Primary Austenitic Solidification Research Articles

Solidification behavior and texture of 316L austenitic stainless steel by laser wire directed energy deposition

The solidification behavior and crystallographic texture of 316L austenitic stainless steel builds fabricated via laser-wire directed energy deposition additive manufacturing (AM) were investigated. Shielding gas set-up and build type (single-track vs. multi-track) were varied, which led to changes in the solidification conditions and the final build compositions. Primary δ-ferrite solidification is predicted based on equilibrium thermodynamic predictions of the bulk feedstock composition. However, the increased solidification velocity of the AM process promotes a solidification mode transition from primary δ-ferrite to primary austenite. Skeletal δ-ferrite and lathy δ-ferrite associated with primary δ-ferrite solidification and interdendritic δ-ferrite associated with primary austenite solidification were observed among the laser-wire directed energy deposition walls. Skeletal and interdendritic δ-ferrite exhibited a (001)δ // (001)γ parallel relationship with austenite and a {001} solidification texture aligned with the build direction for both austenite and δ-ferrite. Lathy δ-ferrite exhibited a Kurdjumov-Sachs orientation relationship, (101)δ//(11¯1)γ, with austenite due to austenite nucleation in the solid-state. It is shown that the solidification behavior of AM 316L is accurately represented by as-built composition data and a dendrite growth model, which combined, encompasses the compositional and solidification condition impacts on the solidification pathway.

Experimental investigations on the microstructural evolution and their influence on mechanical, tribological and corrosion performance of wire-arc additive manufactured SS316L structure

The study investigates the feasibility of emerging wire arc additive manufacturing technology to fabricate steel structures. The grain morphology and phase transformation of the WAAM-printed structure have been thoroughly examined and investigated their influence on the mechanical, tribological, and corrosion performance. The structure is characterized by fine equiaxed grains nearer to the cold substrate and coarse columnar grains along the upper regions. The average grain size in the top, middle, and bottom regions of the printed wall is 12.34 ± 5.81 µm, 10.27 ± 2.84 µm, and 4.33 ± 0.89 µm respectively. The higher temperature gradient in the bottom regions led to the ferrite-austenite solidification mode that switched toward the primary austenite solidification mode in the upper layers. The printed parts witness superior mechanical properties with an improved micro-hardness and tensile strength however reduced ductility compared to the conventionally produced steel. The longitudinal direction of the printed parts experienced slightly higher hardness than the transverse. The tribological performance in different regions is investigated under different loading conditions and discovered an improvement in the wear-resistant properties of the fabricated part to its wrought counterpart even at high load conditions. Moreover, comparative corrosion resistance properties of the WAAM and wrought steel were detected with a slightly higher corrosion rate along the upper region in a moderately saline environment with flowing and stagnant conditions. The study detects the dependence of the characteristics properties on the grain morphology and existing phases in different regions of the arc additive-manufactured steel wall.

Computational simulation of thermo-mechanical field and fluid flow and their effect on the solidification process in TWIP steel welds

The primary austenitic solidification mode of Twinning Induced Plasticity (TWIP) steel weld joints is one of the most important issues limiting its weldability. In order to gain knowledge on this topic, a comprehensive study was carried out through numerical simulation of diffusive-convective phenomena of fluid flow and heat transfer of the melted material in the weld pool of TWIP steel weld joints. Weldments were performed using different heat inputs and constraint conditions. The predictions of convective motion, thermal history and cooling rates estimated by finite element (FE) and finite volume (FV) simulations were correlated with chemical species segregation (Mn, C, Al and Si) and the solidification mode in the fusion zone. The microstructural characterization of weld joints and the numerical results provided a full analysis of the weld pool solidification process. Results revealed a relationship between both the dendrite size and Mn segregation with the estimated velocity field of liquid material in the melted zone. Moreover, the presence of δ-ferrite was experimentally detected in some weld joints and associated with the convective movement of melted material and chemical segregation. The cellular dendritic growth mode found in some weld joints contributed to the formation of δ-ferrite and promoted the transition of the solidification mode from austenitic to ferritic-austenitic. As well δ-ferrite allowed to mitigate hot-cracking and interrupted the Mn-enriched liquid film migration towards the heat-affected zone, avoiding the formation of liquation cracks. The presence of δ-ferrite phase maintained a high mechanical strength providing improved elongation regarding the welded material mechanical properties.

