Weldability and joining characteristics of AISI 430/AISI 1040 steels using keyhole plasma arc welding

AISI 430 and AISI 1040 steel couples were welded using the keyhole plasma-transferred arc (KPTA) welding process. Welded joints were manufactured using three different traverse speeds (0.01, 0.02 and 0.03?m/min) under three different welding currents (130, 135 and 140 A) at a constant plasma gas flow rate (1.1?l/min) and a shielding gas rate (25?l/min). In order to determine the microstructural changes that occurred, the interface regions of the welded specimens were examined by Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD) and Energy Dispersive Spectrometry (EDS) after KPTA welding. Microhardness, V-notch Charpy and tensile tests were conducted to determine the mechanical properties of the welded specimens.     

Investigation of mechanical properties of friction-welded AISI 304 with AISI 1021 dissimilar steels

Austenitic stainless steel and low alloy steels are extensively used in various automotive, aerospace, nuclear, chemical, and other general purpose applications. Joining of dissimilar metals is one of the challenging tasks and most essential need of the present-day industry. It has been observed that a wide range of dissimilar materials can be easily integrated by friction welding. The objectives of the present investigation were obtaining weldments between austenitic stainless steel (AISI 304) with low alloy steel (AISI 1021) and optimizing the friction welding parameters in order to establish the weld quality. In the present study, an experimental setup was designed in order to achieve friction welding of plastically deformed austenitic stainless steel and low alloy steel. AISI 304 and AISI 1021 steels were welded by friction welding using five different axial pressures at 1,430 rpm. The joining performances of friction-welded dissimilar joints were studied, and influences of these process parameters on the mechanical properties of the friction-welded joints were estimated. The joint strength was determined with tensile testing, and the fracture behavior was examined by scanning electron microscopy (SEM) and was supported and backed by energy dispersive spectroscopy (EDS) analysis. Furthermore, the proposed joints were tested for impact strength, and the microhardness across the joint was also evaluated.     

Genetic algorithm based optimization of the process parameters for gas metal arc welding of AISI 904 L stainless steel

The present study is focused on welding of super austenitic stainless steel sheet using gas metal arc welding process with AISI 904 L super austenitic stainless steel with solid wire of 1.2 mm diameter. Based on the Box — Behnken design technique, the experiments are carried out. The input parameters (gas flow rate, voltage, travel speed and wire feed rate) ranges are selected based on the filler wire thickness and base material thickness and the corresponding output variables such as bead width (BW), bead height (BH) and depth of penetration (DP) are measured using optical microscopy. Based on the experimental data, the mathematical models are developed as per regression analysis using Design Expert 7.1 software. An attempt is made to minimize the bead width and bead height and maximize the depth of penetration using genetic algorithm.     

不锈钢薄板光纤激光焊接的组织与性能

采用GSI的JK-200FL型连续光纤激光器实现了 0.2mm厚304不锈钢片的对接焊.在氩气保护下,优化后工艺参数为激光功率90W,光斑直径0.2mm.焊接速度1200mm/min,获得成形良好,无缺陷的焊缝.采用金相显微镜可见焊缝组织由边缘细小的柱状晶和中心部位细小的等轴晶组成.经硬度测试和弯折测试,表明焊缝处的硬...     

Study on microstructure and mechanical properties of dissimilar steel joint developed using friction stir welding

In the present study, microstructure and mechanical properties of dissimilar weld of structural steel and ferritic stainless steel (FSS) plates of thickness 3 mm were investigated. The plates were butt welded by friction stir welding and defect-free welds were produced at a traverse speed of 20 mm/min and rotational speed of 508 rpm using a tungsten carbide tool. The weld joint consisted of alternate bands of both steels resembling an onion ring pattern. In the weld joint, six distinct regions were found including both the base metals. The stir zone of structural steel revealed refined grain structure of ferrite, pearlite, and martensite whereas in ferritic stainless side, highly refined ferritic grains with grain boundary martensite was observed and also confirmed by x-ray diffraction (XRD). The hardness of the weld joint varies from 186 to 572 HV. This scatter of hardness in stir zone is due to the presence of metal from both sides. The ultimate tensile and yield strengths of the transverse weld specimens was higher than the structural steel base metal whereas lower than the ferritic stainless steel, having fracture from structural steel side.     

