Weld Microstructure Research Articles

Determination of heat input impact on residual stress, microstructural phase transformation and mechanical characteristics of welded S690QL steel joints by Taguchi optimisation approach

ABSTRACT This article focuses on optimising the submerged arc welding process to improve the microstructural and mechanical characteristics of welded S690QL steel joints efficiently without preheating, using a Taguchi optimisation approach. Trail runs were performed initially for bead-on-plate studies to optimise the weld cycle ranges by investigating weld characteristics such as microstructural morphology and toughness in the weld zone. Selected weld cycle ranges from bead-on-plate studies were further analysed and optimised through butt weld investigations. The phase transformations in microstructure at the weld and heat-affected zone from tempered martensite, martensite, and bainite to dendritic ferrite, lath bainite, and lath martensitic phase were observed with a change in heat input from 0.91 kJ/mm to 1.37 kJ/mm. The weld residual stresses were tensile at the weld and compressive away from the weld zone, diminishing gradually with an increase in transverse distance from the weld. The overall weld efficiency, weld residual stress concentration and mechanical characteristics of the welded butt joint were improved at a controlled heat input of 1.19 kJ/mm. An increase in heat input beyond the optimised limits influences the extent of the heat-affected zone and the joint’s toughness due to the coarsening of the weld microstructure towards the fusion boundary.

Investigation of Microstructure and Mechanical Properties of Al Alloys Lap Joints by Friction Stir Welding

An experimental investigation on effect of friction stir lap welding (FSLW) process parameters on mechanical and microstructure of AA6082-O welds is presented. Three process parameters namely tool rotational speed (1000,1400 & 2000 rpm), tool shoulder diameter (18, 20 & 22 mm) and tool traverse speed (28, 56 & 80 mm/min) are considered. Experiments are planned as per L9 Taguchi array. Data are analyzed in terms of S/N ratio and Analysis of Variance (ANOVA). Tensile shear strength is observed in the range of 11.79 MPa to 29.23 MPa. It is observed that tool diameter and tool rotational speed are most significant factors affecting tensile shear strength. Optimum levels of process parameters (28 mm/min tool traverse speed, 18 mm tool diameter and 1400 rpm tool rotational speed) is decided based on analysis of experimental data. Using optimum process parameters for friction stir lap welding of Al alloys improved quality of welded joints can be made. Use of optimized parameters will improve the performance of the products in terms of durability and load carrying capacity.

In-situ EBSD-DIC simulation of microstructure evolution of aluminum alloy welds

A comprehensive understanding of the dynamic evolution of weld microstructure under external loads can provide key insights for high-performance laser welding. A novel in-situ EBSD-DIC simulation method is introduced to study the microstructure evolution of laser welded aluminum alloys under uniaxial tensile action. An advanced crystal plastic finite element model (CPFEM) is developed, which combines the real microstructure, grain orientation and grain size effects. The results show that the dislocation density in columnar grain zone is higher than that in equiaxed grain zone. The continuous accumulation of dislocations in the columnar region results in a high work-hardening rate. This high work hardening rate enhances the plastic deformation capacity of the columnar crystal region, resulting in local strain concentration. Columnar zones are more prone to fracture because the high-strain region is a potential fracture site. In addition, low Angle grain boundary (LAGBs) is one of the reasons that the dislocation density of the columnar grain zone is higher than that of equiaxed grain zone during tensile process, which is conducive to dislocation slip of columnar grains. This study is a fundamental innovation in simulating the microstructure evolution of laser welding. This marks a major breakthrough in simulating the evolution of crystallographic features such as grain orientation, microstress and strain and dislocation density under external loads. This work can further provide practical guidance for “microstructure characteristics - mechanical property regulation”.

