Journal of Welding Science

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In this study the microstructure and mechanical properties of super duplex stainless steel UNS S32750 welding was studied. For this purpose, the method of gas tungsten arc and filler metal AWS ER2594 with a diameter of 4.2 mm was used. In order to investigate the microstructure light microscopy and electron microscopy equipped with backscatter electron diffraction were used. Mechanical properties were studied by hardness and tensile tests. Weld metal had  Cast structure with austenite in the dendrite form  located in ferrite matrix. It was also observed in the melting zone after welding, the ferrite volume fraction decreased to 50 percent 60% base metal ferrite) ,Due to the low cooling rates and  high heat input method in the gas tungsten arc welding. Vickers micro-hardness test method was carried out on the samples showed that average about 285 Vickers hardness of base metal; however, hardness in the fusion region due to increased austenite fraction fell to 250 Vickers. But hardness in the heat-affected zone due to lower volume fraction of austenite and ferrite phase formation of chromium carbide intermetalic compounds increased to 340 Vickers. The results of the tensile test showed that the tensile strength decreased with increasing heat input, because of increase the size of grains due to the increased heat input.

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Cellulose is a natural biopolymer with the general (C6H10O5)n formula, which according to AWS A5.5 standard, more than 40wt% of coating of cellulosic electrodes is consisted of cellulose. In this study to evaluate the effect of cellulose type on the performance of E8010-P1 cellulosic electrode, equal  amounts  of two celluloses with the same commercial properties but produced by two different companies, were used for production of two E8010-P1 electrodes.Experimental studies illustrate significant difference between structural and mechanical properties of deposited weld metals from these electrodes. FTIR, DTA and XRD testes of as-received celluloses show despite the same brandforthese celluloses, their properties such as bonds types,thermal behavior and crystallinity are different that cause variation ofweld metal penetrate and tensile strength around 25±2% and 5±2%respectively.

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In this research, lap joint frictionstir welding of IF sheets with thickness of 0.7 mm is investigated. For this purpose, mechanical properties of joints and also microstructural evolutions are studied. It was found that increase in tool rotational speed and decrease in travel speed results in increase in fracture stress of welded joints. Texture study indicates that no changes can be observed in texture components after friction stir welding. This phenomenon in texture components can be related to high stacking fault energy of IF steel and consequently severe dynamic recrystallization during welding. The results show with increase in the tool rotational speed between 900-1400 Rev/min, ultimate force of fracture of friction stir welded joints is increased. Also, it is concluded from results that with increase in tool travel speed between 50-160 mm/min, ultimate force of fracture of welded joints is decreased. Finally it is proved from results of this paper that in the frictionstir welding of IF sheets with thickness of 0.7 mm, maximum force of fracture of welded joints is achieved in rotational speed of 1400 Rev/min and travel speed of 105 mm/min.   

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In this study, microstructural features and mechanical properties of Incoloy 825-316L stainless steel dissimilar joints have been investigated. For this purpose, pulsed gas tungsten arc welding method was employed and 316L, Inconel 82 and Inconel 625 alloys were used as filler metal. First, specimens were cut. Pulsed gas tungsten arc welding was performed using peak and base currents of 220 A and 110 A, respectively. Microstructure of welded joints was studied using metallographic observations and energy dispersive spectroscopy (EDS) analysis. In order to evaluate the mechanical properties, tensile and microhardness measurements were done on the joints. In all specimens, dendritic and equiaxed and/or cellular growth of austenite phase was observed. Incoloy 625 weld metal had the finest dendritic structure. Tensile test results revealed the ductile fracture with a high percent of elongation for all specimens. The highest tensile strength and percent of elongation of 610 MPa and 48% were obtained for specimen welded using Inconel 625 filler metal. Inconel 625 and 316 stainless steel weld metals showed the highest and lowest microhardness with values of 232 HV and 224 HV, respectively.  

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In this study, commercially pure titanium and aluminum alloy 5083 in connection rotational speed of 1120 rpm and a feed rate of 50 mm per minute for butt welding by friction stir welding has been successfully completed. Micro-structure, hardness and tensile test was conducted on the connection. Welding area is a composite of aluminum and titanium particles that the particles plays an important role in increasing hardness and tensile strength. Welding area is also has three areas. Vickers hardness is 480 times the area of welding means that the hardness in the area of the base metal of titanium and aluminum increased by 16% and 60% for titanium aluminum intermetallic compounds is created in the area is weld.

