Post-weld Heat Treatment Conditions Research Articles

Regulating the partially mixed zone via post-weld heat treatment to enhance sulfide stress corrosion cracking resistance of the Inconel 625/X80 weld overlay

This paper investigated the effect of post-weld heat treatment (PWHT) on microstructure evolution and sulfide stress corrosion cracking (SSCC) behavior of the fusion boundary (FB) region of Inconel 625/X80 weld overlay, with a focus on the partially mixed zone (PMZ). Three heat treatment regimens were designed, namely 620 °C/10 h, 620 °C/20 h, and 670 °C/10 h, in which 620 °C/20 h was proved to be the optimal parameter. The 10-hour PWHT conditions might induce heterogeneous carbon distribution owing to insufficient tempering duration, exacerbating the hardness mismatch in the FB region and thus promoting the development of SSCC. Following the 620 °C/20 h treatment, most of the brittle phase with high hardness in the FB region was eliminated, reducing the nucleation site for SSCC. More importantly, martensite in the PMZ was transformed into austenite with rod morphology, while cementite adjacent to the PMZ might evolve into dispersed refined austenite. Austenite shows low hydrogen sensitivity, enhancing the SSCC resistance of the PMZ. On the other hand, the carbides in the X80 matrix might restrict the diffusion of hydrogen toward the PMZ, thereby reducing the susceptibility of the PMZ to SSCC.

Residual stress relief strategy in thick steel weldments via local induction heat treatment: Simulation and neutron diffraction experiment

This study investigated the effect of local induction post-weld heat treatment (PWHT) on residual stress relief in thick submerged arc welded steel plates. A combination of numerical and neutron diffraction methods was used to examine the effect of various PWHT parameters, such as annealing temperature and holding time, on the relief of residual stress in welded plates with various thicknesses. A sequentially coupled thermal–mechanical finite element model was used to calculate the residual stress distribution in welded AH36 steel plates before and after PWHT. The model was validated by comparing its predictions with the experimental measurements, and the results showed good agreement. The residual stress of the thick welded plates was effectively reduced via PWHT with local induction. The primary mechanism for this stress release was identified as stress relaxation caused by creep strain. Furthermore, a process map was established considering the PWHT conditions and plate geometry. This map provides a means of determining the optimal PWHT conditions to achieve desired stress reduction levels.

Investigation of effect of post weld heat treatment on microhardness and microstructure of auto TIG welded stabilized SA213 TP347H weldments

Investigation explores the weldability of Niobium stabilized TP347H austenitic stainless steel tubes through the application of optimized welding parameters using Auto TIG welding. This research investigates the influence of post weld heat treatment conditions on microhardness, microstructures, sensitization due to Cr23C6 precipitation, presence of Niobium carbides and formation of twin boundaries in the weldment. Extended post weld heat treatment duration resulted in notable decline in microhardness from 280 to 180 VHN within initial 5-h of soaking. Nevertheless, further prolongation of soaking time (10–15 h) exhibited subsequent rise in microhardness levels to 200 VHN in base, weld and heat affected zone. Increase in hardness is attributed to the emergence of annealing twins in base metal and the precipitation of Niobium carbides within weld and heat affected zone, confirmed by advanced analytical scanning electron microscope. Energy dispersive spectrum line mapping reveals presence of Cr23C6 precipitation following 1-h soak at 720 °C. Subsequent prolongation of soaking time (5-h) demonstrates desensitization in the base metal. Additionally, cooling rate of 300 °C/hr during post weld heat treatment reduces required time for microstructure homogenization, resulting in increased hardness compared to 100 °C/hr rate in the weldment. However, beyond a 5-h soaking time, the cooling rate has a negligible impact on microhardness. Ultimate Tensile Stress of 674.82 and 665.28 N/mm2 for TP347H was achieved against the minimum requirement of 515 N/mm2 as per American Society of Mechanical Engineers Section IX standard.