Numerical Study on Welding Residual Stress and Microstructure in Gas Metal Arc Welding Square Tube–Plate Y-Shaped Joints

Welding residual stresses significantly influence the mechanical behavior of hollow section joints, especially in the pivotal connection zones of steel structures employed in construction. The research object of this study is the Q355 steel square tube–plate Y-joint welded using Gas Metal Arc Welding (GMAW) with CO2 Shielding. The thermodynamic sequence coupling method was employed to simulate the temperature field, microstructure distribution, and welding residual stresses in square tube–plate Y-joints. Based on the monitored temperature field data and the cross-sectional dimensions of the weld pool, this study calibrated the finite element model. Subsequently, the calibrated finite element model was employed to analyze the influence of microstructural phase transformations and welding sequences on the welding residual stresses in square tube–plate Y-joints. The research findings indicate that the peak transverse welding residual stresses in the branch pipes of the four joint zones were lower when considering the phase transformation effect than when not accounting for it in the calculations. There was no significant difference in the transverse and longitudinal welding residual stresses on the surface of branch pipes under the three welding sequences. However, there were certain differences in the microstructural content of the weld zones under the three welding sequences, with the martensite content in the third welding sequence being significantly lower than that in the other two sequences.

Effects of nano-modification on the microstrfuctural evolution and mechanical properties of AA7075/AA6061 aluminum alloy joints fabrica ted by laser-MIG hybrid welding technique

In this study, a rigorous comparative analysis is conducted to assess the implications of 7075 welding wire and 7075 welding wire fortified with 1.0 wt% of TiC nanoparticles on the microstructural characteristics, distribution patterns of secondary phases, grain refinement, and mechanical properties of AA7075/AA6061 dissimilar aluminum alloy joints produced via laser-MIG hybrid welding. The experimental results show that: The introduction of TiC nanoparticles prompts a transformation in the weld microstructure, transitioning from coarse dendritic morphologies to finer equiaxed dendritic structures. The grain size and the strengthening phases have both undergone a process of refinement. Notably, a marked increase in high-angle grain boundaries (HAGBs) and a concomitant decrease in low-angle grain boundaries (LAGBs) are observed in the nano-modified weld. Nano-modification yields substantial improvements in the mechanical properties of the welded joint. Specifically, the softening width of the AA6061 heat-affected zone (HAZ) is reduced by approximately half (from 8 mm to 4 mm), while the minimum microhardness of the joint has been increased from 34.1 Hv to 62.4 Hv. Moreover, the average ultimate tensile strength (UTS) of the joint has been enhanced from 95.7 MPa to 208.9 MPa, while the average yield strength (YS) has been increased from 57.1 MPa to 155.1 MPa.

Investigate on dissimilar welding of high-entropy alloy and 310S with various fillers

This study investigates the microstructure and mechanical properties of non-equimolar CoCrFeMoNi high-entropy alloy (HEA) and SUS310S stainless steel dissimilar welds using different filler materials. The dissimilar welding was performed on gas tungsten arc welding with Inconel 82, Inconel 625, and 316L stainless steel fillers. The non-equimolar CoCrFeMoNi HEA is shown effective weldability with these fillers, maintaining distinguished phase stability and structural integrity. Microstructural analysis revealed varied grain morphologies influenced by the heat in the fusion zone and heat-affected zone. Mechanical properties were evaluated through tensile and hardness tests, showing that welds with Inconel 625 filler exhibited superior strength and ductility. The weld hardness value was maintained at 170 HV, with a yield strength of 301 MPa and an ultimate tensile strength of 587 MPa, resulting in a joint efficiency of 106 %.

