processing conditions, presents good densification but also hot cracks, caused by the liquation of an inter-dendritic Cu-rich phase. Microstructure of the as-built alloy is characterised by face centred cubic (FCC) columnar grains, containing Cu-poor dendrites and Cu-rich inter-dendritic areas. The alloy, which was designed to be strengthened by spinodal decomposition and precipitation, was subjected to different thermo-mechanical treatments to try and improve its properties. Direct ageing and solution treatment and ageing produced a strong but brittle material (tensile strength of 683 MPa and elongation to failure of 1.3%), whereas hot isostatic pressing followed by controlled cooling was able to heal pores and cracks while triggering the desired microstructural transformations (spinodal decomposition and precipitation). This resulted into a balanced set of mechanical properties (tensile strength of 473 MPa and elongation to failure of 7.6%). This work shows that proper post-processing can mitigate the issues typically affecting LPBF fabricated HEAs, producing tailored microstructures with satisfactory mechanical performances.

Dissimilar autogenous TIG joint of Alloy 617 and AISI 304H steel for AUSC application

To reduce costs and improve high-temperature performance in Advanced Ultra Super Critical (AUSC) boilers, it is necessary to weld austenitic steel to Inconel alloy. In this study, the autogenous tungsten inert gas (TIG) welding process was used to join Alloy 617 and an austenitic AISI 304H steel plate of thickness 5 mm. Microstructural analysis showed that the microstructure formation was uneven along the weldments, with columnar and cellular dendrites near the interface while the central area of the weld exhibited a combination of columnar, cellular, and equiaxed dendrites. The use of energy dispersive spectroscopy and electron probe micro-analysis unveiled the presence of an unmixed layer at the interface between the weld and AISI 304H steel. Furthermore, a notable variation in the concentration of alloying elements such as Fe, Cr, Ni, Co, and Mo was observed. Within the weld metal, inter-dendritic areas showed the presence of precipitates rich in Cr, Ti, and Mo. Meanwhile, the heat-affected zone (HAZ) of Alloy 617 exhibited the presence of phases like Cr and Mo-rich M23C6 as well as Mo-rich M6C. Hardness tests showed non-uniform hardness along the weldments, with a hardness of 199 ± 6 HV in the weld metal and 225 ± 4 HV in Alloy 617 HAZ, and 207 ± 7 HV in AISI 304H HAZ. The Mo and Cr segregation in the inter-dendritic spaces led to a decline in the tensile properties of the welded parts and resulted in failure from the region of the weld metal.

Weldability study of 304HCu stainless steel using varestraint and “Gleeble” based hot ductility tests

The susceptibilities of 304HCu SS to solidification and liquation cracking are assessed in the current work and the underlying mechanisms are clarified. The development of γ + Nb4C3 eutectic along the interdendritic areas in the fusion zone is attributed for solidification cracking in this stainless steel. To forecast and rank the susceptibility of an alloy to solidification cracking, a novel technique is put forth and experimentally confirmed. Using the measured temperature gradient, welding speed and Scheil's solidification module, a relationship between the liquid fraction and mushy zone width is derived. Liquation cracking susceptibility evaluated using “Gleeble™” based hot ductility test is observed to be high which is attributed to the constitutional liquation of primary Nb(C,N) and secondary M23C6 phases present in the base metal. Further, the influence of phosphorus on the local solidus temperature in the partially melted zone of the alloy is discussed in the context of liquation cracking.

The CrFeNbTiMox refractory high-entropy alloy coatings prepared on the 40Cr by laser cladding

In order to improve the performance of 40Cr coal mining cutter teeth, the CrFeNbTiMox (x = 0.2, 0.4, 0.6, 0.8, 1) refractory high entropy alloy (RHEAs) coatings were prepared on the 40Cr by laser melting. The effects of the Mo on the phase, microstructure, hardness, wear and corrosion resistance of the coatings were investigated. The results show that the coatings consist of BCC (Im3m), C14-Laves (P63/MMC), C15-Laves (Fd3m) and ordered B2 phase (Pm3m). The BCC phase increased and the C14-Laves phase decreased as the Mo element content increased. The central part of the coating is mainly composed of dendrites and some swelling crystals, the dendritic areas increase and the swelling crystals decrease with the increase of Mo elements. The Mo and Nb elements are mainly concentrated in the dendritic areas, and the Cr and Fe are enriched in the interdendritic areas. With the increase of the Mo element, the hardness of the coating increased from 676 HV to 841 HV, which is about 3.7 times higher than that of the substrate. Dry sliding friction and wear tests show that the wear resistance of the coating improves with the increase in Mo. The Mo1 coating has the lowest wear loss weight, wear volume and wear rate. In the 3.5 % NaCl solution, the polarization curves and the EIS fitting results show that the corrosion resistance of the coating improves with the addition of Mo elements. The hardness, wear and corrosion resistance of the 40Cr substrate is significantly improved due to the refractory high entropy alloy coating.