Investigation of the fracture resistance of high strength ferritic steel welds in gaseous hydrogen environment

Hydrogen is expected to play a major role in the decarbonization of the energy grid. As a fuel, it possesses an elevated energy density per unit mass, about twice as much as natural gas but also a very low mass density; for this reason, it is preferably stored and transported at elevated pressures in the gas phase to achieve a comparable volumetric energy density. High strength quenched and tempered ferritic steels are widely used for gaseous hydrogen storage despite the fact that hydrogen affects material properties and result in higher fatigue crack growth rate and lower fracture toughness.This work presents the results of a comprehensive fracture toughness test program in gaseous hydrogen for the characterization of base metal, heat affected zone and weld metal on a high strength, quenched and tempered steel, suitable for the construction of hydrogen pressure equipment.Full penetration, butt welded joints were made using partly mechanized gas metal arc welding technique on a weldable, high strength steel, namely EN 101216-3 grade P690 QL2. Two different welding procedures were evaluated, and fracture toughness tests were conducted according to ASTM E1820 requirements, in high purity (99.9995%) hydrogen gas at a pressure of 200 bar on specimens extracted from base metal, heat affected zone and weld metal. While base metal and weld metal exhibited stable crack growth behavior, heat affected zone showed variable behavior as a function of the post-weld heat treatment conditions. It was found that local micro-hardness spots are a concern and should be controlled through dedicated post weld heat treatment operation to limit hardness values for use of welds in H2 gas conditions.

Numerical fracture toughness evaluation of SS316L CT specimens using an Elastic Plastic Fracture Mechanics (EPFM) approach

In this study, fracture toughness was determined using an elastic-plastic fracture mechanics approach via numerical simulation. The material chosen for study is austenitic stainless steel 316L, which is extensively used in the nuclear industry for core internal structures. Three different SS316L conditions were considered for the analysis, including welded and post-weld heat-treated conditions aged at 300 °C for 10,000 hours (over-aged) and at 400 °C for 5,000 hours (peak-aged). A compact tension (CT) specimen of standard dimensions, which was taken from ASTM E1820–01, was used to perform the analysis. The J-integral value that is obtained for those three conditions was compared with the base material, which was taken from the open literature. It was found that theJ-integral values of SS 316L for welded conditions were lower than the base material. Also, J-integral values of SS 316L for the two post-weld heat-treated conditions were found to be greater than the weldments but less than the base material. It can also be noted that the values obtained for the SS316L weldments and the post-weld heat-treated sample aged at 335 °C for 10,000 hours were notably similar.

Effect of post-weld heat-treatment and solid-state thermomechanical treatment on the properties of the AA6082 MIG welded joints

Post-weld heat treatment (PWHT) and solid-state thermomechanical treatment (TMT) via friction stir processing (FSP) have been shown to enhance the mechanical properties of aluminum alloys. The current work investigates the effects of PWHT and TMT on the microstructure and mechanical performance of AA6082-T6 welded butt joints welded using the MIG process. The 5 mm thick AA 6082-T6 plates were joined in butt configuration using MIG welding with ER 5356 filler wire, 120 A current, 0.3 mm/s weld speed, and argon shielding gas at 15 L/min flow rate. PWHT was performed on the MIG welds per the T6 temper procedure. TMT was implemented via FSP using a pinless tool rotating at 800 rpm and traversing speed at 200 mm/min with a 3° tilt angle. Microstructural analysis, hardness mapping, tensile testing, and fracture surface evaluation were utilized to characterize the as-welded, PWHT, and TMT samples. The results demonstrate that both PWHT and TMT significantly refine and homogenize the microstructures of the welded joints. However, the TMT samples displayed superior hardness and tensile strength compared to the as-welded and PWHT conditions. The TMT-processed welds achieved approximately 99% joint efficiency versus only 69% and 85% for the as-welded and PWHT samples. In summary, PWHT and especially TMT via FSP are effective at enhancing the mechanical properties of MIG welded AA6082-T6.