Characterization of the microstructure and mechanical properties of activated tungsten inert gas welded and hot-wire tungsten inert gas welded super austenitic stainless steel AISI 904L

Super austenitic stainless steel AISI 904L is a premium stainless steel variant known for its superior properties and ability to retain the same in highly challenging conditions. This study investigates the feasibility of welding 10-mm thick plates of AISI 904L through activated tungsten inert gas welding and hot-wire tungsten inert gas welding methods. The fabricated joints are then subjected to solidification mode study, ferrite number analysis, microstructural characterization, and mechanical tests. Results of the solidification mode study indicated primary austenitic solidification in both the weld joints. The ferrite number measurement revealed that the hot-wire tungsten inert gas weld joint had a higher δ-ferrite content of 1.58 over 0.99 of the activated tungsten inert gas weld joint. A microstructure study confirmed the presence of refined equiaxed grains in the fusion zone of the hot-wire tungsten inert gas weld joint, while the activated tungsten inert gas weld joint displayed equiaxed grains crammed between the columnar grains and dendrites. Liquid penetrant inspection of bend-tested samples proved the soundness and quality of both weld joints. The hot-wire tungsten inert gas weld joint excelled over the activated tungsten inert gas weld joint with a higher microhardness value. During tensile tests, activated tungsten inert gas and hot-wire tungsten inert gas weld joints displayed average ultimate tensile strength values of 521 and 514 MPa, respectively. The impact toughness of the activated tungsten inert gas weld joint was 248 J, while it was 220 J for the hot-wire tungsten inert gas weld joint. Field emission scanning electron microscope analysis equipped with energy-dispersive spectroscopy and elemental color mapping provided details about weld microstructure and the reasons for the material's failure. The study proved the efficiency and soundness of the 10-mm thick joints of AISI 904L fabricated by activated tungsten inert gas and hot-wire tungsten inert gas welding techniques.

Effect of Microstructural Bands on the Localized Corrosion of Laser Surface-Melted 316L Stainless Steel

The localized corrosion of laser surface melted (LSM) 316L stainless steel is investigated by a combination of potentiodynamic anodic polarization in 0.1 M HCl and microscopic investigation of the initiation and propagation of localized corrosion. The pitting potential of LSM 316L is significantly lower than the pitting potential of wrought 316L. The LSM microstructure is highly banded as a consequence of the high laser power density and high linear energy density. The bands are composed of zones of changing modes of solidification, cycling between very narrow regions of primary austenite solidification and very wide regions of primary ferrite solidification. Pits initiate in the outer edge of each band where the mode of solidification is primary austenite plane front solidification and primary austenite cellular solidification. The primary austenite regions have low chromium concentration (and possibly low molybdenum concentration), which explains their susceptibility to pitting corrosion. The ferrite is enriched in chromium, which explains the absence of pitting in the primary ferrite regions. The presence of the low chromium regions of primary austenite solidification explains the lower pitting resistance of LSM 316L relative to wrought 316L. The influence of banding on localized corrosion is applicable to other rapidly solidified processes such as additive manufacturing.

Solidification Cracking Susceptibility of the Weld Metal of Additively Manufactured 316L Stainless Steel

In this study, the solidification cracking susceptibility of the weld metal of additively manufactured 316L stainless steel was investigated. Laser powder bed fusion was employed to fabricate rectangular specimens with a thickness of 4 mm, and Trans-Varestraint tests were performed to evaluate the weldability of the specimens. Subsequently, the maximum crack lengths were measured and used as indices of susceptibility. The results showed that the weld metal of additively manufactured 316L stainless steel had higher susceptibility to solidification cracking than that of conventional wrought 316L stainless steel. The high susceptibility was considered mainly due to the primary austenite solidification mode in the weld metal of the additively manufactured specimen having a relatively higher content of nitrogen. Key words: Additive manufacturing, Powder bed fusion, Solidification cracking, 316L stainless steel

Comparison of two types of low-transformation-temperature weld metals based on solidification mode

ABSTRACTTwo types of low-transformation-temperature weld metals were devised, one associated with primary austenite solidification, the other primary ferrite solidification. The martensite start temperature of both low-transformation-temperature weld metals was about 125°C. Experimental results showed that low-transformation-temperature weld microstructure associated with primary austenite solidification was martensite with 8.0% retained austenite, whereas that one related to primary ferrite solidification primarily consisted of martensite and δ-ferrite. Accordingly, both welded joints had little distinction between distortion and residual stress, indicating that weld metal associated with primary ferrite solidification played the same function as primary austenite solidification on residual stress reduction. Moreover, the low-transformation-temperature weld metal associated with primary ferrite solidification had higher tensile strength and hardness than that based on primary austenite solidification.

