In situ analysis of the strain evolution during welding using low transformation temperature filler materials

ABSTRACT

Compared to conventional welding consumables using low transformation temperature (LTT) filler materials is an innovative method to mitigate tensile residual stresses due to delayed martensite transformation of the weld. For the effective usage of LTT filler materials, a deeper understanding of the complex processes that lead to the final residual stress state during multi-pass welding is necessary. Transformation kinetics and the strain evolution of multi-pass welds during welding were investigated in situ at the beamline HEMS@PETRAIII, Germany. Compared to conventional welds, the total strain was reduced and compression strain was achieved when using LTT filler materials. For an optimal use of the LTT effect in the root of multi-pass welds, the alloying concept must be adapted taking care of dilution.     

Effect of dilution on fatigue behaviour of welded joints produced by low-transformation-temperature fillers

ABSTRACT

Low-transformation-temperature (LTT) fillers with various martensitic transformation start (M_s) temperatures were used to produce fillet welds. In comparison with conventional welds, the fatigue strength of the LTT fillet welds offers a significant improvement, with a minimum increase of 145%. Owing to the substantial dilution of base metal, the Cr and Ni alloying elements in the LTT weld metals decrease, resulting in an increase of the M_s temperatures. Therefore, the fillet welds produced using the LTT filler material with the lower M_s temperature (92°C) exhibit a larger compressive residual stress and higher fatigue strength.     

Clarification on development of skeletal and lathy ferrite morphologies in stainless steel welds

Abstract

Inoue and co-workers have quoted the present authors as reporting that lacy (or lathy) ferrite in austenitic stainless steel welds forms only during single phase ferrite solidification (F). It was actually reported that both lathy and skeletal ferrite morphologies had been observed in single phase ferrite solidified welds. However, it was also reported that these two ferrite morphologies were observed in F/A (primary ferrite with secondary solidification as austenite) solidified welds. The aim of this letter is to clarify that both ferrite morphologies were observed in both F and F/A solidification modes.     

Effect of low transformation temperature weld filler metal on welding residual stress

Abstract

The effect of weld filler metal austenite to acicular ferrite transformation temperature on the residual stresses that arise during the gas metal arc welding of a low carbon steel has been examined using a finite element model. It was found that the stress levels in the weld can be tailored by the appropriate selection of the filler metal and compressive, near zero or tensile residual stresses produced. Reasonable agreement was obtained between the model and the stresses measured using neutron diffraction both in welds using conventional and low transformation temperature filler metal.     

Weldability of X100 linepipe

Abstract

Research has been carried out to identify weld metal compositions and microstructures capable of meeting high strength and toughness requirements for X100 seam welded linepipe. Single pass, multiwire submerged arc welds were made in experimental, high strength low alloy steel plates using consumables to give a wide range of weld metal alloying. Work has shown that the optimum strength and toughness are obtained in Mo–B–Ti alloyed weld metals with P _cm values between 0.218 and 0.250. Weld metal microstructures were almost fully acicular ferrite with an ultrafine grain size (1–2 µm). Dilatometric studies demonstrated that at typical weld cooling rates the optimised welds transformed at significantly lower temperatures than those reported for X65 plate deposits, which contain acicular ferrite in the form of idiomorphic primary ferrite and intragranular Widmanstätten ferrite. The maximum rate of transformation in the optimised welds occurred between 515 and 570°C, which indicates that the acicular ferrite in this case consisted of intragranular Widmanstätten ferrite and/or bainite. The ferrite would appear to have a fine plate morphology growing from large as well as small inclusions, but not very far before the onset of hard impingement, thereby ensuring an ultrafine grain size. Tensile strengths of 708–784 MPa were achieved with an 80 J Charpy impact transition temperature toughness between -68 and -115°C. More highly alloyed weld metals containing 2–3%Mn and 1.5%Si transformed at lower temperatures and showed increased strength, but there was a substantial loss of toughness, attributed to the relatively unimpeded growth of large ferrite plates from larger inclusions, and the replacement of ultrafine acicular ferrite between these plates by blocks of martensite–austenite. One pass per side, multiwire submerged arc welds manufactured to the optimum weld metal chemistry confirmed their applicability for thin section X100 linepipe.     