Evaluation of metallurgical and mechanical properties of 12 mm thick aerospace grade MDN 250 steel by plasma ARC welding technique

Carbon-free nickel alloy maraging steel has high demand in manufacturing aerospace vehicles and hypersonic missiles. Due to the absence of carbon and the strengthening of intermetallic precipitates, maraging steel can attain high strength and toughness with ductility. This material has enormous weldability in both annealed and post-weld heat-treated (PWHT) conditions. During high-thickness sections, the heat flow rate and the number of passes were found to be redundant. The existence of reverted austenite (RA) has been identified because prolonged aging also has an impact on the mechanical characteristics of the weldment. The present research demonstrates the characterization of plasma arc welded (PAW) maraging steel MDN 250 in welded and PWHT conditions. The weldments were subjected to three types of heat treatment, namely, (i) Subsequent Aging (TA), (ii) Solution treating + Subsequent Aging (STA), and (iii) Homogenizing + Solution treating + Subsequent Aging (HTA). This study also emphasizes the importance of precipitates and RA in affecting the strength and toughness of welded joints. The HTA treatment solely helps to eliminate the RA from the weldment. The microstructural study depicts the formation of reverted austenite in the TA condition. The reverted austenite has not been found in the microstructure under HTA conditions. The EBSD (Electron backscatter diffraction) analysis has resulted that the RA has been eliminated. The EDS (Electron Dispersive Spectroscopy) analysis shows that segregation of the enriched alloys has been effectively lowered in HTA condition. Compared to the other weldments’ mechanical characterization, the HTA condition gives supremacy results. The average ultimate tensile strength of 1830 MPa has been achieved in HTA condition, with a yield strength of 1809 MPa. The average fracture toughness results of 88.3 MPa√ m was obtained in HTA condition. The work display of PAW (Plasma Arc Welding) is capable of meeting all of the requirements for welding maraging steel in high-thickness sections.

Investigation of Friction Hydro-Pillar Processing as a Repair Technique for Offshore Mooring Chain Links

Repairing links of offshore mooring chains has presented a significant industry challenge, primarily arising from modifications in material properties, encompassing alterations in microstructure, hardness, and residual stress. In this context, the present work investigates the method of friction hydro-pillar processing (FHPP) applied to R4 grade mooring chain steel. Joints in as-repaired and post-weld heat treatment (PWHT) conditions were subjected to residual stress (RS) tests using the neutron diffraction technique, microhardness mapping, and microstructural evaluations. The process generated peaks of tensile and compressive stresses in different directions and hardness below that of the parent material in the softening zone. The friction zone promoted high hardness levels in the thermo-mechanically affected zone (TMAZ) with a maximum of 19% of the ultimate tensile strength of the parent material. As expected, the PWHT restored the RS and reduced the hardness; however, 4 h PWHT allowed the elimination of a hardness higher than that of the base material.

Influence of Short-Time Post-Weld heat treatment on the performance of friction stir welded AA7075 aluminum sheets

Zinc-containing aluminum alloys of the 7xxx series represent materials with highest potential for lightweight applications due to their superior strength combined with low density. Unfortunately, robust processing of these alloys remains a challenge, as these alloys are still considered not being weldable by conventional methods, where hot cracking is a critical issue. However, it has been numerously shown that joints being characterized by excellent properties can be obtained by friction stir welding (FSW). Here, one possibility for further improvement is to perform a post-weld heat treatment (PWHT) to stimulate precipitation hardening after welding. Two different PWHT with 300 s and 10 s soaking time at 480 °C followed by water quenching and artificial aging for 24 h at 120 °C were performed. The heat treatment with a short soaking time led to a higher quasi-static strength as compared to the condition upon PWHT with 300 s soaking time and the FSW condition. Fatigue tests in the low-cycle and high-cycle fatigue regimes revealed a reduction in fatigue strength due to the onset of grain growth near the surface for both PWHT conditions. In consequence, removal of the surface layer led to an improvement in fatigue strength.

