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This paper describes a high-current Gas Metal Arc Welding (GMAW) process using a constant voltage power source developed for high-efficiency welding of thick stainless steel plates. A short arc len...

The formation mechanism of microstructure of duplex stainless steel weld metals with different N content and heat input and the effects of microstructural factors on pitting corrosion resistance of...

Solidification cracking has been a serious problem in austenitic stainless steels. Since solidification cracking often occurs at the solidification grain boundary, the grain boundary character distribution (GBCD) in the weld metal may affect the solidification cracking susceptibility. On the other hand, the columnar grains of the weld metal are formed by the epitaxial growth from the grains in the base metal. Therefore, it is expected that microstructure and cracking susceptibility of the weld metal can be reduced by controlling the microstructure of the base metal. In this study, the effect of microstructure of the base metal on the microstructure and solidification cracking susceptibility of the weld metal was examined. The GBCDs of the base metal of the type 310S stainless steel were changed by the thermomechanical process. The solidification cracking susceptibility was evaluated by the Trans-Varestraint test. The thermomechanically processed specimen had larger ratio of coincidence site lattice (CSL) boundaries compared with those of the as-received specimen. Moreover, the specimen was found less susceptible to solidification cracking than was the as-received material. The GBCD analysis indicated that the complex shape and distribution of the grain boundaries in the thermomechanically processed specimen affect the initiation and propagation of solidification cracks.

The relationship between grain boundary segregation behaviour of sulphur and intergranular fracture in 10% nickel steel weld metal solidified with austenite single phase was investigated. In the wel...

To optimize welding conditions that ensure the safety and reliability of laser welds, this study established an evaluation method of the fatigue strength for the laser welds of steel sheets over a short period of time. This study focuses on a fatigue limit estimation based on dissipated energy which is caused by micro plastic deformation. As a result, the area at which the temperature changes, due to dissipated energy, is locally high is the fracture origin of the laser welds. The fatigue limit of the laser welds is almost the same as the stress amplitude at which a temperature change occurs due to dissipated energy.

Varestraint test is one of the most-used methods to evaluate weld solidification cracking susceptibility. However, the standard about the detailed test method and the evaluation method has not been ...

The 355 aluminium alloy is known to have excellent thermodynamic characteristics that render it suitable as a raw material for rheocasting and thixoforming. However, besides the controllable transition from solid to liquid phase, the refined microstructure required in the semisolid range is one of the key factors with a strong influence on the rheology of the material. This paper intends to analyse the in situ behaviour of the microstructure, in terms of morphological change, using high-temperature laser scanning confocal microscopy. The 355 alloy was prepared via conventional casting, and refined with a 30-s exposition via ultrasonic melt treatment (UST - 20 Hz, 2 kW). The material was reheated up to the thixoforming target temperature of 595 °C at which it was maintained for 0, 30, 60, 90, and 120 s, after which all the samples were cooled in water. The samples subjected to UST prior to the heat treatment were more refined in terms of microstructural evolution; they exhibited reduction in grain size (~107 ± 16 μm), smallest primary phase particle size (~81 ± 7 μm), and high circularity shape factor (~0.59 ± 0.19 μm). In situ observation methods were employed to analyse evolution mechanisms such as Ostwald ripening and coalescence.

The nanoscale structure of ferrite in a 22% Cr duplex stainless steel weld metal (fabricated with grade 2209 filler wire) aged at 400 °C was characterized via scanning transmission electron microscopy with energy-dispersive X-ray spectroscopy through the Super-XTM detector; the results were compared with those of a corresponding grade base metal (2205). The weld metal-ferrite exhibited a more pronounced spinodal decomposition than the base metal-ferrite because of its higher Ni content. Moreover, the presence of Ni-rich solute clusters with a body-centered-cubic structure was notably evident in the weld metal-ferrite. The investigation of the precipitation hardening mechanism using the Ardell model confirmed that, besides the extended spinodal decomposition, Ni-rich solute clusters significantly contributed to the improved age hardening performance of the weld metal-ferrite in the 22% Cr duplex stainless steel.