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In this investigation, the effect of heat input of SMAW process on the microstructure and mechanical properties of Hadfield steel weld joints was investigated. For this purpose, 4 annealed sheets with thickness
2 mm prepared from Hadfield steel and then welding applied by SMAW process with 6.75 and 11.25 kJ/mm heat input values. The evaluation of the microstructures of welding joints was conducted by optical microscopy and the joints mechanical properties were examined by tensile, charpy impact and microhardness measuring tests. The results indicated that by increasing the heat input in the SMAW process, microstructure consisted from smaller grains, and strength and microhardness increased but impact energy was reduced.  

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The fine grain structure of friction-stir welded aluminum alloys is unstable during post weld heat treatment and some grains abnormally grown. In this study, the sequence of abnormal grain growth during T6 heat treatment of Al-7075 friction-stir weld and its effect on mechanical properties of the weld was studied. The results showed that heat treatment in 510 ˚C resulted in drastic grain growth in stir zone and fine equiaxed grains in the stir zone of as-welded joint were substituted by millimeter-scale irregular grains. Post weld heat treatment resulted in decrease in the tensile elongation from about 10% to 1.5% although the joint tensile strength improved by 28%. In addition, post weld heat treatment changed the fracture location from the 
heat-affected zone to the stir zone.

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Nowadays, cemented carbides-steels joints by brazing method are taken into consideration. One of the problems of these joints is the creation residual stresses that can reduce it with choose correct parameters of brazing. In this study, Silver base alloy filler containing copper, zinc and cadmium have been used in temperature 780°C and the effect of time parameter 5, 10 and 15 minutes on microstructure and mechanical properties were investigated. The results indicated that brazing in 15 minutes causes a columnar growth of solid solution phase of copper from cemented carbide side to steel and provides maximum strength of 94MPa. As well as, by passing of time wetting angle of cemented carbide surface reduces from 40° to about 27°.

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In this research, the microstructure and mechanical behavior of dissimilar joint of AISI 321 stainless steel to ASTM A57CL1 were studied. For this purpose, the GTAW process and ER 308L filler metal with diameter of 1.8 mm were used. In order to study the microstructure and fracture surface of weld samples, optical microscope and scanning electron microscope (SEM) were used. Also, the mechanical behavior of the joint was examined by impact, tension and microhardness tests. It was found that the microstructure of weld metal was austenite with skeletal ferrite. Also in some areas the lacy ferrite was seen. All samples were fractured from ASTM A537CL1 steel with a ductile manner during the tension test. The weld metal indicated high impact energy about 205 J. 

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In the present research, the parameters of FSW process were optimized for the mechanical properties of thin aluminum- scandium alloys by a design of experiment (DOE) technique. The optimum conditions providing the highest mechanical properties were found by this method. Among the three factors and three levels tested, it was concluded that the tool rotational speed had the most significant effect on the mechanical properties and the travel speed had the next most significant effect. The effect of tool tilt angle was less important when compared to the other factors. The EBSD results demonstrated a recrystallized equi axial structure and the existence of a mixture of B and Ccomponents in the weld nugget.

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In this research, two different filler metals, ERNiCrMo-3 and ER309L, were used for developing different microstructure, austenite (γ) and austenite and ferrite (γ+δ) in the weld metal and fatigue properties of welded samples were evaluated in the air and sea water environments. Microstructural studies indicated a good agreement between predicted microstructures via schiffler diagram and metallographic studies. Evaluation of fatigue properties in the air and sea water environments revealed the austenitic weld metal, like base metal microstructure, improved the fatigue strength of welded samples. Fractographic studies and FESEM-EDS analysis showed more ductile fracture of welded samples by using ERNiCrMo-3, formation of more uniform and deeper dimples in the final zone of fatigue fracture, than that of welded samples by using ER309L. Furthermore, unlike dimple formation centers in welded samples by using ER309L, Mo-Ti rich intermetallics caused formation of dimples in the welded sampled via ERNiCrMo-3.

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In this research, gas tungsten arc welding of dissimilar joint between 4130 low alloy steel and AISI 201 austenitic stainless steel was investigated. Four filler metals i. e. ERNiCr-3, ER 309L, ER 308L and ER 80SB2 were used. After welding, microstructural features of various areas and also fracture surfaces were examined using optical microscopy and scanning electron microscopy. Tensile test was conducted in order to study the mechanical properties of each joint. It was found that ERNiCr-3 is fractured from fusion zone and the others were fractured from 4130 base metal. Also, some second phase particles such as NbC were seen in the ERNiCr-3 weld joint. SEM observation showed that the fracture behavior of ERNiCr-3 weld joint is semi brittle and the others are ductile. The fusion zone of ERNiCr-3 weld joint was fully austenitic and consisted of equiaxed grains and no crack was seen in this area. The fusion zone of ER 308L and ER 309L were composed from cellular dendrite and finally ER 80S-B2 weld joint was consisted of lath martensite.