New model for prediction of ferrite number of stainless steel welds

Abstract

A new semi-empirical model for predicting the ferrite content of stainless steel welds has been developed. This model predicts the ferrite number of stainless steel welds as a function of composition. The model is based on an equation representing the free energy change between ferrite and austenite. This model has been derived from published data of experimental weld metal compositions and their corresponding ferrite numbers. The predictive capability of this model was found to be good and describes the effect of alloying elements on the ferrite number. This model is comparable in accuracy to currently available constitution diagrams but is applicable to a wider range of alloy compositions.     

Microstructural characterisation of stir zone containing residual ferrite in friction stir welded 304 austenitic stainless steel

Abstract

Friction stir welding was applied to a 2 mm thick 304 austenitic stainless steel plate. The microstructural evolution and hardness distribution in the weld were investigated. The stir zone (SZ) and thermomechanically affected zone (TMAZ) showed dynamically recrystallised and recovered microstructures, respectively, which are typically observed in friction stir welds in aluminium alloys. The hardness of the SZ was higher than that of the base material and the maximum hardness was observed at the TMAZ. The higher hardness at the TMAZ was attributed to high densities of dislocations and subboundaries. Microstructural observations revealed that the ferrite was formed along grain boundaries of the austenite matrix in the advancing side of the SZ. It is suggested that the frictional heat due to stirring resulted in the phase transformation of austenite to ferrite and that upon rapid cooling the ferrite was retained in the SZ.     

Development of new low transformation temperature welding consumable to prevent cold cracking in high strength steel welds

Abstract

A low transformation temperature (LTT) welding consumable has been developed to prevent cold cracking in high strength steel welded joints without preheating. In the LTT welded joint, the residual tensile stress is reduced by martensitic expansion of weld metal formed by the LTT consumable. In the weld cracking tests, cold cracking in the LTT weld metal is successfully prevented under high restraint conditions, but cold cracking occurs at very low joint restraint strength in case the weld metal is fully martensitic. Chemical compositions of the consumable are designed to retain austenite in martensite in the newly developed weld metal to absorb the diffusible hydrogen into the austenite to prevent cold cracking. In the newly developed LTT weld metal, cold cracking is almost fully suppressed without preheating under every joint restraint condition.     

Formation mechanism of vermicular and lacy ferrite in austenitic stainless steel weld metals

Abstract

Solidification and subsequent transformation of austenitic stainless steel weld metals that solidified in the ferritic–austenitic mode were investigated from the viewpoint of crystallography. The formation mechanisms for the vermicular and lacy ferrite observed in the weld metals were clarified. The ferrite morphology is determined by both the crystallographic orientation relationship between ferrite and austenite established at the stage of ferrite nucleation and the relationship between the welding heat source direction and the preferential growth directions of ferrite and austenite. In particular, for the formation of continuous lacy ferrite, it is necessary that the ferrite continues to grow with the Kurdjumov–Sachs orientation relationship with austenite that is established at the stage of ferrite nucleation.     

Brazing of UNS S32101 and UNS S32304 lean duplex stainless steels and UNS S32750 super duplex with AWS A5.3 BNi-7 (Ni–Cr–P) filler metal

Summary

Weld metals solidified in the ferritic-austenitic solidification mode (FA mode) have dual phases of ferrite and austenite in their as-solidified condition, where ferrite exhibits different morphologies depending on the chemical composition and welding conditions. This paper describes an investigation of the effect of the solidification and transformation sequence on the formation of final ferrite morphologies. Austenite is formed through either a eutectic reaction or peritectic reaction at the dendrite boundaries after the primary formation of ferrite. During the eutectic formation of austenite, the <100>_δ direction of the primary ferrite and the <100>_γ direction of the eutectic austenite are parallel to each other and lie along the growth direction of the primary dendrites. However, any specific lattice plane relationship between the two phases is not identified. During cooling after solidification, the austenite extends into the primary ferrite via solid-state transformation, and the final morphology of the ferrite is vermicular without any coherent orientation relationship between the primary ferrite and eutectic austenite. During peritectic formation of austenite, the Kurdjumov-Sachs orientation relationship is established between the primary ferrite and peritectic austenite, and the <100>_γ direction of the peritectic austenite is not parallel to the growth direction of the primary dendrites. During cooling after solidification, the primary ferrite transforms into austenite, and the final morphology of the ferrite is lathy, since the primary ferrite and peritectic austenite have a favourable coherent orientation.     

