Resistance-Spot-Welded AZ31 Magnesium Alloys: Part I. Dependence of Fusion Zone Microstructures on Second-Phase Particles

A comparison of microstructural features in resistance spot welds of two AZ31 magnesium (Mg) alloys, AZ31-SA (from supplier A) and AZ31-SB (from supplier B), with the same sheet thickness and welding conditions, was performed via optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). These alloys have similar chemical composition but different sizes of second-phase particles due to manufacturing process differences. Both columnar and equiaxed dendritic structures were observed in the weld fusion zones of these AZ31 SA and SB alloys. However, columnar dendritic grains were well developed and the width of the columnar dendritic zone (CDZ) was much larger in the SB alloy. In contrast, columnar grains were restricted within narrow strip regions, and equiaxed grains were promoted in the SA alloy. Microstructural examination showed that the as-received Mg alloys contained two sizes of Al₈Mn₅ second-phase particles. Submicron Al₈Mn₅ particles of 0.09 to 0.4 μm in length occured in both SA and SB alloys; however, larger Al₈Mn₅ particles of 4 to 10 μm in length were observed only in the SA alloy. The welding process did not have a great effect on the populations of Al₈Mn₅ particles in these AZ31 welds. The earlier columnar-equiaxed transition (CET) is believed to be related to the pre-existence of the coarse Al₈Mn₅ intermetallic phases in the SA alloy as an inoculant of α-Mg heterogeneous nucleation. This was revealed by the presence of Al₈Mn₅ particles at the origin of some equiaxed dendrites. Finally, the columnar grains of the SB alloy, which did not contain coarse second-phase particles, were efficiently restrained and equiaxed grains were found to be promoted by adding 10 μm-long Mn particles into the fusion zone during resistance spot welding (RSW).     

Effects of Process Parameters upon the Shape Memory and Pseudo-Elastic Behaviors of Laser-Welded NiTi Thin Foil

This article discusses the effects of laser welding parameters such as power, welding speed, and focus position on the weld bead profile, microstructure, pseudo-elasticity (PE), and shape memory effect (SME) of NiTi foil with thickness of 250 μm using 100W CW fiber laser. The parameter settings to produce the NiTi welds for analysis in this article were chosen from a fractional factorial design to ensure the welds produced were free of any apparent defect. The welds obtained were mainly of cellular dendrites with grain sizes ranging from 2.5 to 4.8 μm at the weld centerline. A small amount of Ni₃Ti was found in the welds. The onset of transformation temperatures (A _s and M _s ) of the NiTi welds shifted to the negative side as compared to the as-received NiTi alloy. Ultimate tensile stress of the NiTi welds was comparable to the as-received NiTi alloy, but a little reduction in the pseudo-elastic property was noted. Full penetration welds with desirable weld bead profiles and mechanical properties were successfully obtained in this study.     

Fusion zone microstructure and porosity in electron beam welds of an α+β titanium alloy

The effect of electron beam welding parameters on fusion zone (FZ) microstructure and porosity in a Ti - 6.8 Al - 3.42 Mo - 1.9 Zr - 0.21 Si alloy (Russian designation VT 9) has been investigated. It has been observed that the FZ grain width increased continuously with increase in heat input when the base metal was in the β heat-treated condition, while in the α + β heat-treated base metal welds, the FZ grain width increased only after a threshold energy input. The difference is attributed to both the weld thermal cycle and the pinning effect of equiaxed primary alpha on grain growth in the heat-affected zone (HAZ) of α + β heat-treated base metal. Postweld heat treatment (PWHT) in the subtransus and supertransus regions did not alter the columnar grain morphology in the FZ, possibly due to the lack of enough driving force for the formation of new grains by the breaking up of the columnar grains and grain boundary movement for grain growth. As the PWHTs were conducted in a furnace, the role of thermal gradients can be ruled out. Intragranular microstructure in the aswelded condition consisted of hexagonal martensite. The scale of the martensite laths depended on welding speed. The highest porosity was observed at intermediate welding speeds. At low speeds, a majority of pores formed at the fusion boundary, while at high speeds, occurrence of porosity was maximum at the weld center. The trends on porosity can be explained on the basis of solubility of hydrogen in titanium as a function of temperature and the influence of weld thermal cycle on nucleation, growth, and escape of hydrogen gas bubbles. The porosity at slow welding speeds is low because sufficient time exists for the nucleation, growth, and escape of hydrogen gas bubbles, while insufficient time exists for the nucleation of gas bubbles at high welding speeds. The effect of pickling of joint surface, vacuum annealing of the base metal, and successive remelting of the weld metal has also been investigated.     