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The effect of electron beam welding current changes on the microstructure and mechanical properties of the Nb-based alloy has been investigated. The electron beam welding was applied with 4 different currents of 20, 24, 30 and 35 mA on 3mm thick plates. The aspects including different welding regions, geometry and depth of welding penetration, as well as the effect of heat input on the weldability are investigated. The mechanical properties including tensile and microhardness values of the weld was also measured. The results show that in a sample with a 30 mA welding current, the optimum conditions for the depth of penetration, weldability and the geometry of the weld are obtained. The welds showed a cellular structure, and intercellular dendrites in the central region of the weld have been caused due to microsegregations created between the cells. In HAZ, severe recrystallization and grain growth has occurred. Because of the high thermal conductivity of niobium, the HAZ size is relatively large. Based on the 3D Rosenthal’s equation, the recrystallization temperature of alloy was calculated as 713 °C. It is observed that as G × R increases, the grain size in the central line of the weld decreases. The hardness profile shows that the hardness of the weld zone and the HAZ is significantly less than that of the base metal due to elimination of work hardening effect. The tensile strength of the weld for a sample with a current of 30 mA was 281MPa, which is 53% of the tensile strength of the base metal and the weld was broken from the HAZ.

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In this research, microstructure and mechanical properties of AISI316 to AISI430 dissimilar joint were investigated. For this purpose, GTAW process using ER316L and ER2209 filler metals with diameter of 2.4 mm was used. The microstructure and fracture surface of the welded samples were characterized by optical microscopy and scanning electron microscopy. Also the mechanical properties of the welded samples were evaluated by tension, impact and microhardness tests. It was found that the microstructure of the welded sample with ER316L filler metal contained Widmanstatten austenite with inter-dendritic and lathy ferrites. Also, in the welded sample with ER2209 filler metal, Austenite phase in ferrite matrix was seen. In tension test, all samples were fractured from AISI430 side of the joint in a ductile manner. ER2209 weld metal indicated low impact energy of about 27 J, while ER316L weld metal indicated higher impact energy of about 43 J. The fracture surface in both welded samples indicated brittle fracture mode. The microhardness of the weld metal of the welded sample with ER316L filler metal was higher than the welded sample with ER2209 filler metal due to the presence of alloying elements, proper distribution of delta ferrite and finer microstructure.

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In present study, the effect of heat treatment after friction stir welding dissimilar welds T6-7075 and T4-2024 aluminum alloys were investigated. Friction stir welding was performed at a constant rotation speed of 1140 rpm and welding speed 32 mm/min. After welding samples are taken under various heat treatment processes at different aging temperature and time period. Microstructural observations, phase analysis characterization and mechanical properties were performed on welded before and after heat treatment in cross section of welds joint. The results showed that post-weld heat treatment causes abnormal grain growth turns destructive effect on the mechanical properties, while formation of fine and uniform precipitation recovery strength and ductility of welds joints. It is found heat treatment based on T6-7075 and T6-2024 procedure has highest and lowest impact on the restore of weld strength. Tensile test indicate that fracture occurred on the interface between TMAZ and HAZ in retreating side (7075) at as-weld joint, if that failure happens in the stir zone by applying PWHT. Surface fracture suggested fractures in PWHT samples are predominantly inter-granular, while in as-weld joint the fractures of joints are mostly trans-granular.

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In the present study, effect of Ni alloying element on the characteristics of deposited weld metal of E7018-G electrode was evaluated. Therefore, electrodes contained different amounts of Ni (0-1.7wt.%) were designed, manufactured and welded via SMAW process. Microstructural studies revealed dichotomy effect of Ni on the deposited weld metal microstructure, i.e. increasing the Ni content up to 1.2wt.% improved the formation of acicular ferrite in the weld metal microstructure and caused significant grain refinement at the reheated zone of weld metal. While, higher Ni content (>1.2wt.%) resulted in some raising in the widmannstatten ferrite content in the weld metal. Strength multiplied by impact energy parameter (UTS×CVN) was used for mechanical properties assessment. Mechanical properties evaluation revealed the highest UTS×CVN parameter achieved in the weld metal contained 1.2wt.% Ni. Hardness of the weld metal increased with increasing Ni content which is related to the formation of micro constituents in the microstructure of weld metal and increasing their content with increasing Ni content.

