Journal of Welding Science and Technology of Iran

Effect of bonding time on microstructure and mechanical properties during TLP bonding of nickel-base superalloys Hastelloy C276 to AISI316 Stainless Steel

M. M. taghvaei

Joining of Hastelloy C276 nickel-base superalloy to AISI316 Stainless Steel using BNi-2 interlayer performed by transient liquid phase process (TLP) at 1150°C for 5 and 30 minutes. Bonding microstructure was studied using an Optical microscope and a scanning electron microscope (SEM). Vickers hardness test and shear strength test have been used to evaluate the mechanical properties. Microstructural studies showed that at 5 and 30 minutes of bonding time, isothermal solidification is completely formed, and the Center of the joint is free of any eutectic intermetallic compounds. Also, Findings showed that the DAZ of Hastelloy C276 nickel-base superalloy contains rich borides of Ni, Cr, Mo, and W, and the DAZ of 316 austenitic stainless steel contains borides rich in Fe, Cr, and Ni.

Effect of diffusion bonding temperature on microstructure properties of Zr/Ti interlayer in the diffusion bonded joints of Zr702 to A516 steel

R. dehmolaei

In this study, the effect of temperature on the microstructure and reactive layer at the interface between the Ti interlayer and the base metal related to the diffusion bonding of Zr702 to A516 low alloy steel was investigated. The joining was done using the spark plasma sintering technique at temperatures of 900, 950 and 1000°C for 30 minutes. Field Emission Scanning Electron Microscope (FESEM) equipped with EDS analysis was used to investigate the microstructure of the interfaces in various joints. Investigations showed that at all temperatures, with the diffusion of atoms and the formation of a reactive layer between the Ti interlayer and Zr702, no intermetallic phases, cracks, porosity and discontinuities were formed at their interfaces. . It was found that increasing the bonding temperature did not cause the formation of new phases and compounds in the interface and only increased the thickness of the reaction layer. The measurement of the thickness of the reactive layer showed that the maximum and minimum amounts of diffusion were 84 microns at 1000 °C and 64 microns at 900 °C respectively

Microstructure and mechanical properties assessment of dissimilar AA5083/AA6061 joint welded by GTAW

A. Rabiezadeh

Despite the increased use of aluminium alloys in several industries, their common concern is the difficulty of joining dissimilar alloys using welding techniques. Based on this, the primary purpose of this research is to assess the mechanical characteristics of dissimilar joining of heat-treatable 6061 and non-heat-treatable 5083 aluminium alloys by gas tungsten arc welding and to discover the link between microstructure and mechanical properties. Similar welds were also implemented and evaluated in order to more properly analyze and compare the outcomes. The quality of the weld generated after establishing the health of the joint using non-destructive testing was evaluated by destructive bending, tensile, metallographic, and hardness tests to check the mechanical and microstructural qualities. The intended dissimilar weld was produced under the parameters of pulse current 120-80 amps, voltage 20 volts, welding speed 15 cm/min, and filler 5356. It should be highlighted that the dissimilar weld had the maximum joint efficiency, and with perfect control of welding settings and the absence of flaws, only 36% loss of strength was recorded when compared to the base metal. Metallographic images revealed that the formation of hot cracks in the dendritic structure of the weld metal is the major cause of strength loss for 5083 similar weld and the production of numerous porosities in the weld metal for 6061 similar welds.

Influence of Rolling on Microstructure and Mechanical Properties of Bronze-Steel Explosive Welded Sheets

Gh. Khalaj

In this paper, the microstructure and mechanical properties of the plain carbon steel-bronze interface of explosive welding and rolling were investigated. Explosive connection was done at two stop distances and with two different thicknesses of explosive material. Rolling of the welded composite was done at both ambient and preheated temperatures of 300 °C and with a constant thickness reduction of 33.3%. The results showed that the wave interface of the steel-bronze connection includes different parts. By rolling, the connection interface was stretched and flattened and the vortex areas were compressed together and in some cases entered the steel field. The steel particles separated from the background along the wave crest and remained as isolated islands in the bronze background. On the other hand, in the areas near the vortex, a part of the bronze flying metal was caught under the wave and was observed as islands separated from the bronze background inside the steel. Porous areas were crushed and compressed as a result of rolling. The rolling force and temperature had partially removed the diffusion barriers and a metal bond had been formed between bronze and steel. During the connection, the voids and shrinkage pores were pressed together due to rolling and the separate borders were close to each other. Explosive joining and cold rolling had increased the hardness in the interface, and hot rolling has led to a decrease in the hardness in the interface. In the hardness test, the welding samples are arranged in the order of the highest impact energy. The effects of welding parameters remain after cold and hot rolling and the hardness rating does not change.