Friction stir welding of additively manufactured A20X aluminum alloy: welding process, mechanical properties, and microstructure

Friction stir welding of additively manufactured A20X aluminum alloy: welding process, mechanical properties, and microstructure

Influence of the longitudinal welded joint microstructure of X52 and X70 large diameter pipes on resistance to hydrogen embrittlement

The article covers influence of a set of gradient microstructures of large diameter pipes (LDP) on resistance to hydrogen embrittlement. The object of the study were specimens of longitudinal welded joints of X52 and X70 LDP before and after slow strain rate tensile tests (SSRT) in gaseous nitrogen and hydrogen. It was found that fracture of X52 specimens during SSRT occurred with multiple crack initiation centres at the interfaces of the pearlite–ferrite structural constituents, while fracture of X70 specimens resulted in a single crack propagation. Steels Х52 and Х70 fractured not in the heat-affected zone (HAZ) recrystallisation area containing islands of martensite-austenite phase, but in the high-temperature tempering zone, which is characterised by anisotropic ferrite-perlite (Х52) and ferrite-bainite (Х70) microstructure. Finely dispersed uniform structure of bainite ferrite despite the content of martensite-austenite component is not a source of hydrogen crack initiation. Although a welded joint of X70 steel is characterised by higher strength, it is less susceptible to the embrittlement effects of gaseous hydrogen than X52, which is probably due to the finer and more uniform structure of X70 steel. Presence of ferrite-pearlite banding in the structure of X52 steel has a more negative effect on resistance to hydrogen embrittlement than increased hardness of the HAZ high-temperature tempering area of X70 steel.

On the evolution of root weld microstructure and properties during automatic girth welding of high strength pipeline steel

ABSTRACT Properties of root weld are important for service safety of pipelines, while microstructure and properties of root weld would alter due to heat affect of following welding passes. Evolution of root weld microstructure and properties during automatic girth welding of X80 pipeline was studied. Microstructure of the original root weld primarily consists of acicular ferrite (AF) and side-plate ferrite (SPF), and it is mostly affected by hot pass and first filling pass weld, after which SPF and AF coarsened significantly and some interlock ferrite combined with each other. During subsequent welding, no significant microstructural changes was found. However, impact toughness of root weld slightly increased after hot pass and first filling pass in spite of microstructure coarsening. In contrast, hardness of root weld notably dropped due to microstructure coarsening of hot pass and first filling pass, and then it was retrieved in following welding passes due to tempering effect.

Microstructural evolution and mechanical property of high-strength metastable β titanium alloy joint via electron beam welding

Obtaining a fundamental understand of the relationship between weld microstructure and mechanical properties is critical for ensuring a high weld quality. This work explored the micro-mechanism responsible for the mechanical properties of a 10-mm-thickness metastable β titanium alloy (Ti–3Al–5Mo–4Cr–2Zr–1Fe, wt.%) joint welded by electron beam welding (EBW). Weld microstructure and its evolution behavior were revealed by means of multi-scale microstructure characterization. Obtained results indicate that the absence of α phase and formation of nano-scale ω particles occurred in the coarse columnar β grains of the fusion zone (FZ). Intense dissolution and significant coarsening of secondary α phase occurred in the heat affected zone. Between the FZ and HAZ, a partially melted zone was observed and contains few equiaxed β grains. Compared to the base material, the as-welded EBW joint shows significant softening in weld seam and a slight decrease of 17% in ultimate tensile strength, while a severe reduction of 73% in elongation. It was observed that majority of plastic deformation is confined to the narrow FZ, indicating a significant localization of tensile strain. This leads to premature fracture of the joint within the FZ and consequently to significant deterioration of the overall ductility. This work contributes to advancing the understanding of the role of microstructural evolution on the mechanical properties of high-strength titanium alloy joints via EBW.