Investigating the microstructure and mechanical properties of deposited metal with ENiCrFe-7 covered electrode

The effect of post weld heat treatment (PWHT) on microstructure and mechanical properties of deposited metal using ENiCrFe-7 covered electrode was investigated. The PWHT was conducted at 615 °C for 24 h. The results showed that three types of precipitates existed in both as-welded and PWHT deposited metals, i.e., NbC carbides, Al-Ti oxides in grains, and M23C6 carbides on grain boundaries. The M23C6 carbides coarsened after PWHT. The room temperature and elevated temperature (350 °C) tensile strength decreased by about 30 MPa, and elongation increased by about 3%–4% after PWHT. The tensile specimens presented ductile fracture feature and the dimples in PWHT condition were larger than that in as-welded condition. The hardness of deposited metal in as-welded condition was higher than that of PWHT condition. The impact toughness showed no significant change after PWHT. Both as-welded and PWHT impact specimens showed a mixed fracture mode with dominant ductile fracture and cleavage fracture.

Effect of solutionizing and double ageing treatments on the microstructural characteristics and tensile properties of Inconel 718 welds

Inconel 718 joints were fabricated using the pulsating direct current gas tungsten arc welding (PDCGTAW) and laser-arc hybrid welding (LAHW) techniques using Ni-Cr-Mo-rich filler. A cyclic post-weld heat treatment (PWHT) comprising 980 °C/20 min/air cooling; followed by two-stage ageing 720 °C/8 h/furnace cooling and 620 °C/8 h/air cooling was performed on both joints. The liquation cracking was noticed on the heat-affected zone (HAZ) of the LAHW joints. Microstructural characteristics were assessed on the joints in both as-welded (ASW) and PWHT conditions. Regardless of the joints, the coarse Mo-rich segregates were noticed in the fusion zone (FZ) in the ASW conditions. On the contrary, the partial dissolution of MC, precipitation of δ-Ni3Nb needles and the coarsening of strengthening precipitates were observed on LAHW and PDCGTAW joints after subjecting to cyclic PWHT respectively. Tensile studies corroborated that there is a considerable enhancement in the tensile and 0.2% offset yield strengths of LAHW joints after being exposed to PWHT, despite the formation of HAZ liquation cracking.

Local microstructure evolution of a V-containing Fe–Cr–Ni–Mo weld metal subjected to post-weld heat treatment

The high-strength steels are widely used in modern shipbuilding and marine facilities. However, welding of >900 MPa grade steels is particularly challenging owing to the lack of understanding of fine microstructure for the weld metal (WM). The present investigation is mainly focused on a V-containing Fe–Cr–Ni–Mo WM fabricated by gas metal arc welding (GMAW) in aspects of localized microstructure evolution during post-weld heat treatment (PWHT). Microanalysis of the localized microstructure of inter-dendritic regions (IDRs) and dendrite core region (DCRs) for WMs was conducted by transmission electron microscopy (TEM), transmission kikuchi diffraction (TKD) and atom probe tomography (APT), complimented by nanoindentation hardness testing. It is found that the microstructure of WM in as-welded (AW) and PWHT condition was characterized by elongated martensitic laths with high-density dislocations in IDRs, while that in DCRs was coarse bainitic microstructure with relatively fewer dislocations. Most of retained austenite (RA) formed during cooling after welding was decorated martensite lath boundaries within IDRs owing to the segregation of austenite stabilizing elements after solidification. For PWHT condition, more numerous and smaller nano-scale MC carbides were observed in IDRs compared to DCRs. Furthermore, V atoms were mainly responsible for the nucleation of nano-scale MC carbides, and the growth and coarsening process of them were mainly controlled by diffusion of Mo atoms. Besides, the RA could also decompose into nano-scale MC carbides during PWHT. The IDRs of the PWHT specimens showed the average nanohardness value of 7.4 ± 2.3 GPa, which was higher than that of the DCRs (4.0 ± 0.2 GPa).