Welding parameters and the grain structure of weld metal — A thermodynamic consideration

The grain structure of the weld metal can significantly affect its resistance to solidification cracking during welding and its mechanical properties after welding. An experimental study was conducted to investigate the effect of two basic welding parameters,i.e., the heat input and the welding speed, on the grain structure of aluminum-alloy welds. Gas-tungsten arc welding was performed under various heat inputs and welding speeds, with thermal measurements in the weld pool being carried out during welding and the amounts and nuclei of equiaxed grains in the resultant welds being examined using optical and electron microscopy. The experimentally measuredG/R ratios and the clearly revealed heterogeneous nuclei together demonstrated the thermodynamic effect of the heat input and welding speed on the weld metal grain structure.     

Fusion zone microstructure and porosity in electron beam welds of an α+β titanium alloy

The effect of electron beam welding parameters on fusion zone (FZ) microstructure and porosity in a Ti −6.8 Al −3.42 Mo −1.9 Zr −0.21 Si alloy (Russian designation VT 9) has been investigated. It has been observed that the FZ grain width increased continuously with increase in heat input when the base metal was in the β heat-treated condition, while in the α+β heat-treated base metal welds, the FZ grain width increased only after a threshold energy input. The difference is attributed to both the weld thermal cycle and the pinning effect of equiaxed primary alpha on grain growth in the heat-affected zone (HAZ) of α+β heat-treated base metal. Postweld heat treatment (PWHT) in the subtransus and supertransus regions did not alter the columnar grain morphology in the FZ, possibly due to the lack of enough driving force for the formation of new grains by the breaking up of the columnar grains and grain boundary movement for grain growth. As the PWHTs were conducted in a furnace, the role of thermal gradients can be ruled out. Intragranular microstructure in the aswelded condition consisted of hexagonal martensite. The scale of the martensite laths depended on welding speed. The highest porosity was observed at intermediate welding speeds. At low speeds, a majority of pores formed at the fusion boundary, while at high speeds, occurrence of porosity was maximum at the weld center. The trends on porosity can be explained on the basis of solubility of hydrogen in titanium as a function of temperature and the influence of weld thermal cycle on nucleation, growth, and escape of hydrogen gas bubbles. The porosity at slow welding speeds is low because sufficient time exists for the nucleation, growth, and escape of hydrogen gas bubbles, while insufficient time exists for the nucleation of gas bubbles at high welding speeds. The effect of pickling of joint surface, vacuum annealing of the base metal, and successive remelting of the weld metal has also been investigated.     

Microstructure Evolution during Friction Stir Welding of Mill-Annealed Ti-6Al-4V

In this study, mill-annealed Ti-6Al-4V plates were successfully friction stir welded over a wide range of processing parameters using a tungsten-1 pct La₂O₃ tool. Two K-type thermocouples embedded in the tool indicated that approximately 25 pct of the heat generated during welding was transferred out of the workpiece and into the tool. The thermocouple data, combined with observations of the microstructure, indicated that the stir zone of all welds exceeded the β transus. The microstructure and texture of two representative welds made just above and high above the β transus were investigated with scanning electron microscopy and electron backscatter diffraction (EBSD). The β phase orientations were reconstructed with a fully automated technique from the as-collected α phase data through knowledge of the Burgers orientation relationship. The results suggest that the fine β grains in the stir zone are formed from the base material ahead of the advancing tool by dissolution of secondary and primary α phase, and there is no further recrystallization. These grains subsequently deform by slip and rotate toward the orientations that are most stable with respect to the shear deformation induced by the tool. In the highest temperature weld, diffusion tool wear in the form of periodically spaced bands provided an internal marker of the tool/workpiece interface during welding. The flow patterns evident within the tungsten-enriched bands suggest that flow is considerably more chaotic on the advancing side than in the central stir zone.     