Dissimilar unbeveled aluminum to steel butt joint achieved by laser-arc hybrid welding-brazing

In this study, unbeveled butt joints of 2 mm thick steel and aluminum plates were welded using a laser-arc hybrid process. The influence of welding speed and wire feed speed on joint weld formation, microstructures, and mechanical properties were investigated. The results indicate that using a laser-arc hybrid heat source enables good weld formation of steel/aluminum dissimilar metals without groove preparation, even under high welding speed conditions. The steel side interface formed Fe₂(Al,Si)₅ near the steel and Fe(Al,Si)₃ near the aluminum. As the welding heat input decreased, the thickness of the intermetallic compounds gradually reduced. With an increase in welding speed or wire feed speed, the tensile strength of the joint first increased and then decreased, reaching a maximum of 104.47 MPa. Cracks propagated rapidly along the intermetallic compound region, resulting in brittle fracture characteristics. The three-point bending test showed a maximum longitudinal bending angle of 53.82° and a maximum transverse bending angle of 36.54°.

Influence of adjustable ring modes on molten pool behavior and microstructure of Al–Si coated boron steel in fiber laser welding

The influence of adjustable ring modes on the phase transition and microstructural evolution in conduction mode laser welding of Al–Si coated boron steel was investigated. Distinct geometric variations and molten pool behavior were observed through a ring-shaped beam effect. The ring beam introduced by ring-beam-mode (RBM) and dual-beam-mode (DBM) laser welding inhibited Al segregation into the fusion zone (FZ). The ring beam caused the Al molten particles to be driven towards the outer boundaries of the weld pool. A ring-beam-mode (RBM) and a dual-beam-mode (DBM) laser welding inhibited Al segregation into the FZ, resulting from a minimal temperature gradient and extension of the solidification time. Phase transition calculations demonstrated that a mount of residual ferrite within the FZ is significantly correlated with the Al concentration at specific temperature points, indicating a predominant role of a central-beam-mode (CBM) FZ in δ-ferrite formation. The RBM and DBM effectively suppressed Al segregation into the FZ, leading to a reduction in ferrite formation and the development of a refined microstructure characterized by a uniform and high density of geometrically necessary dislocations. Electron backscattered diffraction (EBSD) analysis revealed a higher proportion of low-angle grain boundaries in the RBM and DBM, attributed to the unique thermal distribution induced by the ring beam. These findings highlight the critical role of beam mode in tailoring the microstructure and properties of laser welds in Al–Si coated boron steel.

Effect of Filler Wire Composition on Weld Metal Microstructure and Mechanical Properties in X80 Steel Laser Welds.

Laser welding was performed using different filler wires, ER70S steel, commercially pure iron, and pure nickel filler, in the context of welding X80 pipeline steel to assess the microstructure and mechanical properties of the weld metal. Introducing an ER70S wire promoted acicular ferrite formation in the fusion zone, compared to a bainitic microstructure in an autogenous laser weld. The use of pure iron wire was considered as a potential strategy for reducing hardenability, as it led to the dilution of alloying elements in the fusion zone, increasing ferrite content and reducing weld metal hardness to a level compliant with API pipeline standards. The addition of pure nickel wire was used to reveal the degree of weld metal mixing imposed by the laser (thus providing an unambiguous tracer element) when it is combined with filler material dilution in the fusion zone, revealing that the upper region contained 38% wire material and the lower region only 12%. This accounts for the differences observed between the upper versus lower portions of the weld metal when other wires are used, and the use of hardness mapping and micro-indentation demonstrates the correlation between the variations in mechanical properties and microstructural differences introduced by incomplete mixing of the filler wire elements.

Optimizing weld strength and microstructure in CP-titanium and 304 stainless steel friction welds with chromium interlayer

