Weld Metal Research Articles

Fracture toughness and microstructural analysis of rotary friction welded S355J2 and SS316L steels for critical applications

Dissimilar metal welding is seeing growing adoption across industries to enhance structural functionality and efficiency. Achieving high-quality, defect-free dissimilar weld joints requires a comprehensive understanding of the interrelationships between the welding-induced microstructural changes and the material's performance characteristics, particularly its fracture-related properties. This study investigates the impact of microstructural changes on the fracture toughness of dissimilar welds between structural low-carbon steel (S355J2) and austenitic stainless steel (SS316L) prepared using the Rotary Friction Welding (RFW) technique. Welding preforms were created from respective pipe pup pieces. The evaluation involves microstructural analysis, tensile testing, hardness testing, and fracture toughness testing using compact tension specimens derived from various zones of the weld joints. Results revealed significant microstructural differences across the weld joint. The weld region exhibited stable hardness with a maximum of 208 HV1 in S355J2′s thermo-mechanically affected zone (TMAZ). High tensile strength (Ultimate Tensile Strength 540 MPa, Yield Strength 367 MPa) with failures mainly on the S355J2 side. The fracture toughness (KQ) matched parent metal values, with the RFW weld centre line (WCL) showing superior crack tip opening displacement (CTOD) of 0.35 mm. Fractography generally indicates ductile failure.

Computational modeling and virtual analysis using a moving heat source to join AZ61A and AA7075 alloys with the application of a titanium alloy interlayer

Laser beam welding (LBW) uses a concentrated laser beam to fuse materials, providing benefits such as a smaller heat-affected zone (HAZ), speed, accuracy, adaptability across multiple materials, and seamless adoption into automation processes. Achieving optimal weld quality with LBW remains difficult due to the need to select the appropriate welding process variables and proper interlayer between dissimilar materials. Due to the high cost and safety risks to operators and equipment in LBW, it is challenging to use the practical experiment. Additionally, welding materials with high thermal conductivity and lower melting temperatures, such as AZ61A and AA7075, is a considerable challenge. Previous research focused on process parameters in laser beam welding of various metals, but not enough consideration has been given to the effect of a titanium interlayer on AA7075 and AZ61A using virtual data. This study aims to fill these gaps by using simulation data to assess the effects of process parameters and the titanium interlayer during LBW of dissimilar materials. A backpropagation neural network with the gradient descent learning rule was used for optimization, and a central composite design was used to predict the optimal process parameter interaction. The result indicates the optimum equivalent strain is obtained at the values of beam radius between 4.5 to 5 mm. The maximum equivalent stress reached during welding speed is between 4 to 4.5 mm/s. The maximum residual stress was obtained at the number of segments of 160. The predicted maximum and average anticipated errors for peak temperature are 0.1655 % and 0.0210 %, while for residual stress it is computed as 0.1766 % and 0.0754 %. The Ti-interlayer in magnesium and aluminum laser welding reduces peak temperatures, allows for uniform energy distribution, minimizes localized heating, and enhances weld quality while lowering residual stress.

Hardness and Microstructure Characterization of Hardfacing Alloys Deposited by The Shielded Metal Arc Welding (SMAW) on AISI 1045 Medium Carbon Steel

A ring frame is a machine used for yarn production in the textile industry. Continuous use of the machine results in wear on the shaft timing pulley on the ring frame machine. To improve this condition, repairs are needed, one of which uses the hardfacing method. This study aims to determine the effect of hardfacing on the microstructure and hardness of the shaft timing pulley made from AISI 1045. The hardfacing process used the shielded metal arc welding (SMAW) method with welding current variations of 115 A, 125 A, 135 A, 145 A, and 155 A. In this study, the electrode used was AWS A5.1 E7018 with a diameter of 3.2 mm. The hardfacing product obtained was then finished with a lathe to produce a shaft with a final diameter of 30 mm. In this study, microstructure and hardness tests were carried out on specimens before and after finishing. The results of this study showed that an increase in current caused an increase in the number of pearlite phases in the weld metal and HAZ (heat-affected zone) areas. While in the base metal, the increase in current increased the number of ferrite phases. The highest hardness value was found in specimens that were hardfaced with a current of 145 A. However, the hardness of the hardfacing layer will decrease with the use of currents greater than 145 A. The hardness of the specimens with hardfacing treatment at a current of 145 A resulted in hardness in the weld metal, HAZ, and base metal of 225 HV, 209 HV, and 203 HV, respectively. After the finishing process, the weld metal, HAZ, and base metal in this specimen produced a hardness of 225 HV, 217 HV, and 208 HV, respectively.