A Study on Laser Beam Welding (LBW) Technique: Effect of Heat Input on the Microstructural Evolution of Superalloy Inconel 718

The effect of heat input from laser beam welding (LBW) on the microstructural evolution of superalloy Inconel 718 was investigated. LBW was carried out on 1.6-mm-thick sheets with an average grain size of 13 μm (ASTM # 9.5), and four different heat inputs in the range of 74.5 mm⁻¹ to 126.6 J mm⁻¹ were used. Full penetration was achieved in all weld experiments. Microstructures of the welds were evaluated using an optical microscope and a field emission scanning electron microscope. Increasing the heat input changed the resulting weld shape from a wine glass shape to a stemless glass shape with wider surface bead widths, and the measured average dendrite arm spacing was increased from 1.06 μm to 2.30 μm, indicating the corresponding solidification rate in the range of 1.75 × 10⁵ K s⁻¹ (°C s⁻¹) to 3.5 × 10⁶ K s⁻¹ (°C s⁻¹). The welds also were free from microfissuring even at the lowest heat input trials. The Nb concentration of Laves phase for the current LBW samples was ≈20.0 wt pct. The coefficients of partition and distribution for Nb were determined to be approximately 3.40 and 0.50, respectively.     

A Comparison of Residual Stress Development in Inertia Friction Welded Fine Grain and Coarse Grain Nickel-Base Superalloy

The effect of the base material microstructure on the development of residual stresses across the weld line in inertia friction welds (IFWs) of high-strength nickel-base superalloy RR1000 was studied using neutron diffraction. A comparison was carried out between tubular IFW specimens generated from RR1000 heat treated below (fine grain (FG) structure) and above (coarse grain (CG) structure) the γ′-solvus. Residual stresses were mapped in the as-welded (AW) condition and, after a postweld heat treatment (PWHT), optimized for maximum alloy strength. The highest tensile stresses were generally found in the hoop direction at the weld line near the inner diameter of the tubular-shaped specimens. A comparison between the residual stresses generated in FG and CG RR1000 suggests that the starting microstructure has little influence on the maximum residual stresses generated in the weld even though different levels of energy must be input to achieve a successful weld in each case. The residual stresses in the postweld heat treated samples were about 35 pct less than for the AW condition. Despite the fact that the high-temperature properties of the two parent microstructures are different, no significant differences in terms of stress relief were found between the FG and CG RR1000 IFWs. Since the actual weld microstructures of FG and CG RR1000 inertia welds are very similar, the results suggest that it is the weld microstructure and its associated high-temperature properties rather than the parent material that affects the overall weld stress distribution and its subsequent stress relief.     

Effect of dispersed Al<Subscript>3</Subscript>Sc particles on dynamic recrystallization in P/M 7000 series alloys

Al₃Sc particles are well known to be a recrystallization inhibitor in Al alloys. In this study, 0.4, 0.8 and 1.5 mass% Sc were added to 7000 series Al alloys in supersaturation by using powder metallurgy. By subjecting rapidly solidified powders of these alloys to a heat treatment at 773 K, Al₃Sc particles were precipitated in the matrix. Subsequently, hot extrusion was carried out at 773 K. During extrusion, continuous dynamic recrystallization (DRX) occurred and fine DRX grains with a diameter of 1 mm were formed. The number of DRX grains was the largest in the 1.5Sc alloy. Even though the amount of Sc added in this case was two times larger, the number of DRX grains in 0.4Sc was almost the same as that in 0.8Sc. Since continuous DRX occurs only under conditions where the grain boundary mobility is low, the number of DRX grains is strongly related to the pinning force on the initial grain boundary exerted by Al₃Sc particles. The pinning force varied with the diameter and volume fraction of Al₃Sc particles. When the pinning force was calculated from the diameter of Al₃Sc particles, which was measured by TEM, it was proven that the number of DRX grains was proportional to the calculated pinning force. Except in the case of 0.4Sc, the Al₃Sc particle diameter was twice that obtained at the maximum pinning force (d _max ). It is possible to promote continuous DRX by decreasing the Al₃Sc particle diameter in 0.8 and 1.5Sc alloys. Lowering the heating rate before heat treatment for degassing reduced the critical nucleus size for precipitation of Al₃Sc particles as well the diameter of Al₃Sc particles. Thus, the pinning force increased in 0.8Sc and 1.5Sc alloys, and the number of DRX grains also increased, as expected.     