Intermediate temperature decomposition of supercooled high nitrogen austenite

Abstract

The mechanism of decomposition transformation of Fe–N the austenite system has been investigated. An improved process of austenitic nitriding, achieved by applying controlled nitrogen potential theory, allowed high nitrogen austenite samples with a uniform nitrogen concentration to be produced. The key point of this gas nitriding process is to keep the atmosphere at very low nitrogen potential. As a result, the nitride layer on the surface of the pure iron foil was reduced and pure iron ferrite was thoroughly nitrided, forming high N austenite (γ-Fe[N]) that is thermally stable at room temperature. The nitrogen concentration of this austenite was determined as 9·32 at.-%, which is almost the maximum value achievable in Fe–N austenite.     

Influence of deep cryogenic treatment on the microstructure and properties of AISI304 austenitic stainless steel A-TIG weld

Appropriate deep cryogenic treatment can improve comprehensive mechanical properties of the AISI304 austenitic stainless steel activating flux tungsten inert gas (A-TIG) welds. The microstructure of the welds before and after deep cryogenic treatment was all austenite with a small amount of δ-ferrite. The vermiform ferrite + austenite distributed in the whole weld, but the lath-shaped ferrite + austenite mixed components only distributed in the centre of the weld. The phases in the two welds were all Cr–Ni–Fe–C and Fe–Ni solid solutions, ferric carbide (i.e. Fe₃C) and chromic carbides (i.e. Cr₂₃C₆ and Cr₇C₃). After deep cryogenic treatment, the grain size of the weld was decreased a certain of degree, and the carbide phase content was increased. The strength and micro-hardness of the weld joints were increased due to the grain refinement. The intergranular corrosion resistance of the weld was reduced because the precipitation of chromium carbides at the austenite grain boundary.     

Basic alloy development of low-transformation-temperature fillers for AISI 410 martensitic stainless steel

ABSTRACT

This study discusses the effect of Ni content of low-transformation-temperature (LTT) fillers on welding residual stresses of AISI 410 plates. The plates were joined by LTT fillers with 11?wt-% Cr and varying Ni from 3 to 11?wt-%. Evaluation of varying Ni content on the martensitic transformation temperature (M_s) by dilatometric tests indicates that the M_s of LTT fillers decreases from 335°C to 67°C by increasing Ni wt-%. Residual stress measurements show the highest compressive longitudinal stress (?310?MPa) in the weld bead deposited by the LTT filler contained 7?wt-% Ni and M_s?=?202°C. This result is associated with the highest final expansion strain (0.37%) in this composition. Microstructural analyses show the presence of retained austenite by increasing the Ni more than 7?wt-%.     

Dynamic Ferrite Transformation Behaviors in 6Ni-0.1C Steel

Phase transformation from austenite to ferrite is an important process to control the microstructures of steels. To obtain finer ferrite grains for enhancing its mechanical property, various thermomechanical processes followed by static ferrite transformation have been carried out for austenite phase. This article reviews the dynamic transformation (DT), in which ferrite transforms during deformation of austenite, in a 6Ni-0.1C steel recently studied by the authors. Softening of flow stress was caused by DT, and it was interpreted through a true stress–true strain curve analysis. This analysis predicted the formation of ferrite grains even above the Ae₃ temperature (ortho-equilibrium transformation temperature between austenite and ferrite), where austenite is stable thermodynamically, under some deformation conditions, and the occurrence of DT above Ae₃ was experimentally confirmed. Moreover, the change in ferrite grain size in DT was determined by deformation condition, i.e., deformation temperature and strain rate at a certain strain, and ultrafine ferrite grains with a mean grain size of 1 μm were obtained through DT with subsequent dynamic recrystallization of ferrite.     