Si-bronze to 304 stainless steel GTA weld fusion zone microstructure and mechanical properties

Si-bronze and 304 stainless steel were joined using gas tungsten arc (GTA) welding with two different welding (filler) rods matching the base metals. Cross-sections of the welds were analyzed using light optical microscopy (LOM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and hardness testing. Mechanical testing was performed for welds from each of the two filler metals using cross-weld tensile bars. For (1) the Si-bronze filler weld, partial mixing resulted in (a) copper-based regions with enhanced hardness due to iron-based islands and (b) iron-based regions with elevated hardness due to Si enrichment. Joint strength was ~ 90% that of the base Si-bronze strength of 340MPa, and elongation was ~ 48%, as compared to the base Si-bronze elongation of 55%. For (2) the stainless steel filler rod (a) primary austenite solidification and (b) micro-fissures were identified in the fusion zone. Thermodynamics calculation software was used to model solidification mode, demonstrating that the Cu (contributed by the Si-bronze) stabilized primary austenite solidification, which led to solidification micro-cracking or micro-fissuring. Micro-fissuring caused low ductility in the transverse weld tensile specimens. Fractography was performed to characterize the fracture mechanisms. For the stainless filler weld, a Cu film formed in interdendritic spaces between primary austenite grains.

Solidification behaviour of laser welded type 21Cr–6Ni–9Mn stainless steel

The solidification mode and microstructures were characterised for various processing parameters for laser welding 21Cr–6Ni–9Mn stainless steel. Two heats with varying nitrogen content showed both primary ferrite and primary austenite solidification. Weld ferrite content varied from 1 to 11 vol.-%, and decreased as travel speed increased. Base metal nitrogen content affected both solidification mode and weld ferrite content. Nitrogen loss from the weld pool was found to range from 10 to 45%, and decreased with increasing travel speed. Solidification mode was dependent on both chemical composition and processing parameters. The solidification mode shifted from primary ferrite to primary austenite as travel speed increased due to increased undercooling. Solidification mode varied within welds with constant nitrogen content, and the change in solidification mode was attributed to changes in undercooling along the weld cross-section. It is proposed that the variation of solidification mode with undercooling is affected by both the solidification rate and thermal gradient.

Metallographic and fracture characteristics of resistance spot welded TWIP steels

In this study, the microstructural characterisation, mechanical testing and fractography investigation were performed on twinning induced plasticity (TWIP) steels, fabricated with resistance spot welding. Failure mode during the cross-tensile test was found to follow the sequences of strain localisation of both sheets, crack initiation at notch tip, crack following along the fusion boundary and, finally, ductile shear fracture along the sheet thickness direction. On the other hand, failure in the tensile shear test was always directed along the sheet/sheet (s/s) interface; the interfacial failure and shear deformation were observed at the weld centreline. Solidification occurred as a primary austenitic solidification mode, and no martensitic transformations were detected through electron backscatter diffraction analysis. The fusion zone was mainly composed of austenite with directional solidification towards the centreline; the columnar dendritic and equiaxed structures were identified. Interdendritic C and Mn cosegregation were confirmed by electron probe microanalysis.

Henry Granjon Prize Competition 2012 Winner Category B: “Materials Behaviour and Weldability” Influence of the [creq+Nieq] Alloy Level on the Transition Between Solidification Modes in Austenitic Stainless Steel Weld Metal

It is well known that primary austenitic solidification modes [A, AF] are related to hot cracking susceptibility in the welding of austenitic stainless steels; therefore the transition between primary austenitic solidification mode [AF] and primary ferritic solidification mode [FA] is of utmost importance and traditionally has been related to a critical Creq /Nieq ratio. This paper presents the experimental results obtained when analysing the effect of alloy level on the transition between solidification modes in austenitic stainless steel weld metals. With this aim, two series of compositions of austenitic stainless steel samples were prepared using an electric arc remelting furnace, keeping the overall alloying composition at two constant levels of [Creq+Nieq] = 30 wt% and [Creq+Nieq] = 40 wt% while changing the Creq/Nieq ratio from 1.22 up to 2.00 in each series. The experimental results show that for an alloy level of [Creq+Nieq] = 30 wt%, the critical Creq/Nieq ratio for the [AF]/[FA] transition takes place between 1.38 and 1.55, while in case of [Creq+Nieq] = 40 wt% the critical Creq/Nieq ratio takes place between 1.28 and 1.32, which is lower in value and narrower in range than the values obtained for the lower alloyed series. A comparison between these experimental results and other authors’ previous research is presented. Results reveal the importance of the alloy level [Creq+Nieq ] as a key parameter in the transition between solidification modes.

