Liquation Microfissuring in the Weld Heat-Affected Zone of an Overaged Precipitation-Hardened Nickel-Base Superalloy

The effect of preweld overaging heat treatment on the microstructural response in the heat-affected zone (HAZ) of a precipitation-hardened nickel-base superalloy INCONEL 738LC subjected to the welding thermal cycle (i.e., rapid) was investigated. The overaging heat treatment resulted in the formation of an interfacial microconstituent containing M₂₃X₆ particles and coarsening of primary and secondary γ′ precipitates. The HAZ microstructures around welds in the overaged alloy were simulated using the Gleeble thermomechanical simulation system. Microstructural examination of simulated HAZs and those present in tungsten inert gas (TIG) welded specimens showed the occurrence of extensive grain boundary liquation involving liquation reaction of the interfacial microconstituents containing M₂₃X₆ particles and MC-type carbides. In addition, the coarsened γ′ precipitate particles present in the overaged alloy persisted well above their solvus temperature to temperatures where they constitutionally liquated and contributed to considerable liquation of grain boundaries, during continuous rapid heating. Intergranular HAZ microfissuring, with resolidified product formed mostly on one side of the microfissures, was observed in welded specimens. This suggested that the HAZ microfissuring generally occurred by decohesion across one of the solid-liquid interfaces during the grain boundary liquation stage of the weld thermal cycle. Correlation of simulated HAZ microstructures with hot ductility properties of the alloy revealed that the temperature at which the alloy exhibited zero ductility during heating was within the temperature range at which grain boundary liquation was observed. The on-cooling ductility of the alloy was significantly damaged by the on-heating liquation reaction, as reflected by the considerably low ductility recovery temperature (DRT). Important characteristics of the intergranular liquid that could influence HAZ microfissuring of the alloy in overaged condition are also discussed.

On the Role of Grain Boundary Serration in Simulated Weld Heat-Affected Zone Liquation of a Wrought Nickel-Based Superalloy

The effects of grain boundary serration on boron segregation and liquation cracking behavior in a simulated weld heat-affected zone (HAZ) of a wrought nickel-based superalloy 263 have been investigated. The serrated grain boundaries formed by the developed heat treatment were highly resistant to boron segregation; the serrated sample contained 41.6 pct grain boundaries resistant to boron enrichment as compared with 14.6 pct in the unserrated sample. During weld thermal cycle simulation, liquated grain boundaries enriched with boron were observed at the peak temperature higher than 1333 K (1060 °C) in both unserrated and serrated samples; however, serrated grain boundaries exhibited a higher resistance to liquation. The primary cause of liquation in this alloy was associated with the segregation of the melting point depressing element boron at grain boundaries. The hot ductility testing result indicated that the serrated grain boundaries showed a lower susceptibility to liquation cracking; the grain boundary serration led to an approximate 15 K decrease in the brittle temperature range. These results reflect closely a significant decrease in interfacial energy as well as a grain boundary configuration change by the serration.     

Microstructural Analysis of Fusion Zone in Gas Tungsten Arc-Welded Newly Developed Co-Based Superalloy

Metallurgical and Materials Transactions A - The fusion zone (FZ) microstructure of a newly developed gas tungsten arc-welded cobalt-based superalloy called CoWAlloy1 is characterized. Elemental...     

Numerical Modeling of Gas Tungsten Arc Welding of a Newly Developed Cobalt-Based Superalloy

Metallurgical and Materials Transactions A - A three-dimensional finite-element thermal model with a volumetric moving heat source is developed to simulate the gas tungsten arc welding process of a...     

Effects of Carbon Variation on Microstructure Evolution in Weld Heat-Affected Zone of Nb-Ti Microalloyed Steels

We investigated the effects of C concentration variation from 0.028 to 0.058 wt pct on microstructure of the coarse grained heat-affected zone (CGHAZ) of low heat input girth welded Ti-Nb microalloyed steels by using electron microscope and atom probe tomography. It is found that the CGHAZ microstructure exhibits a systematic response to C variation. Increased C raises the temperature for precipitation of NbC. This leads to coarser (Ti, Nb)N-Nb(C, N) but finer delayed strain-induced NbC in the high-C steel than in the low-C steel. Fine strain-induced NbC are ineffective in preventing austenite grain coarsening in CGHAZ due to their fast dissolution upon heating. For a given inter-particle spacing originally determined by (Ti, Nb)N particles, increased epitaxial growth of Nb(C, N) on pre-existing (Ti, Nb)N in the high-C steel results in a smaller austenite grain size of 34 µm in the CGHAZ of the high-C steel than that of 52 µm in the low-C steel. Increased C promotes a microstructure consisting of bainitic lath structure with C Cottrell atmospheres at dislocation debris and martensitic layers of 30 to 100 nm in thickness at inter-lath boundaries in the CGHAZ. Increased C promotes configuration of crystallographic variants belonging to different Bain groups in the neighbors, preferentially twin-related variant pairs within a bainite packet.