Influence of heat treatment on microstructure and mechanical properties of pulsed Nd: YAG laser welded dissimilar sheets of Hastelloy C-276 and monel 400

The study involved using a pulsed Nd:YAG laser welded Hastelloy C-276-Monel 400 dissimilar sheet by the process parameters viz. a pulse energy of 10 J, pulse repetition rate of 20 Hz and pulse duration of 0.006 s under spot weld mode. The objective was to investigate the effects of various post weld heat treatment (PWHT) conditions on the welded sheets. Microscopic analysis showed that the fusion zone and interfaces between the two metals contained smaller dendritic grains containing chromium-rich carbides and nickel-rich oxides. Both the Hastelloy C-276 and Monel 400 interfaces exhibited these traits. The PWHT of the quenched weld (water cooling) produced higher mechanical strength, while the annealed weld (furnace cooling) resulted in lower strength. Tensile failures were observed in the fusion zone for quenched and normalized welds, and in the base alloy of Hastelloy C-276 side for annealed weld under ductile fracture mode. XRD analysis showed the presence of more secondary phases and intermetallic compounds in the fusion zone and Hastelloy C-276 side in the annealed weld. The corrosion study indicated that the fusion zone and Monel 400 side had better corrosion resistance, followed by the Hastelloy C-276 side.

Effect of post weld heat treatment on weld metal microstructure and hardness of HFCA-TIG welded ASTM-B670 high temperature alloy joints

In this investigation, the effect of post weld heat treatment (PWHT) conditions on weld metal (WM) microstructure and hardness of ASTM B670 alloy joints are studied for gas turbine engine applications. This high temperature alloy was joined using high frequency compressed arc TIG (HFCA-TIG) welding process. The precipitation hardening was performed on ASTM-B670 alloy joints directly after welding (DPH); after solutionizing the welds at 980 °C (980ST+PH) and at 1065 °C (1065ST+PH). The WM of ASTM-B670 alloy showed better response to PWHT in minimizing the Laves phases and enhancing the WM hardness of joints. The DPH, 980ST+PH and 1065ST+PH joints showed 55.63%, 58.80% and 64.08% enhancement in hardness of WM compared to as welded (AW) joints owing to the precipitation of hardening phases after PWHT. The 1065ST+PH joints revealed higher hardness of WM than DPH and 980ST+PH joints It is attributed to the complete dissolution of Laves phases in WM causing more Nb available for precipitation hardening of WM. Nevertheless, the PM hardness of 1065ST+PH joints are lower than 980ST+PH joints owing to the severe grain growth. The HFCA-TIG welds showed volume fraction of Laves phase up to 5.10% in WM which is 80.38% and 36.25% lower than constant current TIG (CC-TIG) and pulsed current TIG (PC-TIG) welds. It is attributed to magnetic compression and high frequency pulsation of arc which minimizes input of heat in welding and offers greater refinement of WM.

Welding of AA6061-T6 Sheets Using High-Strength 4xxx Fillers: Effect of Mg on Mechanical and Fatigue Properties.

Al-Si-Mg 4xxx filler metals are widely used in aluminum welding owing to their excellent weldability and capability for strength enhancement by heat treatment. However, weld joints with commercial Al-Si ER4043 fillers often exhibit poor strength and fatigue properties. In this study, two novel fillers were designed and prepared by increasing the Mg content in 4xxx filler metals, and the effects of Mg on the mechanical and fatigue properties were studied under as-welded and post-weld heat-treated (PWHT) conditions. AA6061-T6 sheets were used as the base metal and welded by gas metal arc welding. The welding defects were analyzed using X-ray radiography and optical microscopy, and the precipitates in the fusion zones were studied using transmission electron microscopy. The mechanical properties were evaluated using the microhardness, tensile, and fatigue tests. Compared to the reference ER4043 filler, the fillers with increased Mg content produced weld joints with higher microhardness and tensile strength. Joints made with fillers with high Mg contents (0.6-1.4 wt.%) displayed higher fatigue strengths and longer fatigue lives than joints made with the reference filler in both the as-welded and PWHT states. Of the joints studied, joints with the 1.4 wt.% Mg filler exhibited the highest fatigue strength and best fatigue life. The improved mechanical strength and fatigue properties of the aluminum joints were attributed to the enhanced solid-solution strengthening by solute Mg in the as-welded condition and the increased precipitation strengthening by β″ precipitates in the PWHT condition.

Influence of Microstructure and Mechanical Properties of Dissimilar Rotary Friction Welded Inconel to Stainless Steel Joints.