Investigation of Mechanical Properties in Welding of Stainless Steel SA240-TP316 and Steel SA516-GR60 Cladded with Stainless Steel SA240-TP316

A. Afsari

Stainless steel cladding is the formation of an alloy by creating a thin layer of stainless steel on another metal. In this research, a layer of SA240-TP316 austenitic stainless steel was coated on SA516-GR60 steel. Experiments were conducted to compare the mechanical properties of SA240-TP316 and claded SA516-GR60 steel welds in order to investigate the possibility of replacing the SA240-TP316 steel alloy. Examining the results of the chemical analysis of SA240-TP316 alloy shows that the coating has a similar chemical composition to SA240 alloy and with increasing depth, the hardness of the weld metal and the percentage of chromium is higher and the percentage of molybdenum in the weld alloy is lower. Comparing the ultimate strength of SA516 alloy after cladding and welding with SA240 stainless base alloy shows the improvement of tensile strength. In the first case, the strength changes in the range of 470 to 503 MPa and in the second case in the range of 477 to 570 MPa. The highest hardness was obtained in the heat affected area. Bending test showed that bending without cracking up to 180 degree angle is a sign of weld metal remaining ductile. The results of the impact test also show the ability to absorb energy, especially around the voltage of 150 volts.

Investigating the microstructure and hardness of 17-4PH steel and Stellite cladded by direct laser deposition process on 17-4PH steel substrate

M.R. Borhani

The purpose of this research is to laser cladding of stellite6 and stainless steel 17-4PH powders on the substrate of stainless steel 17-4PH, and investigate its solidification microstructure. The results showed that the microstructure of the stellite6 cladding has a cobalt solid solution ground phase with an FCC structure and Cr₇C₃ and Cr₂₃C₆ carbides. Also, the values of the primary dendrite distance and the distance of the secondary dendrite arm have decreased by moving away from the interface; The reason for this is related to the difference in the cooling rate in different parts of the coating. The microstructure of 17-4PH stainless steel coating includes martensitic, ferritic, and austenitic phases; Due to the same chemical composition of the substrate and the cladding, the weight percentage of elements such as iron, nickel, chromium, and copper did not change from the cladding to the interface. It indicates the uniformity of the chemical composition of the cladding and the substrate. The calculated microhardness for the cladding of stellite6, the substrate and the cladding of stainless steel 7-4PH is about 480, 350, and 350 respectively. The reason for the higher microhardness of the cladding is the presence of chromium carbides (Cr₇C₃ and Cr₂₃C₆) formed in the cobalt field and the cobalt solid solution field of the cladding.

Liquation and re-solidification in thermo-mechanically affected zone during friction stir spot welding of AZ91 alloy substrate

S.M. Mousavizadeh

The present research aims to study the liquation and re-solidification of liquid during friction stir spot welding of AZ91 alloy. Although friction stir spot welding is a solid-state process, the presence of Mg₁₇Al₁₂ intermetallic compounds results in liquation during the welding process. In this study, friction stir spot welding was performed with a tool rotational speed of 2500 rev/min and a tool dwell time of 5 seconds. The microstructural assessment was carried out by optical and scanning electron microscopes. The results showed that initiation of liquation from the inner and outer edge of the eutectic precipitates occurred based on the melting of residual eutectic. Moving toward stirred zone, a liquid film formed along the grain boundaries. The liquid re-solidified as a composite structure of α-Mg/, which α-Mg phase dispersed in γ-Mg₁₇Al₁₂matrix. Also, the results showed that eutectic morphology resulting from re-solidification is related to the cooling rate. Eutectic morphology changed from granular to fibrous by increasing the cooling rate. Also, the liquid film along the grain boundaries re-solidified as a divorced eutectic.

The effect of filler metal on the mechanical and tribological properties of AISI 1.6959 steel joint using TIG welding process

Sh. Heidari

In this study, the mechanical and tribological properties of 4 different types of welding filler metals were examined on a 1.6959 steel (DIN35NiCrMoV12-5) by the Gas Tungsten Arc Welding process. The fillers used in this study include ER70S-6, ER80S-G, ER80S-Ni1, ER80S-B2. The main reasons for choosing these fillers in this study are their availability and close chemical composition to the base metal. To evaluate the weld and quality of weld joints, tensile, impact, hardness and abrasion tests performed on the samples and related microstructures was investigated by optical microscope. The results indicated that the presence of molybdenum and chromium alloying elements in ER80S-B2 filler and related microstructure at HAZ has led to an increase in weld strength up to 38 percent. The best and worst wear resistance obtained from the filler ER 80S-Ni1 and ER 70S-6 respectively. The best weld quality and mechanical properties were acquired in welding using ER 80S-B2 welding filler metal.