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In this study the effect of activating fluxes on the penetration depth, microstructure and microhardness of AISI316L austenitic stainless steel were evaluated by three TIG process variations (TIG, A-TIG and FB-TIG) and the results were compared together.. After selecting the optimal flux in the second stage, the effect of that on the penetration depth, microstructure and weld microhardness of  welded 316L austenitic stainless steel by A–TIG and FB-TIG methods, were evaluated and  the results were compared by the sample which was welded by TIG process. At this stage, it was found that the depth and width to depth ratio in FB-TIG method is slightly greater than the other two methods. Also in FB-TIG method, eqiaxed dendritic zone in the center line of weld is slightly greater than in A-TIG method. Study of microhardness of weld in three methods shows that in A-TIG and FB-TIG methods hardness of center line is more than TIG method.

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The structural and hardness developed in advanced high-strength steel DP590 have been investigated with the help of optical microscopy and scanning electron microscopy on resistance spot welded specimens. The hardness diagram of the weld sections was prepared by microhardness test and the temperature peak and heat distribution were simulated by menas of the Abaqus software. The results show that according to the temperature generated in each region of the weld nugget, the HAZ and base metals have different microstructures, and these difference affects the hardness of the regions. The presence of tempered martensite islands with a fraction of 44% in ferrite matrix in base metal, mainly martensitic structure in the nugget, and martensitic structure along with scattered areas of ferrite in the HAZ was observed. The results of the microhardness tests showed difference in hardness values of the regions, and also it was observed that the hardness values increased in the HAZ and weld zone. The hardness values measured in the nugget, base metal, and HAZ were around 400, 200, and 450 HV which were in accordance with the observed structures

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The surface of continuous casting moulds with high number of castings may be worn or destructed. As result, an approach for increasing these moulds life is necessary. In this project, the goal is the restoration of the DHP copper sample. In this project, the destruction of the copper sample is done by creation of groove using a CNC machine. The restoration of the sample is done using OAW and filler to fill groove area. In this project, the effect of preheating temperature, filler type and heat treatment of welding area on hardness, microstructure, chemical analyses of welding area and thermal conductivity of the weld are investigated. The preheating temperature range of 300 to 450^oC was selected. The Cu-P and Cu-Ag-P fillers were chosen to fill the groove of the weld area. The scanning electron microscope (SEM), energy dispersive x-ray spectroscopy (EDS), micro hardness tester, optical microscope and thermal conductivity meter were employed for evaluation of the results in this project. The results showed that the increase of preheating temperature creates oxide layers and the decrease of preheating temperature causes the incomplete filling of the welding area. Finally, the preheating temperature of 400 ^oC was a proper choice considering the above mentioned factors. The stress relieving operation to decrease stress and preserve the mechanical properties in the temperature of 250 to 400 ^oC and duration two hours was carried out. The result demonstrated that the selected temperature causes no unwanted decrease on the hardness. It was also found that increasing the annealing duration, decreases the hardness of weld for Cu-P filler for Cu-Ag-P filler increasing the annealing duration, first decreases the weld hardness and then increases the weld hardness. The Cu-P filler was compared with Cu-Ag-P filler. The results showed that the Cu-Ag-P filler has less hardness (around 10 percent) than the filler without silver. On the other hand, the thermal conductivity of the Cu-Ag-P filler was around 10 percent more than the thermal conductivity of the Cu-P. It is obvious that the selection of the filler type depends on the type of base metal and its geometry. The results showed that the segregation in the Cu-P filler with 7.2 percent phosphorous, because of the proximity of the weld structure to the eutectic point, has slightly happened; while, the selection of the Cu-Ag-P filler with 6 percent silver caused severe segregation of silver to 90 percent silver at the center of weld at the non-dendrite area

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Nowadays, aluminum and its alloys have extensive applications in marine and aerospace industrious owing to their excellent properties. Among these alloys, 5xxx series of aluminum alloys have also excellent corrosion resistance, high toughness and strength and also good weldability. Decrease in yield strength and also tensile strength due to the grain growth in the heat affected zone is of the main problems in the welding of these series of Al alloys. In this research work, gas tungsten arc weld joints in two modes i. e. direct current and pulsed current were compared in order to study the effect of this parameter on the microstructure, mechanical properties and corrosion resistance of weld joints. Also, the effect pulsed current parameters such as peak current and basic current were investigated. Microstructural evolutions and fracture surfaces of weld joints were examined by optical microscope and scanning electron microscope, respectively. It was found that the fracture behavior of all joints is in a ductile manner. Also, tensile test and electrochemical polarization were conducted in order to study the mechanical properties and corrosion behavior of weld joints.