Investigation of Process Parameters on the Mechanical Strength in Ultrasonic Metal Welding of Aluminum to Copper Dissimilar Joints

Investigation of Process Parameters on the Mechanical Strength in Ultrasonic Metal Welding of Aluminum to Copper Dissimilar Joints

Timed Thermodynamic Process Model Applied to Submerged Arc Welding Modified by Aluminium-Assisted Metal Powder Alloying

An EERZ (effective equilibrium reaction zone) model was applied to the modified SAW (submerged arc welding) process to simulate the SAW process metallurgy in the gas-slag-metal reaction system. The SAW process was modified by adding Al as a de-oxidizer with alloying metal powders of Cr, Cu, and Ti. The static gas-slag-metal equilibrium model can accurately calculate the weld metal oxygen content (ppm O) for conventional SAW but not for the modified SAW process. The static equilibrium model overpredicts the reaction of Al. EERZ model runs were made for 2000–2500°C because this is the reported temperature range in the SAW arc cavity. The weld metal composition was adequately calculated, especially the weld metal ppm O, at the following effective equilibrium temperatures: 2400°C for Al-Cr additions, 2200°C for Al-Cr-Cu additions, and 2000°C for Al-Cr-Cu-Ti additions. Model results show that Ti metal powder can serve a de-oxidizer role in the presence of Al, resulting in Ti loss to the slag. Ti is also lost to the gas phase as TiF3(g) and TiF2(g) compared to little loss of Cr to the gas phase as Cr(g) and CrO to the slag phase.

Pitting behavior of austenitic stainless-steel welded joints with dense inclusions and methods to enhance pitting resistance

PurposeThis study aims to assess the pitting resistance of austenitic stainless steel welded joints fusion zone (FZ) with high density of inclusions before and after surface treatment, including potentiostatic pulse technique (PPT) and pickling.Design/methodology/approachThe potentiodynamic polarization tests and critical pitting temperature tests were carried out for estimating pitting resistance. The PPT and pickling were performed as surface treatment. Scanning electron microscope (SEM) and energy dispersive spectrometer were used for characterize the microstructure and elemental distribution. Electron back-scattered diffraction (EBSD) was used to assess the portion of phases and morphology of grains.FindingsThe weld metal exhibits a higher degree of alloying compared to the base metal, and it contains d-phase and sulfur-containing inclusions. Sulfur-containing inclusions serve as initiation sites for pitting, and they diminish the pitting resistance of weld metal. Both PPT and pickling can remove sulfur-containing inclusions, but PPT causes localized dissolution of the weld metal matrix around the inclusions, while pickling does not. Because of the high density of inclusions, certain pits initiated by PPT are significantly deeper, which makes the formation of stable pitting easier. Because of the high density of inclusions, certain pits initiated by the PPT are deeper. This characteristic facilitates the progression of these initial defects into fully developed, stable pits.Originality/valueAnalysis of pitting initiation in shielded metal arc welding FZ with PPT and ex situ SEM tracking observation. Explanation of why the PPT surface treatment is not able to enhance the pitting resistance of stainless steel with a high inclusion density.

The corrosion analysis of X80 pipeline steel welded joint using wire beam electrode and numerical simulation methods

PurposeThe purpose of this study is to characterize the galvanic corrosion behavior of a simulated X80 pipeline steel welded joint (PSWJ) reconstructed by the wire beam electrode (WBE) and numerical simulation methods.Design/methodology/approachThe galvanic corrosion of an X80 PSWJ was studied using WBE and numerical simulation methods. The microstructures of the coarse-grained heat affected zone, fine-grained heat affected zone and intercritical heat affected zone were simulated in X80 pipeline steel via Gleeble thermomechanical simulation processing.FindingsComparing the corrosion current density of coupled and isolated weld metal (WM), base metal (BM) and heat-affected zone (HAZ), the coupled WM exhibited a higher corrosion current density than isolated WM; the coupled BM and HAZ exhibited lower corrosion current densities than isolated BM and HAZ. The results exhibited that the maximum anodic galvanic current fitted the Gumbel distribution. Moreover, the numerical simulation results agreed well with the experimental data.Originality/valueThis study provides insight into corrosion evaluation of heterogeneous welded joints by a combination of experiment and simulation. The method of reconstruction of the welded joint has been proven to be a feasible approach for studying the corrosion behavior of the X80 PSWJ with high spatial resolution.