This study investigates the effect of a Cr-interlayer on the hardness and friction-welded joint strength between CP-titanium and 304 stainless steel. Rotary friction welding, with its adjustable parameters such as upset pressure, is the preferred method for this dissimilar joint. Due to the difference between these two base metals, a metallic interlayer like chromium, is crucial for controlling the formation of intermetallic compounds (IMCs). Welding was conducted at three different upset pressures, both with and without the Cr-interlayer. Tensile and microhardness tests were performed, complemented by phase analysis and microstructural characterization using XRD and SEM. Our findings reveal that employing a chromium layer and higher upset pressures enhances strength while reducing the presence of brittle IMCs in the welds. At the CP-titanium side, dynamic recrystallization occurs due to increased heat generation at the interface and strain occurred by materials flow, facilitating IMC formation, especially evident at 250 MPa upset pressure. Interestingly, relatively higher strength at 150 MPa is attributed to the absence of IMCs. Conversely, higher strength results at 350 MPa due to from the flow of softened material, effectively purging IMCs from the weld zone. Notably, both β-titanium and chromium-based IMCs form in the presence of the chromium interlayer, resulting in decreased joint hardness and increased overall ductility. In conclusion, our study's findings contribute to bridging the gap between theoretical strength and practical application, significantly advancing joint performance.

Numerical simulation of GTAW for ZW61 magnesium alloy thin plates: Coupling the finite element method with the cellular automata method

ZW61 magnesium alloy has a wide range of application prospects as a lightweight green engineering material. In this paper, the temperature field and microstructure of gas tungsten arc welding (GTAW) for ZW61 magnesium alloy are simulated by the finite element method and the cellular automata (CA) method. The results show that the microstructure in the center of the fusion zone (FZ) is all equiaxed grains affected by compositional supercooling. While at the edge of the molten pool, the crystals produced by associative crystallization evolve into columnar grains after undergoing competitive growth. Furthermore, the temperature field of the molten pool alters as the welding heat input increases. Especially, the temperature gradient behind the molten pool slows down. Thus, the cooling rate during solidification of the molten pool decreases, increasing the size of the weld microstructure. Meanwhile, solute concentration plays an essential role in the weld microstructure evolution. The rise in Zn content both refines the size of the equiaxed grains and inhibits the growth of the columnar crystals. Moreover, the experimental results of the thermal cycling curves and the FZ microstructure exhibit minimal error with the simulation results, verifying the reliability of the model.

Influence of friction stir welding on the localised corrosion behaviour of AA2060 T8E30 and AA2099 T83 Al-Li alloys

The effect of friction stir welding (FSW) on the microstructure and localised corrosion behaviour of the dissimilar weld of AA2099 T83 and AA2060 T8E30 alloys is investigated. FSW results in a drastic change in the microstructure thus altering their corrosion behaviour. The heat-affected region exhibits similar attack morphology to their respective base metal but is the most protected region. The stir zone (SZ) is the most susceptible to attack. During immersion of the entire weld, attack initiation occurs from the AA2060 SZ due to galvanic activity within the region caused by the overlap of the grains in the weld zone.

Diminishing residual stress and distortion by in-situ rolling tensioning to increase fatigue performance of friction stir welded AA2024-T3 joints

In this research, local mechanical tensioning treatment in the form of in-situ rolling tensioning (ISRT) was applied during friction stir welding of AA2024-T3 sheets. Two types of roller configurations were used. First, a single roller located at the rear of the tool which passed over the weld region and secondly, two rollers were located next to the weld zone symmetrically. Subsequently, several experiments comprising residual stress, distortion and fatigue crack growth (FCG) measurements were carried out combined with microstructure, texture, hardness and tensile tests. Results demonstrated that a single roller ISRT effectively diminished residual stress in the nugget zone (NZ) from + 11.7 MPa to −45.3 MPa accompanied by better weld FCG resistance. Apart from residual stress reduction, the improved weld fatigue performance was likely correlated with the modifications of weld microstructure and texture due to rolling tensioning.

Simulation of Friction Stir Welding of AZ31 Mg Alloys.