Study of laser butt welding of SUS301L stainless steel and welding joint analysis

This paper describes a study on laser butt welding of 4 and 2 mm SUS301L stainless steel and a detailed analysis of welding joints. The gap tolerance of butt joint was also studied with optimized process parameters. The electrolytic etching in 10 % oxalate solution was used to test the intergranular corrosion of the 4 mm SUS301L welded joint. Fatigue property of the 2 mm SUS301L welded joint was tested under the conditional cycle times of 1?×?10⁷. Using optical microscopy, the changes of metallurgical microstructure in the weld zone of 4 mm SUS301L were also studied. It has been found that laser butt welding of 4 mm SUS301L is able to achieve sound metallurgical morphology and high strength weld joint when the butt gap is within certain tolerance. The weld joint also has good resistance to intergranular corrosion and has a fatigue limit of 310 MPa.     

Microstructural studies and impact toughness of dissimilar weldments between AISI 316 L and AH36 steels by FCAW

In this study, AISI 316 L austenitic stainless steel and AH36 low-alloy ship building steel pair were joined with flux-cored arc welding method by using E309LT1-1/4 filler metal under four different shielding gas compositions containing CO₂ at different ratios. Microstructure, impact toughness of welded materials, and their microhardness distribution throughout joining were determined. In macro- and microstructure examinations, stereo optical microscope, scanning electron microscope (SEM), SEM/energy dispersive spectroscopy, and SEM/mapping analysis techniques were used. After notched impact toughness, fracture surfaces were examined using the scanning electron microscope. This study investigated effects of shielding gas composition on microstructure, impact toughness, and microhardness distribution of transition zone between AH36 steel and weld metal of joined material. It is observed that based on an increase in amount of CO₂ in shielding gas, impact toughness values of the weldment decreased. Microhardness values change throughout weld metal depended on shielding gas composition. Moreover, an increase in amount of CO₂ within shielding gas decreased δ-ferrite amount in weld metal. The increase in amount of CO₂ within shielding gas leads to expanded transition zone in interface between AH36 and weld metal and also affects notched impact toughness values negatively due to the inclusion amounts occurring in weld metal and hence caused it to decrease.     

Evaluation of the metallurgical and mechanical properties of friction-welded joints of dissimilar metal combinations AISI2205/Cu

In this study, the joining performances of AISI2205/Cu friction-welded joints were studied using different friction pressures (35, 50, and 65 MPa) and friction times (6, 9, and 12 s). The microstructural properties of welded samples were examined by scanning electron microscopy. In order to determine the phases that occurred during welding, welded samples were examined with energy dispersive spectrometry and X-ray diffraction analysis. The microhardness across the interface of samples was measured, and also the strength of the joints was determined with tensile tests. The experimental results indicate that the tensile strength of friction-welded AISI2205/Cu components were significantly affected by joining friction pressure and friction time selected.     

Microstructure and mechanical properties of similar and dissimilar stainless steel electron beam and friction welds

Microstructure and mechanical properties of similar and dissimilar welds of austenitic stainless steel (AISI 304), ferritic stainless steel (AISI 430), and duplex stainless steel (AISI 2205) have been studied. Welding processes electron beam welding and friction welding were used. Optical, scanning electron microscopy, and electron probe microscopy were carried out to study the microstructural changes. Residual stress, hardness, tensile strength, and impact toughness testing were conducted to study mechanical behavior. Dissimilar metal electron beam welds of austenitic–ferritic, ferritic–duplex, and austenitic–duplex stainless steel welds contained coarse grains, which are predominantly equiaxed on austenitic, duplex stainless steel side, and they are columnar on the ferritic stainless steel side. Diffusion of elements was significant in electron beam welding and insignificant in friction welds. Austenitic–ferritic stainless steel exhibited tensile residual stress on the ferritic stainless steel side adjacent to the interface, compressive stresses on the austenitic stainless steel side that matches with the delta ferrite microstructure observed in this region. High compressive stresses were noted on duplex stainless steel side interface compared to austenitic stainless side interface. The highest tensile strength was observed in duplex–austenitic stainless steel joints. The impact strength and notch tensile strength of electron beam weldments are higher than the friction weldments. All electron beam and friction welds showed toughness lower than parent metals.     

Experimental investigation of the effect of vibration on mechanical properties of 304 stainless steel welded parts

Some of the problems that occur during the welding process include the creation of coarse grains in the weld structure and the hardening of the weld region, which reduce the strength and impact resistance of the welded parts. One technique to improve the mechanical properties of weld is the application of mechanical vibration to the molten pool. In this article, the effect of vibrating the part during welding on the mechanical properties of steel plates has been investigated in the tungsten inert gas (TIG) welding process. The plate is made of stainless steel 304 with 2 mm in thickness. A filler material has also been used for welding so that the effect of vibration can be observed on the weld pool region. The experimental tests have been performed under different welding conditions with respect to voltage, current, welding speed, vibrations amplitude, and frequency. Then, the resultant mechanical properties of the tested parts were measured. Also, the microstructure obtained by applying the vibration has been examined. Based on these experimental results, the effect of mechanical vibration on mechanical properties of the weld was investigated. Moreover, considering the mechanical properties obtained from these experiments, the optimum values of amplitude, frequency, and welding speed were determined.     