Effects of Weld Metals and Heat Input on the Softening of Gas Metal Arc Welded Joint for Abrasion Resistant Steel

Effects of Weld Metals and Heat Input on the Softening of Gas Metal Arc Welded Joint for Abrasion Resistant Steel

Joint Quality Assessment of Ultrasonic Metal Welded Parts by Fracture Surface Evaluation

In ultrasonic metal welding, low specific resistances and large joining surface cross-sections require the use of mechanical testing to quantify the joint quality. In this study, different quality features of ultrasonically welded joints made of pure copper sheet are investigated during the successive phases of joint formation. Two test series with different workpiece geometries are examined. It is shown that mechanical quality features such as shear and peel forces behave differently over the formation of the joint and are not transferable. As an alternative to these, laser scanning microscopy is used to record images of the fracture surface that describe the growth of the joint area during formation. The study finds that shear tensile force growth and joint area growth are non-linear and comparable, with optimized welds achieving joint areas of 30 mm2 out of 64 mm2 and 6 mm2 out of 16 mm2. Although overall quality increases with increasing welding time, the material strength in the joint zone decreases. Depending on the original rolling condition, between 43% and 59% of the original material strength can be identified as the joint strength. The automatic analysis of fracture images is a suitable alternative to mechanical testing for similar joints.

Flux-cored arc welding of 316L austenitic stainless steel: the effect of different shielding gas mixtures on microstructural features and weld performance

ABSTRACT Double-pass flux cored arc welding (FCAW) of 316 L austenitic stainless steel was performed using different shielding gas mixtures. Microstructural features and weld performance were evaluated. Based on the Creq/Nieq ratio of fusion zone and cooling rate, different morphologies of ferrite (skeletal, lathy, and dendritic) and austenite with various volume fractions were produced. An increase in Creq/Nieq ratio can increase the strength level because the presence of ferrite in the weld metal acts as a second-phase strengthening agent. On the other hand, ferrite is a suitable place for sigma phase precipitation. Highest joint efficiency resulted in the specimen welded via GTAW. The ductility of welds was ranked as CO2 +Ar shielded FCAW > GTAW > CO2 shielded FCAW > self-shielded FCAW. At room temperature, variation of delta-ferrite content (Creq/Nieq ratio) does not affect toughness. However, an increased amount of CO2 in shielding gas will result in decreased toughness values because of the enhanced formation of oxide inclusions. Increasing CO2 content of shielding gas from 0% to 18% and finally to 100% will result in decreasing toughness values from the highest value of 76J to 40 J and finally the lowest value of 38J.

The formation control and microstructure evolution of macrosegregation in laser offset welding on steel-nickel dissimilar alloy

To precisely control the melting of two base metals, laser offset welding is an effective method for managing the interfacial microstructure in dissimilar metal welds. Macrosegregation exhibits a markedly different morphology near the steel-nickel fusion line, which plays an important role in premature creep failure. In this study, it was found that an offset of the laser beam towards the nickel correlated with an increase in macrosegregation. When the laser beam was biased towards the steel, the partially mixed zone (PMZ) and transition zone (TZ) of 9Cr steel were identifiable within the macrosegregation, displaying a distinct solidification mode. Lath martensite and fine austenite formed in the PMZ, with alternating distributions of martensite and austenite observed in the TZ. Conversely, when the laser beam was biased towards the nickel, the unmixed zone (UMZ) of 9Cr steel was observed within the macrosegregation. Nanoindentation tests revealed that the maximum nanohardness in macrosegregation reached 5.90 GPa in the PMZ due to the formation of lath martensite, while the minimum nanohardness was 1.30 GPa in the TZ due to reduced martensite formation. Additionally, the TZ exhibited a significant reduction in resistance to plastic deformation. The various microstructures of macrosegregation were attributed to the solidification process and the dilution rate of 9Cr steel. When the liquidus temperature of WM exceeded 1455℃, a wide TZ formed in the macrosegregation due to adequate mixing. In contrast, when the WM had a significantly lower liquidus temperature than the 9Cr steel, only UMZ and PMZ formed in the macrosegregation due to preferential solidification and insufficient mixing. To minimize macrosegregation and eliminate the softening TZ, a laser beam offset towards the steel between 0.1 mm and 0.2 mm is recommended.