Phase Transformations of an Fe-0.85 C-17.9 Mn-7.1 Al Austenitic Steel After Quenching and Annealing

Low-density Mn-Al steels could potentially be substitutes for commercial Ni-Cr stainless steels. However, the development of the Mn-Al stainless steels requires knowledge of the phase transformations that occur during the steel making processes. Phase transformations of an Fe-0.85 C-17.9 Mn-7.1 Al (wt.%) austenitic steel, which include spinodal decomposition, precipitation transformations, and cellular transformations, have been studied after quenching and annealing. The results show that spinodal decomposition occurs prior to the precipitation transformation in the steel after quenching and annealing at temperatures below 1023 K and that coherent fine particles of L1₂-type carbide precipitate homogeneously in the austenite. The cellular transformation occurs during the transformation of high-temperature austenite into lamellae of austenite, ferrite, and kappa carbide at temperatures below 1048 K. During annealing at temperatures below 923 K, the austenite decomposes into lamellar austenite, ferrite, κ-carbide, and M₂₃C₆ carbide grains for another cellular transformation. Last, when annealing at temperatures below 873 K, lamellae of ferrite and κ-carbide appear in the austenite.     

Numerical simulation of dynamic strain-induced austenite–ferrite transformation in a low carbon steel

A modified cellular automaton modeling has been performed to investigate the dynamic strain-induced transformation (DSIT) from austenite (γ) to ferrite (α) in a low carbon steel. In this modeling, the γ–α transformation, ferrite dynamic recrystallization and the hot deformation were simulated simultaneously. The simulation provides an insight into the mechanism of the ferrite refinement during the DSIT. It is found that the refinement of ferrite grains derived from DSIT was the result of the increasing ferrite nuclei density by the “unsaturated” nucleation, the limited ferrite growth and the ferrite dynamic recrystallization. The effects of prior austenite grain size and strain rate on the microstructural evolution of the DSIT ferrite and the characteristics of the resultant microstructure are also discussed.     

Interphase precipitation of Fe2Hf Laves phase in a Fe–9Cr/Fe–9Cr–Hf diffusion couple

Periodically arrayed rows of fine Fe₂Hf Laves phase particles were found to form in ferritic matrix containing 9 weight percent chromium and a few weight percent hafnium. Microstructural investigation suggests that the particles were formed on cooling through interphase precipitation during the phase transformation from δ ferrite to austenite, and the austenite was subsequently transformed into the α ferrite. The interphase precipitation mode may be effectively used to strengthen ferritic heat resistant steels with Laves phase.     

Phase formation during solidification of AISI 304 austenitic stainless steel

Following casting of AISI 304 strip, both cellular and skeletal ferrite were observed within individual austenite grains. It is proposed that solidification commences with primary austenite, γ_p, to produce cellular ferrite and further solidification results in the formation of ferrite but its subsequent epitaxial transformation to austenite at the γ_p interface produces skeletal ferrite in addition to cellular ferrite.     

Ferritic–austenitic stainless steels dissimilar resistance spot welds: metallurgical and failure characteristics

The paper addresses the microstructure and failure characteristics of dissimilar resistance spot welds between austenitic stainless steel and ferritic stainless steel. The fusion zone (FZ) of dissimilar welds exhibited complex microstructure consisting of ferrite, austenite and martensite. The development of this triplex structure in the FZ was explained by analysing the phase transformation path and austenite stability. Results showed that all dissimilar welds failed in partial thickness–partial pull-out failure mode. It was shown that the fraction of the nugget fracture of the weld is reduced by increasing the FZ size improving the mechanical performance of the weld. Peak load and energy absorption of the similar and dissimilar welds were compared and analysed.     

Effect of activating flux and shielding gas on microstructure of TIG welds in austenitic stainless steel

Abstract

The aim of this research is to study the effect of an activating flux, two shielding gases (100%Ar and 50%Ar z 50%He) and a range of weld currents on the microstructure of autogeneous A-TIG welds on an austenitic stainless steel. Metallographic, Mössbauer, X-ray diffraction and magnetic permeability methods were used in the study to evaluate ferrite content in the welds. The increase in welding current coarsened the microstructure and increased the retained ferrite content in welds made with and without flux. The activating flux increases the ferrite content and changes the distribution of ferrite in the welds. The influence of flux on ferrite content is less significant in Ar/He than in Ar shield welds. The process of filling steel samples, currently used in the Mössbauer method, drastically changes the microstructure of the parent and melted austenitic stainless steels.