The present study has demonstrated the differences in the 475 °C embrittlement behavior of the base and weld metals of a 22 mass% Cr-duplex stainless steel. A grade 2205 solution-annealed plate was used as the base metal. The corresponding Ni-rich weld metal, which comprised multiple layers, was fabricated using a grade 2209 filler wire. The base and weld metals were subjected to isothermal aging for various durations (up to 1000 h) at 400 °C. Microstructural characterization, Charpy impact toughness testing, and Vickers microhardness measurements were conducted before and after aging. Furthermore, the microstructure of the ferrite phase, after aging, was evaluated using transmission electron microscopy (TEM). There was a substantial decrease in the impact toughness in both the base and weld metals with increasing aging time, although the decrease in the impact toughness was more pronounced for the weld metal. The hardening of ferrite was more prominent in each layer of the weld metal than in the base metal. The TEM observations indicated that the ferrite phase in both the base and weld metals underwent spinodal decomposition, which was accelerated in the weld metal. Regarding the major alloying elements (i.e., Cr, Mo and Ni) contained in the ferrite phase, the content of each, Cr and Mo, was lower in each layer of the weld metal than in the base meal, while the Ni content was, conversely, higher in each layer of the weld metal than in the base metal. The higher Ni content promoted the decomposition of ferrite in each layer of the weld metal during aging. This resulted in an acceleration of the 475 °C embrittlement in the multilayered weld metal of the 22 mass% Cr duplex stainless steel compared to the base metal.

Studies on intragranular ferrite with ultra-low O content are scarce, and establishing a technology for the refinement of the microstructure of a weld metal with ultra-low O content through the formation of intragranular ferrite is challenging. In this report, the effect of addition of Ti and Al on the formation of intragranular ferrite in ultra-low-oxygen weld metals was studied. The formation process of the oxide was discussed based on the detailed observation of the oxides and thermodynamic calculations. In the weld metal of Ti added steel with the highest intragranular ferrite area fraction, it was observed that the significant Mn depleted zone (MDZ) formed around a complex oxide containing Ti, Mn and Si. The formation of the MDZ increases the transformation temperature around the oxide and promotes the formation of intragranular ferrite with the oxide as a nucleus. Since the increase in Mn content at equilibrium due to the change in the stable phase during cooling is larger for the inclusion in Ti added steel, it was considered that more Mn diffused from the matrix to the inclusion in Ti added steel and the MDZ formed at the interface between matrix and the inclusion. The promotion of intragranular ferrite formation in an ultra-low-oxygen weld metal is enhanced by oxides with a large increase in the equilibrium Mn content during cooling.

A novel strategy with shot peening (SP) pretreatment was proposed to prevent heat-affected zone liquation cracking during laser cladding of K447A nickel-based superalloy powder over its non-weldable cast structure. High dislocation density accumulated by the SP pretreatment drove the high-temperature zone of the heat-affected zone to recrystallize during the laser cladding process, as a result, the coarse columnar grain with an average dendrite stem and secondary dendrite arm width of 102.67 ± 4.24 μm was transformed into a fine equiaxed grain with an average size of 10 μm. SP could effectively inhibit liquation cracking. With the increase of SP duration, the tendency of the liquation cracking reduced. Compared with no SP BM, the total length of the liquation cracking in the longitudinal section of the laser cladding sample reduced from 1649 μm to 248.8 μm. In-situ experimental observation and process simulation were opted to study the evolution behavior of recrystallization. Recrystallization firstly developed in the region of the intergranular zone at ~1214 °C and gradually the base metal recrystallized between 1232 and 1242 °C except for the region with γ/γ′ eutectic structure. As the temperature rose further, a fine liquid film network developed in the range of 1260–1267 °C. Finally, the stress and strain-based criteria were exercised to evaluate the crack susceptibility of the liquid film. The fine liquid film network adequately constrained the liquation cracking by reducing the driving stress applied to the liquid film as well as by lowering the pressure drop of the liquid film caused by driving strain.