Microstructure and Properties Analysis of Laser Welding and Laser Weld Bonding Mg to Al Joints

Laser welding and laser weld bonding (LWB) Mg to Al joints were obtained in different welding parameters. The penetrations and microstructures of these kinds of joints changed with the increasing of pulse laser power density. Both laser welding and LWB Mg to Al joints with the best properties were obtained in conductive welding mode. In laser welding Mg to Al joint, several intermetallics formed at the bottom of the fusion zone, where some cracks were generated. In laser weld bonding Mg to Al joint, the decomposition of the adhesive caused a baffle effect on the diffusion between the Mg and the Al. The intermetallics formed in the middle of the fusion zone, and the thickness of Mg₁₇Al₁₂ layer was approximately 10 to 20 μm and the Mg₂Al₃ layer was less than 5 μm, which influenced the property of the joint less.     

A study of the weldability and weld related microstructure of cabot alloy 214

The weldability and weld metal microstructure of Cabot Alloy 214 have been investigated with a variety of experimental and analytical techniques. These include Varestraint hot crack testing, hot ductility testing, pulsed Nd:YAG laser welding, scanning and analytical electron microscopy, electron microprobe analysis, and X-ray diffraction. A heat of Alloy 214 containing intentionally alloyed B (0.003 wt pct) and Zr (0.07 wt pct) was much more sensitive to both fusion zone hot cracking as quantified by the Varestraint test and to simulated heat-affected-zone (HAZ) cracking as quantified by hot ductility testing than a heat of Alloy 214 containing no intentionally added B (0.0002 wt pct) or Zr (0.02 wt pct). Scanning electron microscopy of the high B and Zr alloy showed the presence of dendritically-shaped, Zr-rich constituents in interdendritic regions in the gas-tungsten-arc (GTA) welds. Electron microprobe analysis of these welds revealed a segregation pattern of Cr, Al, Mn, and Zr enrichment in interdendritic regions and Ni and Fe enrichment in dendrite core regions. Analytical electron microscopy revealed the presence of ZrX (X = B, C, N, O), M₂₃C₆, andγ′ in the fusion zone of GTA weld specimens,γ′ was also found in the as-received base metal and in the GTA weld HAZ. X-ray diffraction analysis of extractions from the high B and Zr GTA weld metal also indicated the presence of a ZrX-type constituent. The results of this study are in qualitative agreement with earlier work performed on alloys such as NIMONIC 90 and INCONEL 718^∗ relative to the detrimental effect of B and Zr additions on fusion zone and HAZ hot cracking susceptibility. Formerly with Sandia National Laboratories, Albuquerque, NM     

Microstructure Refinement After the Addition of Titanium Particles in AZ31 Magnesium Alloy Resistance Spot Welds

Microstructural evolution of AZ31 magnesium alloy welds without and with the addition of titanium powders during resistance spot welding was studied using optical microscopy, scanning electron microscopy, and transmission electron microscopy (TEM). The fusion zone of AZ31 magnesium alloy welds could be divided into columnar dendritic zone (CDZ) and equiaxed dendritic zone (EDZ). The well-developed CDZ in the vicinity of the fusion boundary was clearly restricted and the coarse EDZ in the central region was efficiently refined by adding titanium powders into the molten pool, compared with the as-received alloy welds. A microstructural analysis showed that these titanium particles of approximately 8 μm diameter acted as inoculants and promoted the nucleation of α-Mg grains and the formation of equiaxed dendritic grains during resistance spot welding. Tensile-shear testing was applied to evaluate the effect of titanium addition on the mechanical properties of welds. It was found that both strength and ductility of magnesium alloy welds were increased after the titanium addition. A TEM examination showed the existence of an orientation matching relationship between the added Ti particles and Mg matrix, i.e., [ 0 1[`1]0 ]<sub>\textMg</sub> //  [ 1[`2] 1[`3] ]<sub>\textTi</sub>  \textand ( 000 2 )<sub>\textMg</sub> //  ( 10[`1]0)_\textTi \left[ {0 1\bar{1}0} \right]_{\text{Mg}} // \, \left[ { 1\bar{2} 1\bar{3}} \right]_{\text{Ti}} \,{\text{and}}\,\left( {000 2} \right)_{\text{Mg}} // \, ( 10\bar{1}0)_{\text{Ti}} in some grains of Ti polycrystal particles. This local crystallographic matching could promote heterogeneous nucleation of the Mg matrix during welding. The diameter of the added Ti inoculant should be larger than 1.8 μm to make it a potent inoculant.     