Investigation on the resistance spot-welded austenitic/ferritic stainless steel

In this work, the effect of weld current on joining capability of austenitic stainless steel (AISI 304) and ferritic stainless steel (AISI 430) sheets with application of resistance spot welding process was investigated. Macrostructure, microstructure, microhardness, tensile shear strength, and failure mode of welded materials were evaluated for different weld currents. The values of weld current were 2.5, 3.75, and 5 kA. It was found that when the weld current increased, the nugget size and the weld strength were increased. Two distinct failure modes including interfacial and pullout were observed during tensile shear test. Finally, an adequate weld current was obtained.     

Modeling and simulation of wire feed rate for steady current and pulsed current gas metal arc welding using 317L flux cored wire

Wire feed rate plays a vital role in determining the weld characteristics in gas metal arc welding (GMAW). The wire feed rate is affected by any change in welding current in the case of steady current GMA welding and by any change in frequency, peak current, base current and duration of peak and base currents in the case of pulsed GMA welding. To predict the wire feed rate for any set of these parameters, a mathematical model was developed from the results obtained by conducting experiments. Electrode resistance heating constant and arc resistance heating constant were also determined by fitting a regression model. The above parametric constants have been used to simulate the wire feed rates for pulsed GMA welding for different pulse parameters using MATLAB. The effects of pulse parameters on the burnoff factor and burnoff rates were also analysed. The investigation was carried out using AWS 5.22–95 filler wire of size 1.2 mm diameter and the base metal used was IS:2062 structural steel plate of 20 mm thickness. An argon and 5% CO₂ gas mixture at a flow rate of 16 l/min was used for shielding throughout the welding.     

SAF2205/16MnR双相不锈钢复合板焊接接头的组织与性能

对SAF2205/16MnR双相不锈钢复合板进行了焊接,基层采用手工电弧焊,以E5015焊条为填充材料,过渡层及覆层采用钨极氩弧焊,以ER2209焊丝为填充材料;对焊接接头进行了拉伸试验,利用扫描电镜、光学显微镜及X射线衍射仪等分析了接头过渡层焊缝及其熔合区域的显微组织及物相组成.结果表明:焊接接头的抗拉强度为512 MPa;覆层母材/热影响区/过渡层焊缝之间的显微组织过渡缓和,且铁素体和奥氏体相的比例均在控制范围内;异种金属熔合界面未出现明显的合金元素短程扩散,且在焊缝金属中未发现有M23C6和σ等脆性相析出;所得接头具有良好的力学性能和耐腐蚀性能.     

Understanding the process parameter interactions in multiple-pass ultra-narrow-gap laser welding of thick-section stainless steels

In laser welding, typical welding penetration depths are in the order of 1–2 mm/kW laser power. The multipass laser welding technique, based on the narrow-gap approach, is an emerging welding technology that can be applied to thick-section welds by using relatively low laser power, but the process is more complicated since it is necessary to introduce filler wire to narrow-gap weld configurations. The aim of this work was to understand significant process parameters and their interactions in order to control the weld quality in ultra-narrow-gap (1.5 mm gap width) laser welding of AISI grade 316L stainless steel. A 1-kW IPG single-mode fiber laser was used for welding plates that were 5 to 20 mm in thickness using the multiple-pass narrow-gap approach. Design of experiments and statistical modelling techniques were employed to understand and optimise the processing parameters. The effects of laser power, wire feed rate, and welding speed on the weld homogeneity, integrity, bead shape, gap bridgability and surface oxidation were studied. The results were evaluated under different optimising constraints. The results show that the models developed in this work can effectively predict the responses within the factors domain.     