The effect of laser surface melting on the microstructure, microsegregation and solidification path of service-aged ECY768 cobalt-based gas turbine nozzle

In this study, the laser surface melting of cobalt-based superalloy ECY768, which has been in service for 40,000 h at a temperature of 1000 °C, has been investigated. Subsequently, laser surface welding and post-welding heat treatment is performed on the samples. This study was conducted in order to restore the microstructure of the damaged service-aged gas turbine nozzle to as-cast state. The results showed that by performing laser surface remelting, the microstructure of as-cast state can be approached. Also, the results of this study have investigated the weldability, microsegregation and solidification path of this superalloy, and it can be used in the repairing this superalloy in the industry. Laser surface melting was performed using a continuous wave fiber laser at various speeds of 10, 12, 14, 20, 50, and 70 mm/s. The microstructure and phase characteristics of the samples were examined using optical and scanning electron microscopes. Upon analyzing the macrostructure of the weld metal, it was observed that the depth of the melt zone at the speed of 12 mm/s is 585 ± 40 μm. In the investigating the microstructure of the solidification modes, namely planar, cellular, columnar dendritic, and equiaxed dendritic, it was observed that microsegregation occurs during laser welding of the samples due to the presence of heavy elements such as tantalum and tungsten. The solidification distribution coefficient for tantalum was calculated to be 0.37, which increased to 0.60 after the solution annealing heat treatment, resulting in an improved segregation behavior. Characterizing the surface hardness profiles of laser-melted samples it was observed that the hardness in the melt zone significantly increased compared to the base metal. The results of the current research indicate that the weldability (resistance to various welding defects, especially hot cracks) of the cobalt-based superalloy ECY768 is acceptable, and this process can be used for rejuvenating service-aged ECY768 cobalt-based gas turbine nozzle.

Comparative corrosion behavior of three titanium alloy base materials and their welds in a simulated chimney environment

This study investigates the corrosion behavior of titanium alloys (TA2, TC4, TB6) in a 3 % sulfuric acid flue gas environment using electrochemical tests and microscopic analyses (SEM/EDS, XRD, metallographic microscopy). Results show that TA2 base metal has lower corrosion resistance compared to its weld metal, while TC4 and TB6 exhibit opposite trends. Specifically, TC4 and TB6 base metals have lower corrosion current densities (0.9 and 0.5 μA/cm2) and higher corrosion potentials then their weld metals (1.93 and 2 μA/cm2). In contrast, TA2 base metal showed higher corrosion current density (2 μA/cm2) than its weld metal (0.35 μA/cm2) and HAZ metal (0.16 μA/cm2).Microscopic analyses reveal β phase transitions in TC4 and TB6 weld areas, leading to larger grain sizes and reduced corrosion resistance. Conversely, TA2 retains finer grains post-welding, enhancing its corrosion resistance. These insights clarify weld corrosion effects and provide valuable guidance for industrial applications of titanium alloys, particularly in designing and maintaining titanium alloy chimneys.

The electrochemical corrosion performance of aluminum alloys grade 6082-T6 weld repair

This research investigated the corrosion behavior of standard current metal inert gas weld repair for 6082-T6 aluminum alloy using ER5356 filler metal. The new and repaired (NW and RW) welds were studied. The welds comprised the weld metal (WM), the heat affected zone (HAZ) (solid solution and softened zones), and the base metal (BM). The study focused on investigating electrochemical corrosion using polarization and electrochemical impedance spectroscopy (EIS) methods in 3.5% NaCl solutions, especially in HAZ, including metallurgical and mechanical examinations. The BM containing an α-Al matrix with Al(Fe,Mn)Si and Mg2Si phases exhibited the maximum hardness (70–104 HV0.1). The WM hardness decreased (67–76 HV0.1) with the α-Al, β-Mg3Al2, and Mg2Si phases. Despite having comparable phases to BM, HAZs showed lower hardness (Solid HAZ: 70–82 HV0.1) due to more intermetallic phases. The RW’s softened HAZ revealed the minimum hardness (52–63 HV0.1) compared to that of the NW (55–70 HV0.1). Besides, the tensile strength of the RW (179.7 MPa) was also lower than that of the NW (174.4 MPa) because of the reheating effect. The electrochemical corrosion results indicated that the BM exhibited the maximum corrosion resistance (the lowest corrosion current density (icorr), the highest corrosion potential (Ecorr), and the charge transfer resistance (Rct)), followed by the HAZ and the WM, respectively. The softened HAZ demonstrated better corrosion resistance than the solid solution HAZ. Conversely, the over-aging effect reduced the softened zone’s pitting corrosion resistance (Ep) compared to the solid solution zone. The RW exhibited inferior corrosion resistance compared to the NW due to increased intermetallic phases, which was consistent with the mechanical results. However, the RW’s softened HAZ corrosion characteristics were inconsistent with its mechanical properties; its hardness and tensile strength were the lowest, but its corrosion resistance was not. Pitting corrosion was observed on the weld surfaces using the SEM.