Charpy V-notch properties and microstructures of narrow gap ferritic welds of a quenched and tempered steel plate

Multipass welds of quenched and tempered 50-mm-thick steel plate have been deposited by a single wire narrow gap process using both gas metal arc welding (GMAW) and submerged arc welding (SAW). Of the five welds, two reported much lower Charpy V-notch (CVN) values when tested at −20 °C. The CVN toughness did not correlate with either the welding process or whether the power source was pulsed or nonpulsed. The only difference in the ferritic microstructure between the two welds of low Charpy values and the three of high values was the percentage of acicular ferrite. There was no effect of the percentage of as-deposited reheated zones intersected by the Charpy notch or the microhardness of the intercellular-dendritic regions. In all welds, austenite was the microconstituent between the ferrite laths. The percentage of acicular ferrite correlated with the presence of MnO, TiO₂, γ Al₂O₃, or MnO. Al₂O₃ as the predominant crystalline compound in the oxide inclusions. In turn, the crystalline compound depended on the aluminum-to-titanium ratio in both the weld deposits and the oxide inclusions. In addition to the presence of less acicular ferrite, the two welds that showed lower Charpy values also reported more oxide inclusions greater than 1 μm in diameter. The combination of more oxide inclusions greater than 1 μm and less acicular ferrite is considered to be the explanation for the lower Charpy values.     

Microstructural factors governing hardness in friction-stir welds of solid-solution-hardened Al alloys

Microstructural factors governing hardness in friction-stir welds of the solid-solution-hardened Al alloys 1080 and 5083 were examined by optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The effect of grain boundary on the hardness was examined in an Al alloy 1080 which did not contain any second-phase particles. The weld of Al alloy 1080 had a slightly greater hardness in the stir zone than the base material. The maximum hardness was located in the thermomechanically affected zone (TMAZ). The stir zone consisted of recrystallized fine grains, while the TMAZ had a recovered grain structure. The increase in hardness in the stir zone can be explained by the Hall-Petch relationship. On the other hand, the hardness profiles in the weld of Al alloy 5083 were roughly homogeneous. Friction-stir welding created the fine recrystallized grains in the stir zone and recovered grains in the TMAZ in the weld of this alloy. The stir zone and the TMAZ had slightly higher dislocation densities than the base material. Many small Al₆(Mn,Fe) particles were detected in all the grains of the weld. The hardness profiles could not be explained by the Hall-Petch relationship, but rather by Orowan hardening. The results of the present study suggest that the hardness profile is mainly affected by the distribution of small particles in friction-stir welds of Al alloys containing many such particles.     

CO2 laser beam welding of 6061-T6 aluminum alloy thin plate

Laser beam welding is an attractive welding process for age-hardened aluminum alloys, because its low heat input minimizes the width of weld fusion and heat-affected zones (HAZs). In the present work, 1-mm-thick age-hardened Al-Mg-Si alloy, 6061-T6, plates were welded with full penetration using a 2.5-kW CO₂ laser. Fractions of porosity in the fusion zones were less than 0.05 pct in bead-on-plate welding and less than 0.2 pct in butt welding with polishing the groove surface before welding. The width of a softened region in the-laser beam welds was less than 1/4 times that of a tungsten inert gas (TIG) weld. The softened region is caused by reversion of strengthening β″ (Mg₂Si) precipitates due to weld heat input. The hardness values of the softened region in the laser beam welds were almost fully recovered to that of the base metal after an artificial aging treatment at 448 K for 28.8 ks without solution annealing, whereas those in the TIG weld were not recovered in a partly reverted region. Both the bead-on-plate weld and the butt weld after the postweld artificial aging treatment had almost equivalent tensile strengths to that of the base plate.     

Fiber Laser Welded AZ31 Magnesium Alloy: The Effect of Welding Speed on Microstructure and Mechanical Properties

This study was aimed at characterizing microstructural change and evaluating tensile and fatigue properties of fiber laser welded AZ31B-H24 Mg alloy with special attention to the effect of welding speed. Laser welding led to the formation of equiaxed dendrites in the fusion zone and columnar dendrites near the fusion zone boundary along with divorced eutectic Mg₁₇Al₁₂ particles and recrystallized grains in the heat-affected zone. The lowest hardness across the weld appeared in the fusion zone. Although the yield strength, ductility, and fatigue life decreased, the hardening capacity increased after laser welding, with a joint efficiency reaching about 90 pct. A higher welding speed resulted in a narrower fusion zone, smaller grain size, higher yield strength, and longer fatigue life, as well as a slightly lower strain-hardening capacity mainly because of the smaller grain sizes. Tensile fracture occurred in the fusion zone, whereas fatigue failure appeared essentially in between the heat-affected zone and the fusion zone. Fatigue cracks initiated from the near-surface welding defects and propagated by the formation of fatigue striations together with secondary cracks.     