The influence of the chemical composition, especially the niobium content, chromium equivalent Creq, and nickel equivalent Nieq, on the weld solidification cracking susceptibility in the austenite single-phase region in the Schaeffler diagram was investigated. Specimens were fabricated using the hot-wire laser welding process with widely different compositions of Creq, Nieq, and niobium in the region. The distributions of the susceptibility, such as the crack length and brittle temperature range (BTR), in the Schaeffler diagram revealed a region with high susceptibility to solidification cracking. Addition of niobium enhanced the susceptibility and changed the distribution of the susceptibility in the diagram. The BTR distribution was in good agreement with the distribution of the temperature range of solidification (ΔT) calculated by solidification simulation based on Scheil model. ΔT increased with increasing content of alloying elements such as niobium. The distribution of ΔT was dependent on the type of alloying element owing to the change of the partitioning behavior. Thus, the solidification cracking susceptibility in the austenite single-phase region depends on whether the alloy contains elements. The distribution of the susceptibility in the region is controlled by the change in ΔT and the segregation behavior of niobium with the chemical composition.

Laser cladding with a paraxial powder-feeding device was used to repair as-cast K447A nickel-based superalloy, a kind of non-weldable alloy with a high Hf content and working as gas-turbine hot-section components. In the present study, the metallurgical evolution behavior of liquid film and liquation cracking mechanisms are studied. The results showed that a kind of uncommon Ni21Hf8 phase was found in the incipient melting regions (IMR) of the intergranular region. In the thermal cycle, γ/Ni21Hf8 eutectic liquefaction, M5B3 dissolved, and γ/γ’ eutectic liquefaction successively occurred in the heating process in IMR, and liquid → γ + γ/γ’ + M5B3 + γ/Ni21Hf8 → γ + γ’(3) + γ/γ’ + γ/Ni21Hf8 + M5B3 occurred in the cooling process. The inhomogeneity of the intergranular structure leads to the liquid film with the characteristics of discontinuous distribution and uneven width. The cracking criterion of the liquid film was established based on pressure drop. When the closed liquid film meets the condition of 2 γ sl 1 / K * ( ρ s / ρ l − 1 * R * dt + ∆ h e ) , the liquid film with a thickness that is greater than critical thickness will be induced into a liquation cracking.

To investigate the effect of alloying elements on the microstructure and mechanical properties of medium-carbon steel weldments, 0.4% carbon steels with different chromium and titanium contents were fabricated by melting and hot-rolling for friction stir welding (FSW). The microstructures in the stir zones of friction stir welded (FSWed) medium-carbon steels without chromium, with 1% chromium and 4% chromium are ferrite and pearlite, bainite, and fully lath martensite, respectively. The prior austenite grain size was refined by the addition of titanium. High densities of ultrafine-twins are observed in the martensite of FSWed 0.4%C–4%Cr and 0.4%C–4%Cr-0.2%Ti steels, while dense auto-tempered iron carbides with less ultrafine-twins are observed in the lath martensite of FSWed 0.4%C–4%Cr-0.4%Ti steel. The strength of FSWed 0.4%C–4%Cr steels is improved by the martensitic structure, while the ductility of 0.4%C–4%Cr steels decreases significantly compared to that of 0.4%C steels with low chromium content. A small amount of 0.4% titanium addition significantly increases the ductility of 0.4%C–4%Cr-0.4Ti steel, leading to a good combination of high strength of 2270 MPa and high elongation of 18.3%. The substructure changes of the lath martensitic structure caused by the addition of titanium contribute to the brittle to ductile transition of FSWed medium-carbon steel with 4% chromium.

The coupling of a hot tensile test with a novel in situ observation technique using a high-speed camera was investigated as a high-accuracy quantitative evaluation method for ductility-dip cracking (DDC) susceptibility. Several types of Alloy 690 filler wire were tested in this study owing to its susceptibility to DDC. The developed test method was used to directly measure the critical strain for DDC and high temperature ductility curves with a gauge length of 0.5 mm. Minimum critical strains of 1.3%, 4.0%, and 3.9% were obtained for ERNiCrFe-7, ERNiCrFe-13, and ERNiCrFe-15, respectively. The DDC susceptibilities of ERNiCrFe-13 and ERNiCrFe-15 were nearly the same and quite low compared with that of ERNiCrFe-7. This was likely caused by the tortuosity of the grain boundaries arising from the niobium content of around 2.5% in the former samples. Besides, ERNiCrFe-13 and ERNiCrFe-15 indicated higher minimum critical strains even though these specimens include higher content of sulfur and phosphorus than ERNiCrFe-7. Thus, containing niobium must be more effective to improve the susceptibility compared to sulfur and phosphorous in the alloy system.