The effect of electron beam welding parameters on the microstructural characteristics and mechanical properties of dissimilar joint between 17-4PH steel and Ti6Al4V alloy

A. Khorram

This study aimed to investigate the effect of electron beam welding parameters on the microstructural characteristics and mechanical properties of the dissimilar joint between 17-4PH precipitation hardening stainless steel and Ti6Al4V alloy. For this purpose, the welding of these two alloys was done without an interlayer and with an interlayer of copper with a thickness of 0.8 mm. Two different welding speeds of 0.7 and 0.9 m/min with four levels of beam offset (0, 0.2, 0.4 and 0.6 mm) from the center of the interlayer towards the steel were used to perform experiments. The results show that in the direct welding of titanium and steel, the joint structure consists of TiFe and TiFe₂+TiCr₂ intermetallic compounds with high hardness (about 900 Vickers). In the welding of titanium and steel by using the copper interlayer, the structure in the weld pool and the interface between the weld pool and steel includes a solid solution of copper and TiFe₂ intermetallic compounds, and at the interface between the weld pool and titanium includes Ti+Ti₂Cu and TiFe. The hardness of the welding zone in the samples welded with copper interlayer is about 400 Vickers. The highest value of hardness is observed at the interface between the weld pool and titanium alloy, as well as at the interface between the weld pool and steel, which is due to the presence of intermetallic compounds with high hardness. By increasing the welding speed and beam offset, the hardness decreases, which is due to the reduction of brittle intermetallic compounds in the joint structure. The welded sample with a welding speed of 0.9 m/min and beam offset of 0.6 mm has the highest shear strength equal to 160 MPa.

Investigation of the phase transformation and the structure of the simulated heat affected zone of double pass welding in X70 microalloyed steel

Gholamreza Khalaj

In multi-pass welding, the heat-affected zone formed in each pass is subjected to another thermal cycle by the next pass. This problem locally changes the microstructure of the heat-affected zone depending on the position of each area relative to the melting line of the next pass, and the overlapping of the heat-affected areas will lead to complex microstructures. In this research, based on the practical conditions of pipe production in the factory, including submerged arc welding with four electrodes in two passes from the inside and outside of the pipe, the thermal cycles of the heat-affected zone were first analyzed. Simulation of thermal cycles of heating and cooling up to the peak temperatures of 950, 1150 and 1350 °C was performed in a dilatometer and the transformation behavior and microscopic structure were studied. Simultaneous modeling of precipitation dissolution and austenite grain growth was done. It was observed that the grain growth reaches a limit in 300 seconds. The main cause of grain growth at temperatures below and above 1150 °C, is the dissolution of fine and coarse deposits of niobium carbonitride, respectively. Also, the modeling of austenite formation and decomposition was done using the classic JMAK equation. It was observed that the parameter n does not depend much on temperature; while parameter k strongly depends on temperature, transformation amount and austenite grain size.

Prediction and optimization of weld geometry in gas metal arc welding (GMAW) using least squares support vector machine

M.R. Maraki

In Wire and arc additive manufacturing (WAAM) based on Gas metal arc welding (GMAW) is one of the methods of manufacturing metal layer by layer. One of this method's basic steps is predicting the welding geometry created in each welding step. In the current research, an experimental study was conducted in this field considering the effective parameters of welding geometry. For this purpose, three parameters of voltage, welding speed, and wire feeding speed were considered as effective parameters on the welding geometry of the process. The width and height of the weld bead was selected as the answer according to the type and application of the research. The least squares support vector machine was used to model the welding geometry in the process. The results obtained from the regression (R2) of train, test, validation, and total were 0.945, 0.793, 0.894, and 0.881 respectively. The comparison between the experimental data and the model data shows the significance of the proposed model.

Investigating laser power in additive manufacturing (AM-LMD) process on the microstructure and hardness of deposited layers on Inconel738

H. Sabet

This research examines the microstructure and microhardness in the additive manufacturing process using the laser metal deposition method with the deposition of Inconel 718 powder on the Inconel 738 substrate. For this purpose, deposition with different laser power was performed on different substrates, and the microstructure and hardness of the layers were studied. Three layers of Inconel 718 powder were deposited on the substrates. The results show that the laser power parameter in the deposition process significantly affects the microstructure of the samples. By increasing the laser power by 100 W, the distance between the phases γ' in the substrate and γ'' in the layers decreased significantly. With increasing laser power, an increase in the geometric dimensions and volume percentage of the γ'' phase was also observed. In addition, increasing the laser power decreased the volume percentage of the Laves phase. By measuring the microhardness of the deposition layers, it was found that the hardness of the third layer decreases with increasing laser power.