Ferrite Grain Size Distributions in Ultra-Fine-Grained High-Strength Low-Alloy Steel After Controlled Thermomechanical Deformation

Plane-strain compression testing was carried out above, around, and below the A _r3 temperature with the deformation temperature, T _def, varying between 1323 K and 973 K (1050 °C and 700 °C), using Gleeble 3500, to develop uniform distribution of ultra-fine ferrite (UFF) grains. Prior austenite (γ) grain structure, developed after soaking at 1473 K (1200 °C), was mixed in nature, comprising both coarse- and fine-γ-grain sizes. Applying heavy deformation in a single pass, just above the austenite-to-ferrite (α) transformation temperature (A _r3), and cooling to room temperature resulted in the formation of UFF grain sizes (average α-grain size ~2 to 3 μm), with the largest grain sizes extending up to ~10 to 12 μm. Water quenching just after deformation prevented the coarsening of UFF grains and restricted the largest grain sizes to under 6 μm. Although the ferrite grain structures appeared homogeneous in slowly cooled samples (cooling rate (CR) 1 K/s), careful observation revealed the presence of alternate bands of coarse- (5 to 10 μm) and fine-α grains (<1 to 3 μm). The final α-grain size distributions were explained in view of the starting γ-grain size variation, dynamic recrystallization (DRX) of γ, dynamic strain-induced γ-to-α transformation (DSIT), and DRX of α and grain growth during slow cooling. Electron backscattered diffraction analysis (EBSD) revealed the presence of a large fraction (70 to 80 pct) of high-angle boundaries, having misorientation ≥15 deg. Compared to the use of the single, heavy deformation pass, the application of a number of lighter passes between A _e3 and A _r3 temperatures is more suitable in industrial rolling conditions, and also has the potential of developing UFF grains with high-angle boundaries.     

Effect of Mechanical Arc Oscillation on the Grain Structure of Mild Steel Weld Metal

The effect of mechanical arc oscillation on the weld metal grain structure in mild steel gas tungsten arc welds has been studied. For welds made without arc oscillation, columnar grains were observed in the weld metal; however, for the same welding parameters, the weld made with arc oscillation had smaller sized relatively equiaxed grains in the weld metal. The strengths for weld made with arc oscillation was higher than that for weld made without arc oscillation, with appreciable increase in ductility; this could be attributed to the reduction in grain size diameter due to arc oscillation. Lower weld metal hardness and increase in heat affected zone hardness was observed in weld made with arc oscillation; this could be attributed to increase in pro-eutectoid ferrite formation with absence of Widmanstatten ferrite structures in the weld metal and less coarsening of grains in the heat affected zone due to increased cooling rate.     

Effect of cooling after welding on microstructure and mechanical properties of 12 Pct Cr steel weld metals

The microstructure of three 12 pct cr steel weld metals with different nickel and nitrogen contents was studied in as-welded condition and after postweld heat treatment with and without intercooling. Tensile strength and impact toughness of the weld metals were investigated in different postweld heat treatment conditions. In weld metals heat treated without intercooling, austenite decomposed by a eutectoid reaction that resulted in M₂₃C₆ aggregates around retained δ-ferrite. Two morphologies of M₂N and MN precipitates were found in a low-dislocation α-ferrite. It was concluded that these phases were also transformed from austenite. In weld metals heat treated with intercooling, M₂₃C₆ precipitates were smaller and more homogeneously distributed. Different MN precipitates were found in the tempered martensite. The fracture mode of the weld metals at room temperature was mainly transgranular cleavage with some fibrous fracture. Intercooling treatment improved Charpy impact toughness of the 12 pct Cr steel weld metals substantially. It was found that the important microstructural factors affecting the impact toughness of the weld metals which were heat treated without intercooling were the sizes of the α-ferrite grains, nonmetallic inclusions, and M₂₃C₆ aggregates. For the weld metals heat treated with intercooling, the factors which affect the toughness of the weld metals were the sizes of martensite packets and nonmetallic inclusions.