The present study aims to evaluate the microstructure, grain size, and mechanical properties of the dissimilar AISI 316L/Inconel 718 (IN 718) rotary friction welded joints under both the as-welded and post-weld heat treatment (PWHT) conditions. Because of reduced flow strength at elevated temperatures, the AISI 316L and IN 718 dissimilar weldments exhibited more flash formation on the AISI 316L side. At higher rotating speeds during friction welding, an intermixing zone was created at the weld joint interface due to the material softening and squeezing. The dissimilar welds exhibited distinctive regions, including the fully deformed zone (FDZ), heat-affected zone (HAZ), thermo-mechanically affected zone (TMAZ), and the base metal (BM), located on either side of the weld interface. The dissimilar friction welds, AISI 316L/IN 718 ST and AISI 316L/IN 718 STA, exhibited yield strength (YS) of 634 ± 9 MPa and 602 ± 3 MPa, ultimate tensile strength (UTS) of 728 ± 7 MPa and 697± 2 MPa, and % elongation (% El) of 14 ± 1.5 and 17 ± 0.9, respectively. Among the welded samples, PWHT samples exhibited high strength (YS = 730 ± 2 MPa, UTS = 828 ± 5 MPa, % El = 9 ± 1.2), and this may be attributed to the formation of precipitates. Dissimilar PWHT friction weld samples resulted in the highest hardness among all the conditions in the FDZ due to the formation of precipitates. On the AISI 316L side, prolonged exposure to high temperatures during PWHT resulted in grain growth and decreased hardness. During the tensile test at ambient temperature, both the as-welded and PWHT friction weld joints failed in the HAZ regions of the AISI 316L side.

Fatigue deformation mechanisms and dislocation model of 41Fe-25.5Ni-23.5Cr alloy welded joints under multistage heat treatment

The fatigue behavior of 41Fe-25.5Ni-23.5Cr alloy welded joints subjected to different multistage post-weld heat treatment (PWHT) conditions was studied. The fatigue life of welded joints under PWHT1 (600 °C-1 h/1050 °C-1 h/950 °C-30 min) was significantly prolonged, which was attributed to the low cyclic hardening rate caused by the small cyclic yielding stress and effective stress. The microstructure analysis indicated that the twin boundaries in the fusion line maintained continuity with those in the base metal, causing the inhomogeneous fatigue deformation to be primarily distributed in the weld metal rather than the fusion line. The crystallographic orientation (001) of weld metal under PWHT1 remained unchanged during fatigue, the slip of bowed dislocation lines was the characteristics of fatigue deformation and the grain growth led to the decrease in weld metal deformation. The crystallographic orientation under PWHT2 (1050 °C-1 h) changed from (111) to (001), and the slip of tangled dislocation lines resulted in an accumulation of weld metal deformation. To study the impact of deformation behavior on fatigue properties, new dislocation slip models were developed based on the increase in dislocation density caused by the parabolic slip area and dislocation line length. The results of this study indicate that multistage PWHT is a remarkable approach to prolong the fatigue life of 41Fe-25.5Ni-23.5Cr alloy welded joints at high temperatures.

Effect of Heat Treatment on the Microstructure and Mechanical Properties of Rotary Friction Welded Dissimilar IN718 to SS304L Alloys

The present study investigated the effect of heat treatment (pre- and post-weld) on the microstructure and mechanical properties of an SS304L/IN718 dissimilar rotary friction welded alloy. Optical and scanning electron micrographs of the dissimilar rotary friction welded SS304L/IN718 joints in solution-treated (ST), solution-treated and aged (STA), and post-weld heat treatment (PWHT) conditions revealed defect-free welds. Furthermore, various zones were observed across the weld region, namely the fully deformed zone (FDZ), thermomechanical affected zone (TMAZ), heat affected zone (HAZ), and base material (BM). Among the SS304L/IN718 dissimilar friction welds with different heat treatment conditions (prior ST and STA, PWHT), the PWHTed dissimilar welds exhibited excellent mechanical properties, which could be attributed to the formation of the strengthening precipitates γ′ and γ″ during double aging in PWHT. In contrast, the mechanical properties were found to be the poorest in the STA condition, possibly due to the dissolution of the strengthening precipitates γ′ and γ″ during friction welding. It was observed that the SS304L/IN718 dissimilar friction welds in the ST and STA conditions failed in the HAZ of the SS304L side, away from the weld interface, indicating that the weld region was stronger than the weakest base metal (SS304L) in the various joints.