Development and Characterization of Novel Corrosion‐Resistant TWIP Steels

AbstractAustenitic steels exhibiting twinning induced plasticity (TWIP) are materials with exceptional mechanical properties. In this work, the development of new grades of TWIP steels exhibiting corrosion resistance is presented. The alloy development was supported by thermodynamic and diffusion calculations within the (FeMnCr)‐(CN) alloy system. For the calculations ambient pressure and primary austenitic solidification were considered as necessary to avoid nitrogen degassing in all processing steps. Manganese is used as an austenite stabilizer, chromium to increase nitrogen solubility and provide corrosion resistance, while carbon and nitrogen provide mechanical strength. Diffusion calculations were used in order to predict the extent of micro segregations and additionally to evaluate the effect of diffusion annealing treatments. The material was cast in a laboratory scale with a nominal composition of Fe‐20Mn‐12Cr‐0.25C‐0.3N. Diffusion annealing was followed by hot rolling and solution annealing resulting in a fully austenitic microstructure. Tensile tests at room temperature were performed, exhibiting yield strengths of 430 MPa and elongation to fracture of 93%. In addition, not only the mechanical properties but also the weldability was studied, focussing on the characterization of the microstructure of bead on plate welds obtained by laser and TIG welding.

Development of Mn-Cr-(C-N) Corrosion Resistant Twinning Induced Plasticity Steels: Thermodynamic and Diffusion Calculations, Production, and Characterization

In this work, the development of corrosion-resistant twinning induced plasticity steels is presented, supported by thermodynamic and diffusion calculations within the (Fe-Mn-Cr)-(C-N) alloy system. For the calculations, ambient pressure and primary austenitic solidification were considered as necessary to avoid nitrogen degassing in all processing steps. Manganese is used as an austenite stabilizer, chromium is used to increase nitrogen solubility and provide corrosion resistance, and carbon and nitrogen are used as interstitial elements to provide mechanical strength. Isopleths of the different elements vs temperature as well as isothermal sections were calculated to determine the proper amount of Mn, Cr, total interstitial content, and the C/N ratio. Scheil and diffusion calculations were used to predict the extent of microsegregations and additionally to evaluate the effect of diffusion annealing treatments. The materials were produced in laboratory scale, being followed by thermomechanical processing and the characterization of the microstructure. Tensile tests were performed with three different alloys, exhibiting yield strengths of 460 Mpa to 480 MPa and elongations to fracture between 85 pct and 100 pct.

Low-Temperature Aging Characteristics of Type 316L Stainless Steel Welds: Dependence on Solidification Mode

Thermal aging embrittlement of light water reactor (LWR) components made of stainless steel cast has been recognized as a potential degradation issue, and careful attention has been paid to it. Although welds of austenitic stainless steels have γ-δ duplex microstructure, which is similar to that of the stainless steel cast, examination of the thermal aging characteristics of the stainless steel welds is very limited. In this investigation, two types of type 316L stainless steel weld metal with different solidification modes were prepared using two kinds of filler metals having tailored Ni equivalent and Cr equivalent. Differences between the two weld metals in the morphology of microstructure, in the composition of δ-ferrite, and in hardening behaviors with isothermal aging at 335 °C have been investigated. The hardness of the ferrite phase has increased with aging time, while the hardness of austenite phase has stayed the same. The mottled aspect has been observed in δ-ferrite of aged samples by transmission electron microscopy (TEM) observation. These characteristics suggest that spinodal decomposition has occurred in δ-ferrite by aging at 335 °C. The age-hardening rate of δ-ferrite was faster for the primary austenite solidification mode (AF mode) sample than the primary ferrite solidification mode (FA mode) sample in the initial stage of the aging up to 2000 hours. It has been suggested that the solidification mode can affect the kinetics of spinodal decomposition.

Modelling of Manganese Sulphide Formation during Solidification, Part II: Correlation of Solidification and MnS Formation

The high temperature properties of steels depend on the solidification parameters and the formation parameters of manganese sulphide precipitates. Therefore, the occurrence of MnS precipitations in relation to primary and secondary microstructures was studied for different steel grades with a primary delta‐ferritic solidification or a primary austenitic solidification. The liquidus and solidus temperatures as well as the δ‐γ‐transformation temperature were calculated thermodynamically and measured by a DTA analysis in order to describe the solidification and transformation temperature range. The MnS formation temperature was calculated thermodynamically and compared to the results of SEM/EDX investigations on fracture surfaces of hot tensile specimens torn at different temperatures after in situ melting and controlled solidification. A special focus of these investigations was the location of MnS precipitates in relation to the primary and secondary grain boundaries. To explain the results, calculations were carried out taking into account the supersaturation of manganese and sulphur during the solidification in residual melt on the primary grain boundaries.