Friction stir welding has been extensively applied for the high-quality bonding of Mg alloys. The welding temperature caused by friction and plastic deformation is essential for determining the joint characteristics, especially the residual stress and weld microstructure. In this work, a modified moving heat source model was proposed by considering the variations in heat generation caused by friction shear stress at both the side and bottom surfaces of the tool. The application of this model was further extended to the entire welding process, especially in the plunging stage. The relative errors between the experimental and simulated peak temperatures at characteristic points were small, with a maximum of 10%, thereby validating the model for accurate temperature prediction. Furthermore, the influence of welding and rotational speed on temperature fields was systematically investigated. At relatively low welding and rotational speeds, the welding temperature increased significantly with either an increase in rotational speed or a decrease in welding speed. However, this effect gradually diminished at higher welding and rotational speeds. These results provide some valuable guidelines for controlling heat generation to improve the quality of Mg alloy welds.

Analysis of fatigue fracture mechanism of laser spiral welding of dissimilar metals of 6082 high strength aluminum alloy and DP980 high strength dual phase steel

This paper investigates the relationship between weld quality, influencing factors, microstructure and mechanical properties of laser spiral dissimilarity welding of 6082 high-strength aluminum alloy and DP980 high-strength dual-phase steel, focusing on the fatigue properties and fracture mechanism of 6082-DP980 dissimilar metal welded joints. The research shows that intermetallic compound layers (IMCs) dominate the fatigue crack initiation stage and part of the crack extension stage, two fatigue crack initiation modes are obtained, one is the main crack initiation mode along the FeAl and FeAl2 interlayer, and the other is the secondary crack initiation mode along the Fe3Al and FeAl interlayer. In the crack propagation stage, due to the diffusion of Fe and Al elements generated by IMCs during the welding process, solid solution strengthening, intergranular strengthening and grain boundary strengthening, in the fatigue crack propagation stage formed a hardened zone, hindering the main crack to continue to expand along the IMCs, the main crack shifted to the expansion of the 6082 base material, thus extending the fatigue life.

Investigation on effects of nano-reinforcement on the mechanical properties, fatigue, and microstructural analysis of dissimilar AA6061- Mg AZ31B weld joints

Weld joints have been subject to substantial improvement in mechanical durability and wear resistance in recent years. This research work challenge can be answered by incorporating nano-materials into the weld zone. Mechanical and metallurgical aspects of friction stir welded (FSW) butt joints made of AA6061 aluminum and Mg AZ31B alloys have been examined in this work, both with and without the use of naturally derived biochar nanoparticles. The biochar particle was extracted from rice husk. Throughout the whole weld joint manufacturing process, a tool with a rotational speed of 1400 rpm, a welding speed of 40 mm min−1, and a tapered pin profiled tool were employed. During the joint fabrication process, the constant axial load of 7 kN, plunge depth of 0.2 mm, and constant dwell time of 0.3 s were also maintained. In order to improve the mechanical attributes of the weld joints, different wt% of biochar such as 1%, 2%, and 3%, were applied at the interface region of the weld joints. The experimental results revealed that the percentage of reinforced nano-materials plays a significant effect in improving the weld joint qualities. The testing results of reinforced friction stir-welded joint qualities were compared to those of simple friction stir welded joints made without and with adding the nanoparticles. The best results were obtained when 2 wt% of biochar particles was added to the weld interface region. The presence of biochar nano-particles, in addition to their contribution to increased grain refinement in the weld nugget region, was also seen in the region. It was discovered that the event distribution of particles at the nugget zone significantly enhanced the mechanical and wear resistance qualities of the weld joints that were manufactured. The optical microscope was used to analyze the microstructures in the weld nugget region, and a scanning electron microscope (SEM) was utilized to examine the fracture analysis of the tensile samples. The presence of 2 wt% biochar particles in the weld nugget region resulted in a considerable increase in the mechanical characteristics of the weld connections. The ultimate tensile strength, hardness, and yield strength of the weld nugget results 197 MPa, 173 HV, 163 MPa. Overall, when compared to the qualities of the base material and plain weld joints. The mechanical properties and wear resistance of the weld joints have improved significantly. When biochar particles were used as reinforcement particles during the fabrication phase of the joint, a mechanism for pinning was observed in the weld microstructure.