Surface melting by gas tungsten arc (GTA) welding and overlaying by cold metal transfer (CMT) brazing using low melting point filler wire were investigated to develop a repair process for cracks in worn cast steel of steam turbine cases. Cr-Mo-V cast steel, operated for 188,500 h at 566 °C, was used as the base material. Silver and gold brazing filler wires were used as overlaying materials to decrease the heat input into the base metal and the peak temperature during the welding thermal cycle. Microstructural analysis revealed that the worn cast steel test samples contained ferrite phases with intragranular precipitates of Cr7C3, Mo2C, and CrSi2 and grain boundary precipitates of Cr23C6 and Mo2C. CMT brazing using low melting point filler wire was found to decrease the heat input and peak temperature during the thermal cycle of the process compared with those during GTA surface melting. Thus, the process helped to inhibit the formation of hardened phases such as intermetallics and martensite in the heat affected zone (HAZ). Additionally, in the case of CMT brazing using BAg-8, the change in the hardness of the HAZ was negligible even though other processes such as GTA surface melting cause significant changes. The creep-fatigue properties of weldments produced by CMT brazing with BAg-8 were the highest, and nearly the same as those of the base metal owing to the prevention of hardened phase formation. The number of fracture cycles using GTA surface melting and CMT brazing with BAu-4 was also quite small. Therefore, CMT brazing using low melting point filler wire such as BAg-8 is a promising candidate method for repairing steam turbine cases. However, it is necessary to take alloy segregation during turbine operation into account to design a suitable filler wire for practical use.

The purpose of this study is to evaluate the corrosion resistance of weld metal by electrochemical methods and discuss the relationship between microstructure and corrosion resistance. Intergranular and pitting corrosion resistances were measured using electrochemical potentiokinetic reactivation (EPR) test and pitting potential measurement respectively. The reactivation ratio and pitting potential corresponded to its chemical composition. The specimens containing more Cr and Mo showed higher resistance. In the EPR test, the dendrite core with a relatively low Cr content was corroded. In the pitting corrosion test, Nb carbide became the initiation site of pitting corrosion which propagated along the cell structure.

The effect of secondary phase formation such as MC carbide during welding on solidification cracking susceptibility of fully austenitic stainless steels with various amounts of alloying elements and carbon was investigated. The solidification cracking susceptibility of Fe-24mass%Cr-26mass%Ni stainless steels with various amounts of niobium, titanium, zirconium, and carbon was evaluated by the Trans-Varestraint test. The addition of alloying elements such as niobium, titanium, and zirconium increased the brittle temperature range (BTR). The BTRs depend on the type and combination of the alloying elements and carbon content. Titanium was the most influential element on the increase in BTR compared to the other elements. The increase in carbon content tended to decrease the BTR, especially for the specimen containing titanium. The alloying elements formed phases such as the film-like MC-type carbide (MC) phase and granular Laves phase in the specimens containing 0.05% C, and a lot of the acicular MC phases in the specimens containing 0.20% C. The start temperature of the secondary phase formation differed depending on the type of the alloying element, and the temperature tended to increase with increasing carbon content. When the additions of niobium and titanium were compared, the amount of titanium segregation during solidification was smaller due to the formation of MC phases. Solidification simulation revealed that a higher amount and faster formation of the MC phase during solidification in 2Ti–20C contributed to reducing the BTR by increasing the carbon content. Thus, it is considered that the weld solidification cracking susceptibility depended on the type and amount of formation morphology, as well as start temperature during solidification corresponding to the composition of alloying elements and carbon.

Shop primer is a predominant cause of pits and blowholes during fillet welding using a conventional CO2 arc welding process. The hot-wire laser welding process for fillet welds employs a reflected laser beam incident on a molten pool for melting the base metal, and produces a weld bead with an extremely low dilution of base metal. In this study, weld-defect prevention in hot-wire laser welding as applied to steel plates coated with shop primer was investigated by examining the vaporization of the shop primer at the molten pool front and beneath the stiffener at the root region. A melting technique employing a reflected laser beam incident on the molten pool surface can efficiently remove the shop primer at the molten pool front during welding. The quantity of several gases and metallic vapors emitted during decomposition of the shop primer at a root was reduced markedly during hot-wire laser welding under extremely low base metal dilution. The above features of the hot-wire laser welding process achieved sound fillet welds without pits and blowholes.