Microstructure and mechanical properties of welds of AZ31B magnesium alloy produced by different gas tungsten arc welding variants

This work aimed to (i) understand conventional and pulse gas tungsten arc welding (GTAW) of AZ31B, and (ii) explore high frequency welding (100 Hz–1500 Hz). GTA welding with alternating current (AC) and direct current electrode positive (DCEP) polarities yielded crack-free partial penetration welds for 6 mm thick AZ31B alloy sheet. Welding under direct current electrode negative (DCEN) polarity with identical parameters as that for AC and DCEP resulted in full penetration welds that had microcracks. Defect-free full-penetration welds could be accomplished with pulse GTA welding using DCEN polarity at a pulse frequency of 1 Hz with a pulse duration ratio of 1:1. The resultant DCEN P 1:1 weld metal had a microstructure finer than the conventional DCEN weld. Welds produced with pulse duration ratios of 1:2 and 1:4 lacked penetration but had a much finer microstructures because of the lower heat input. The arc constriction by the high frequency pulsing in the ActivArc®-High frequency (AA-HF) mode welding was responsible for deeper penetration. Welds produced under DCEN pulsing and AA-HF conditions had hardness higher than conventional DCEN, DCEP and AC GTA welds, attributed to the finer microstructure. AA-HF GTA welding produced defect free deeper penetration welds with good microstructural features/mechanical properties and also gave an advantage of 50% enhanced productivity when welded at 1500 Hz.

Enhancing NDE Reliability for Grade 91 Steel Welds: Ultrasonic Imaging and Microstructural Correlations

Ensuring the integrity of Grade 91 (9Cr-1Mo-V) steel welds is vital for the safe and reliable operation of fossil fuel–fired and nuclear power plants. This study applies an imaging technique for the ultrasonic characterization of two Grade 91 steel welds created with cold metal transfer and flux-cored arc welding processes. Ultrasonic immersion testing in the through-transmission configuration was employed to generate shear waves, which helped identify the weld metal, heat-affected zone, and base metal regions. These weld microstructures were also correlated to their ultrasonic images using metallography, ultrasonic amplitude, hardness measurements, and grain size. The findings from this study can assist practitioners in developing new nondestructive evaluation technologies, improving the inspection reliability of creep strength–enhanced ferritic steel welds by potentially identifying weld microstructure regions susceptible to creep-type failures.

Effect of cobalt on Microstructure and toughness properties of 9Cr-1.8W-0.4Ni-xCo weld metal

In this research, microstructural characterization and mechanical properties of 9%Cr, 0.4%Ni (including W and Mo) steel weld metal with alloyed cobalt were investigated. Due to their strong creep resistance, oxidation resistance, and low thermal expansion, 9%Cr steels are used in nuclear power plants, petrochemical industries, and fossil fuel-powered power plants that operate in high temperature conditions. In this context, weld metals comprising 0.5 %, 1 % and 1.5 % cobalt and cobalt-free weld metal were produced by SMAW (shielded metal arc welding) technique. Microstructure of the weld metals were characterized with optical microscope (OM), scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). Also, XRD analysis was performed on the bulk samples and precipitated carbide/nitride phases extracted from the weld metals. In addition, differential scanning calorimetry (DSC) was used to determine the phase transformations. Thermo-Calc modeling study was also performed. Hardness, tensile and Charpy-V impact tests were carried out to determine the mechanical properties. The hardness did not change significantly when cobalt up to 1.5 % in the weld metal. However, with the increase of cobalt, the yield and tensile strength increased without affecting the elongation value too much. In the Charpy impact tests performed at different temperatures (−40 °C, −20 °C, +20 °C, +40 °C, +60 °C), the amount of cobalt increased toughness, especially at +40 and + 60oC temperatures. Ductile brittle transformation temperature (DBTT) of the weld metal with 1.5 % Co decreased from 29 °C to 15 °C compared to cobalt free weld metal. It is thought that this may be caused by the further separation of C, Cr and W from the matrix through forming precipitate by the cobalt effect. Besides the mechanical properties, microstructure was also affected by adding Co with inhibition of delta ferrite formation which decrease the toughness. Curie temperature increased with increasing cobalt content detected by DSC.