Parameter optimization and mechanism of laser–arc hybrid welding of dissimilar Al alloy and stainless steel

Laser–cold metal transfer arc hybrid welding of 6061 Al alloy and AISI304 stainless steel (304SS) was carried out. Bead morphologies and intermetallic compound (IMC) layer characterizations of the joints were studied in detail. The optimal parameter range for accepted bead appearances (OPRBA) without surface and interface defects was obtained, and the growth mechanism of the IMC layer was summarized. The results showed that the nonuniformity in the thickness and shape along the fusion zone/304SS interface from the top surface to the bottom increases with increasing heat input and is more sensitive to laser power because the interface temperature is dominated by a high-temperature laser keyhole throughout the molten pool. As the welding parameters are within the OPRBA and the heat input is within the range of 80–110 J/mm, the joints are stronger than 130 MPa and the corresponding IMC layer thickness is at the range of 3–6.5 μm. The kinetic analysis showed that a controlling interface temperature no more than 1,120 °C may limit the growth of the IMC layer.     

Friction stir butt welding thin aluminum alloy sheets

0.8-mm-thick alclad 2024-T4 aluminum alloy sheets were friction stir butt welded. A 15-mm diameter shoulder tool was used to guarantee sufficient heat input during welding. A 0.08-mm shoulder plunge depth was adopted to reduce sheet thickness reduction. Sound joints were obtained at rotating speeds from 400 to 1000 rpm and welding speeds from 50 to 150 mm/min. A thickness reduction of 6% was achieved at 1000 rpm and 50 mm/min. Secondary phases firstly precipitated at the black lines in the stir zone (SZ). The hardness of the SZ showed a decrease about 6% compared with the base metal. A maximum tensile strength of 399.5 MPa and an elongation of 5.6% were achieved at 1000 rpm and 150 mm/min. The fracture morphologies showed typical ductile fracture mode.     

Microstructure and mechanical properties of electron beam-welded AISI 409M-grade ferritic stainless steel

This paper deals with the microstructure and mechanical characterization of electron beam-welded AISI 409M-grade ferritic stainless steel joints. Single-pass autogenous welds free of volumetric defects were produced at a welding speed of 1,000?mm/min. The joints were subjected to optical microscopy, scanning electron fractography, microhardness, transverse and longitudinal tensile, bend and charpy impact toughness testing. The coarse ferrite grains in the base metal were changed into fine equiaxed axial grains and columnar grains as a result of characteristic rapid solidification of electron beam welds. Tensile testing indicates overmatching of the weld metal relative to the base metal. The joints exhibited acceptable impact toughness and bend strength properties.     

Positron Annihilation and Complementary Studies of Stainless Steel Exposed to Sandblasting at Different Angles

Defect studies in subsurface zone in stainless steel 304 AISI samples exposed to sandblasting were performed using positron annihilation spectroscopy techniques. Samples were sandblasted with a different impact angle. Conventional experiments based on positrons emitted directly from the radioactive source allowed us to detect vacancies on the dislocation edges in all samples; however, the total depths of subsurface zones depended strictly on the impact angle, i.e., 35 µm for impact angle of 90° and about 12 µm for 30°. The complementary methods such as SEM and optical profilometry revealed also dependencies between the impact angle and roughness of the surface which are not observed in the variable energy positron beam examinations.     

Tribological Properties of Borided AISI 4140 Steel with the Powder Pack-Boriding Method

The present study evaluates the tribological properties of boride layers on the surface of AISI 4140 steel, formed using the pack-boriding method. Commercial EKabor^®2 was used as the boronizing agent and the treatment was carried out at 900, 950, 1000, and 1050 °C for 2, 4, and 6 h, respectively. X-ray diffraction (XRD), scanning electron microscopy (SEM), and microhardness tests were used to characterize the phase composition, microstructure, and local hardness, respectively, of the borided steel samples. Block-on-disc tests were used to investigate tribological properties. Abrasive wear tests were carried out using emery paper at a fixed sliding speed and three different loads. Adhesive wear tests were executed against AISI 52100 steel at a fixed load and distance. The coefficient of friction values (COF) of the samples were determined simultaneously during the tests. The weight loss and COF of the borided samples were compared with untreated samples and the results suggest that both wear resistance and friction properties of the AISI 4140 steel improve with boriding.     

光纤激光焊接ANSI304不锈锅中厚板工艺参数研究

随着海工装备和核电工业的发展,对不锈钢厚板的焊接要求越来越高。采用正交试验方法对6mm厚的ANSI304不锈钢进行光纤激光拼焊,研究了工艺参数（包括激光功率、焊接速度和离焦量）变化对304不锈钢（0Crl9Ni9）焊接结果的影响,结合激光深熔焊原理对试验结果进行了理论分析,并对焊接试件进行了拉伸试验,检测了焊接试件的拉伸性能,获得了6mm厚’ANSI304不锈钢激光焊接的最佳工艺参数。