A model for prediction of cracks in a solidifying shell

A model coupling temperature and stress calculations with cracking criteria has been developed in order to predict crack positions in a solidifying shell. The model is based on a one-dimensional FDM approach suitable for continuous casting of slabs. The strain/stress model is based on a purely elastic analysis of a solidifying shell giving a straightforward comparison between stresses and crack criteria. This approach makes the model easy to use. The model is numerically evaluated using available material data for Fe–2%Ni with primary ferrite solidification and Fe–10%Ni with primary austenitic solidification. The results of the calculations are discussed and the impact of material behavior as well as process parameters is evaluated. Evaluation of the influence of changes in the heat transfer coefficient shows that the rapid changes introduce stresses large enough to induce crack formation in the solidifying shell.

Austenite-preferential corrosion attack in 316 austenitic stainless steel weld metals

Pitting immersion test performed on 316 austenitic stainless steel weld metals showed that austenite is the preferential phase for corrosion attack in 3% ferric chloride solution at critical pitting temperature. This is attributed to the primary austenite solidification mode, with the cores of the cellular dendrites depleted in chromium and nickel relative to the normal composition.

Hot cracking susceptibility in laser weld metal of high nitrogen stainless steels

High nitrogen stainless steels are used as structural materials required to possess high strength and fracture toughness at low temperatures. The solidification mode in weld metals of stainless steels is generally designed to be the primary ferrite solidification mode to prevent hot cracking. The weld metals in some high nitrogen stainless steels, however, exhibit the primary austenite solidification mode because of an austenitizing effect of nitrogen, which enhances hot cracking susceptibility. In addition, laser welding provides the primary austenite solidification mode in weld metals of stainless steels due to the high solidification rate. Therefore, the laser weld metal of high nitrogen stainless steels likely occurs hot cracking.This study was conducted to make clear an effect of nitrogen and the solidification rate on hot cracking susceptibility in the laser weld metals of type 304 stainless steels varied with nitrogen content. The hot cracking susceptibility was examined by the preloading tensile strain (PLTS) cracking test. The PLTS test results showed that hot cracking susceptibility was remarkably increased with increase in the solidification rate and the nitrogen content. On the other hand, the solidification mode in the weld metal was changed from the primary ferrite to the primary austenite, as the solidification rate was raised. The primary austenite solidification mode was also observed in the weld metals with higher nitrogen content at lower solidification rate conditions. The experimental results indicated that the increase in hot cracking susceptibility is in agreement with the transition of solidification mode from the primary ferrite to the primary austenite in the weld metal. The transition of solidification mode in the weld metals of high nitrogen stainless steels could be predicted by the calculation using the modified Kurz–Giovanola–Trivedi model considering the effect of nitrogen.

Time-resolved X-ray diffraction investigation of primary weld solidification in Fe-C-Al-Mn steel welds

In situ time-resolved X-ray diffraction (TRXRD) using synchrotron radiation was used to monitor the phase evolution during welding of Fe-C-Al-Mn steel with 0.05 s resolutions. The primary solidification phase under rapid- and slow-cooling rate conditions was examined. The results showed nonequilibrium austenite solidification during rapid cooling; in contrast to the equilibrium δ-ferrite solidification that occurs under slow cooling conditions. These experimental results were analyzed using computational thermodynamics and interface-response function models. Results of the interface response function calculations considering the effect of carbon alone, predicted a change from primary δ-ferrite to primary austenite solidification with an increase in solid-liquid interface velocity.

Effect of nitrogen addition on microstructure and fusion zone cracking in type 316L stainless steel weld metals

Nitrogen is known to have a significant effect on cracking behaviour of austenitic stainless steel during welding, although reports on its effects have often been controversial. A study was therefore undertaken to examine the effect of nitrogen on the weldability of two type 316L weld metals. Weldability was assessed using the longitudinal moving torch Varestraint test. The brittleness temperature range during solidification was calculated from crack length data. Nitrogen was added through the shielding gas to 316L (base N-0.036%) and 316LN (base N-0.073%) to produce weld metal nitrogen contents in the range 0.04–0.19%. In the primary austenitic solidification mode, nitrogen addition had little effect when the P+S levels were relatively low (316LN with 0.031%P, 0.001%S) while cracking increased for higher impurity levels (316L with 0.035%P, 0.012%S). Nitrogen additions also produced significant coarsening of the primary solidification structure. The study indicates that weldability effects of nitrogen may be influenced by the impurity levels, particularly S. The cracking data showed good correlation with the WRC Cr eq/Ni eq ratio.