Microstructural and Mechanical Properties of Dissimilar Aluminium Alloys by Friction Stir Welding

In the present study, the dissimilar aluminium alloys AA 2014-T651 and AA 7075-T651 of 16 joints was successfully joined with (four welding speeds (50, 60, 70, 80 mm/min), four rotational speeds (900, 1000, 1100, 1200 rpm), four different weld tool profiles (T1=12/4, T2=15/5, T3=16/4, T4=20/5 in D/d ratio) by friction stir welding machine. In the optical microstructure and SEM very fine equiaxed grains are formed in the stir zone. The maximum hardness value is 150 HV obtained in the weld nugget area of the specimen 2 under the conditions of 900 rpm, 70 mm/min for T3 profile. Compare to other tool profiles T3 profile attained maximum hardness value. The minimum hardness value is attained for the specimen 13 for the tool profile T1 was 103 HV compared to all tool profiles. In post weld heat treatment conditions, hardness values were decreased compare with as weld conditions due to over heating followed by ageing. The maximum joint efficiency attained is around 90 to 95% with T2 and T3 profiles at rotational speed of 1000 rpm, 1200 rpm and welding speed of 60, 70 mm/min. The T1 profile attained least joint efficiency of 69.5 % at 900 rpm, 50 mm/min, since it has very less shoulder diameter or contact area and maintain a D/d ratio is 3.

Dissimilar joining of the martensitic grade P91 and Incoloy 800HT alloy for AUSC boiler application: Microstructure, mechanical properties and residual stresses

The presented study intends to analyze the microstructure and corresponding mechanical characteristics of P91 and Incoloy 800HT dissimilar welded joint (DWJ). The thermo-physical property differences between P91 and Incoloy 800HT arise due to their complex alloying composition, making their weldability difficult. Incoloy 800HT is difficult to weld due to its high susceptibility to solidification cracking. The recommended nickel-based filler metals for welding Incoloy 800HT were employed to weld P91 and Incoloy 800HT using conventional gas tungsten arc welding (GTAW). The welded joint morphology and characteristics were analyzed in as-welded (AW) and post-weld heat treatment (PWHT) conditions. The PWHT was performed to observe changes in microstructural inhomogeneity and residual stress relaxation in weld after the heat treatment. An electron probe microanalyzer (EPMA) was utilized to observe the distribution and segregation of elements in different weld regions. The deep hole drill technique was employed to find the distribution of bi-axial residual stresses in the weld fusion zone (WFZ) and heat-affected zone (HAZ) of base metals in both AW and PWHT conditions. The two nickel-based fillers, ERNiCr-3 and ERNiCrMo-3, were employed, and their weld characteristics were compared. The mechanical strength of ERNiCr-3 filler-based DWJ was found superior to ERNiCrMo-3 filler-based DWJ. The standard AW and PWHT ERNiCr-3 filler-based DWJ tensile specimen failed from Incoloy 800HT base metal with an ultimate tensile strength (UTS) of 570 ± 4 MPa and 650 ± 4 MPa, respectively. The ERNiCrMo-3 filler-based DWJ obtained the highest UTS of 679 MPa after PWHT in a subsize specimen. The microhardness for ERNiCrMo-3 WFZ was found to be higher than ERNiCr-3 WFZ microhardness, and PWHT successfully tempered the P91 HAZ. Further, the impact toughness for the ERNiCr-3 WFZ in AW condition was 86 ± 3 J and PWHT did not provide any significant improvements, while ERNiCrMo-3 WFZ had an impact toughness of 47 ± 10 J in AW state and 41 ± 10 J in PWHT state. Thus, a successful weld characteristic study of defect-free P91 and Incoloy 800HT DWJ was completed, and ERNiCr-3 filler was concluded to be an optimum choice of filler to make the DWJ between P91 and Incoloy 800HT.