Understanding the microstructure and mechanical performance of heat-treated Inconel 625/TiC composite produced by laser powder bed fusion

This work aims to develop and characterize Inconel 625 (IN625) reinforced with 1 wt% of sub-micrometric TiC particles processed by the Laser Powder Bed Fusion (LPBF) process. The effect of TiC particles on the IN625 alloy was investigated in the as-built and two heat-treated conditions. A volumetric energy density of 99 J/mm3 could produce bulk IN625 and IN625/TiC samples with residual porosity less than 0.15%. The as-built IN625 and IN625/TiC showed columnar grains along the building direction and sub-micrometric dendritic architectures. The as-built IN625/TiC presented higher hardness, tensile strength, and similar elongation at failure with respect to the as-built IN625 alloy. These mechanical properties are mainly attributed to the reinforcement effect of the TiC particles predominantly located along the grain boundaries, melt pool contours, and interdendritic areas. After heat treatments at 980 °C and 1150 °C, the IN625 alloy and IN625/TiC composite presented different microstructure stability and mechanical properties evolution, revealing greater hardness and tensile strength for the composite. In particular, when heat-treated, the IN625 was subjected to a remarkable dendritic dissolution at 980 °C and recrystallization at 1150 °C. Conversely, the IN625/TiC revealed a limited dendritic dissolution at 980 °C and the inhibition of recrystallization at 1150 °C. Overall, the pinning effect of the TiC particles was effective in providing less microstructure and mechanical properties variations under heat treatments. The current work describes the effect of adding TiC particles on the microstructure stabilization and mechanical properties evolution of additively processed LPBFed IN625 alloy in as-built and heat-treated conditions.

Structural integrity assessment of Inconel 617/P92 steel dissimilar welds for different groove geometry

The work is focused on examining the effect of the weld groove geometry on microstructure, mechanical behaviour, residual stresses and distortion of Alloy 617/P92 steel dissimilar metal weld (DMW) joints. Manual multi-pass tungsten inert gas welding with ERNiCrCoMo-1 filler was employed to fabricate the DMW for two different groove designs: Narrow V groove (NVG) and Double V groove (NVG). The microstructural examination suggested a heterogeneous microstructure evolution at the interface of the P92 steel and ERNiCrCoMo-1 weld, including the macrosegregation and element diffusion near the interface. The interface structure included the beach parallel to the fusion boundary at the P92 steel side, the peninsula connected to the fusion boundary and the island within the weld metal and partially melted zone along Alloy 617 fusion boundary. An uneven distribution of beach, peninsula and island structures along the fusion boundary of P92 steel was confirmed from optical and SEM images of interfaces. The major diffusion of the Fe from P92 steel to ERNiCrCoMo-1 weld and Cr, Co, Mo, and Ni from ERNiCrCoMo-1 weld to P92 steel were witnessed from SEM/EDS and EMPA map. The Mo-rich M6C and Cr-rich M23C6 phases were detected in inter-dendritic areas of the weld metal using the weld’s SEM/EDS, XRD and EPMA study, which formed due to the rejection of Mo from the core to inter-dendritic locations during solidification. The other phases detected in the ERNiCrCoMo-1 weld were Ni3(Al, Ti), Ti(C, N), Cr7C3 and Mo2C. A variation in the microstructure of weld metal from top to root and also along the transverse direction in terms of composition and dendritic structure and also due to the composition gradient between dendrite core and inter-dendritic areas, a significant variation in hardness of weld metal was observed from both top to root and also in the transverse direction. The peak hardness was measured in CGHAZ of P92 while the minimum was in ICHAZ of P92 steel. Tensile test studies of both NVG and DVG welds joint demonstrated that failure occurred at P92 steel in both, room-temperature and high-temperature tensile tests and ensured the welded joint’s applicability for advanced ultra-supercritical applications. However, the strength of the welded joint for both types of joints was measured as lower than the strength of the base metals. In Charpy impact testing of NVG and DVG welded joints, specimens failed in two parts with a small amount of plastic deformation and impact energy of 99 ± 4 J for the NVG welds joint and 91 ± 3 J for the DVG welded joint. The welded joint met the criteria for boiler applications in terms of impact energy (minimum 42 J as per European Standard EN ISO15614-1:2017 and 80 J as per fast breeder reactor application). In terms of microstructural and mechanical properties, both welded joints are acceptable. However, the DVG welded joint showed minimum distortion and residual stresses compared to the NVG welded joint.