Creep rupture properties of dissimilar welded joint of ferritic/martensitic P92 steel and Inconel 617 alloy

The dissimilar welded joint (DWJ) comprising P92 steel and Inconel 617 (IN617) is frequently utilized in advanced ultra-supercritical (AUSC) boilers. In present work the creep rupture behaviour, rupture mechanism and microstructure evolution of DWJ of P92 steel and IN617 with Ni-based ERNiCrCoMo-1 filler, were examined at 650 °C under the stress range of 120–200 MPa. The results of the creep test indicated that the location of creep rupture varied across different testing conditions, encompassing areas such as P92 base metal and the fine-grained heat-affected zone (FGHAZ). The creep tested specimens within the stress range of 180–200 MPa exhibited failure originating from P92 base metal, predominantly influenced by plastic deformation. The failure manifested in a transgranular mode, driven by the formation, growth, and eventually coalescence of microvoids. The creep tested specimens within the stress range of 120–150 MPa displayed the characteristic ofType IV failure, primarily attributed to matrix softening and the absence of adequate precipitates to pin the PAGBs. Microstructural characterization unveiled the presence of microvoids along the PAGBs, facilitating microvoid nucleation primarily owing to the existence of the coarse brittle carbide phase. The growth of these microvoids over a period of time during tertiary stage of creep which lead to their coalescence and the formation of microcracks, ultimately resulting in premature intergranular failure. The specimen creep exposed at 650 °C under the lower stress of 120 MPa exhibited higher creep rupture life for 432 h. The SEM/EDS study of the crept sample of 120 MPa is also confirmed the presence of intermetallic laves phases in regions near the fracture tip and in the heat-affected zones (HAZs). Although the creep tested specimens at 150 MPa and 120 MPa exhibited failure in the FGHAZ and their elemental SEM/EDS analysis confirmed the presence of an oxide layer and notch formation near the interface of P92 base metal and ErNiCrCoMo-1 filler weld. The FESEM study revealed the growth of the oxide layer in the notch region, and it also showed the presence of multiple cracks and microvoids in the oxide layer. The formation and propagation of the oxide notch mainly led to the interfacial failure. The crept specimens subjected to 180 MPa and 200 MPa did not exhibit any cracks or microvoids in HAZs. However, specimens that failed under applied stresses of 120 MPa and 150 MPa revealed the presence of a high density of microvoids in the FGHAZ, inter-critical heat-affected zone (ICHAZ), and in the region of the coarse-grained heat-affected zone (CGHAZ) adjacent to the interface attached with an oxide layer.

Effect Submerged Arc Welding (SAW) of Angular Distortion of T-joint

Submerged Arc Welding(SAW),the molten weld metal is immersed in aflux that protects it from air contamination, forming welding slag which is strong enough to protect the weld metal until it solidifies. The used electrode was AWSA5.17EL12. The base metal being welded is ASTM A283 Grade A. In this study, the effect of angle distortion on the T joint was observed by changing the welding parameters. In order to obtain the optimal results, an attempt was made to link the welding parameters to the angle distortion through a mathematical model by using the Box Behnken statistic technique, the feasibility of which was then tested by using ANOVA analysis. What was obtained was analyzed with the help of the response surface methodology (RSM = Response Surface Methodology) then

Macroscopic and microscopic element distribution in transition zones of GTAW Alloy 52M weld joint and its PWSCC growth behaviour

The microstructure and element distribution in the transition zone (TZ) of Alloy 52M buttering (52Mb) layer near the fusion boundary to the SA508III low alloy steel in a dissimilar metal weld joint with post-weld heat treatment (PWHT) is characterized. Two macroscopic TZs in the heat-affected zone have lower Cr and Ni contents than the bulk Alloy 52Mb. The first TZ near the fusion boundary has the lowest Cr and Ni compositions, accompanying the highest Fe content. Cr depletion and Ni enrichment along with slight Fe enrichment at the dendrite boundaries in the TZs, are more significant than those in the bulk Alloy 52Mb. The number and the maximum depth of local oxidation penetrations at the alloy-inner oxide interface based on the oxidation tests, the number and the maximum length of locally interdendritic cracks, as well as the average crack growth rate (CGR) in terms of the stress corrosion cracking (SCC) band based on the SCC tests in the first TZ are higher than those in the second TZ. The average SCC CGR is enhanced by macroscopic element dilution, while local oxidation penetration, as well as locally interdendritic SCC, are thought to be enhanced by both the macroscopic dilution of Cr in the TZs and the microscopic Cr depletion at dendrite boundaries.