     

Modeling of Grain Structure and Heat-Affected Zone in Laser Surface Melting Process

A combination of phase-field and cellular automata methods is used to study the effect of initial grain size and laser power density on heat-affected zone (HAZ) formation during laser surface melting. Also, an analytical model is developed to estimate the depth of HAZ as a function of initial grain size and process parameters. Both analytical and numerical results indicate that the size of HAZ, as measured with respect to the changes in the grain structure, is inversely proportional to the initial grain size. They also show how increasing the laser power leads to an increase in the extent of HAZ. The proposed models thus provide a basis for the prediction and control of HAZ in laser surface melting.     

Effect of Solution Temperature on the Microstructure and Mechanical Properties of a Newly Developed Superalloy TMW-4M3

The influence of solution temperature on the microstructure and mechanical properties of TMW-4M3 superalloy has been investigated. Comparisons of mechanical properties have also been made between the heat-treated TMW-4M3 variants and the commercial U720Li. The key microstructural variables examined were grain size and the volume fraction and size of the strengthening γ′ precipitates that control the mechanical properties of these alloys. By increasing the solution temperature from 1373 K to 1393 K (1100 °C to 1120 °C), the volume fraction of primary gamma prime dropped from 16.9 pct to 14.5 pct, whereas the average grain size increased from 8.7 μm to 10.6 μm. Compared with an alloy with a smaller grain size, the alloy with a larger grain size exhibited superior resistances to creep and fatigue crack growth without the expense of reduced tensile strength and low-cycle fatigue resistance. This suggested that a higher solution temperature may benefit TMW-4M3 in terms of superior overall properties. The greater overall properties of TMW-4M3 variants than that of commercial U720Li were also demonstrated experimentally. The possible explanations for the improvement of mechanical properties were discussed.     

Characterization of Microstructures across the Heat-Affected Zone of the Modified 9Cr-1Mo Weld Joint to Understand Its Role in Promoting Type IV Cracking

In the postweld heat-treated (PWHT) fusion welded modified 9Cr-1Mo steel joint, a soft zone was identified at the outer edge of the heat-affected zone (HAZ) of the base metal adjacent to the deposited weld metal. Hardness and tensile tests were performed on the base metal subjected to soaking for 5 minutes at temperatures below Ac₁ to above Ac₃ and tempering at the PWHT condition. These tests indicated that the soft zone in the weld joint corresponds to the intercritical region of HAZ. Creep tests were conducted on the base metal and cross weld joint. At relatively lower stresses and higher test temperatures, the weld joint possessed lower creep rupture life than the base metal, and the difference in creep rupture life increased with the decrease in stress and increase in temperature. Preferential accumulation of creep deformation coupled with extensive creep cavitation in the intercritical region of HAZ led to the premature failure of the weld joint in the intercritical region of the HAZ, commonly known as type IV cracking. The microstructures across the HAZ of the weld joint have been characterized to understand the role of microstructure in promoting type IV cracking. Strength reduction in the intercritical HAZ of the joint resulted from the combined effects of coarsening of dislocation substructures and precipitates. Constrained deformation of the soft intercritical HAZ sandwich between relatively stronger constitutes of the joint induced creep cavitation in the soft zone resulting in premature failure.     

Tensile Deformation Behavior and Phase Transformation in the Weld Coarse-Grained Heat-Affected Zone of Metastable High-Nitrogen Fe-18Cr-10Mn-N Stainless Steel

The tensile deformation behavior and phase transformation in the weld coarse-grained heat-affected zone (CGHAZ) of a metastable high-nitrogen austenitic stainless steel was explored through tensile tests, nanoindentation experiments, and transmission electron microscopy analysis. True stress–strain response during tensile test was found to be seriously affected by δ-ferrite fraction, which depends on peak temperature of the CGHAZs. The strain-induced martensitic transformation (SIMT) occurred in base steel, whereas the SIMT disappeared and deformation twinning occurred predominantly in the CGHAZs. The relationship among true stress–strain response, nanoindentation hardness, and deformed microstructures was carefully investigated and discussed in terms of changes of stacking fault energy.     

Use of Friction Stir Processing for Improving Heat-Affected Zone Liquation Cracking Resistance of a Cast Magnesium Alloy AZ91D

Metallurgical and Materials Transactions B - In this work, a cast magnesium alloy AZ91D was friction stir processed. Detailed microstructural studies and Gleeble hot ductility tests were conducted...     

1000MPa级超高强钢的SH-CCT曲线及其热影响区的组织和性能简

 采用热膨胀法结合显微金相与硬度检测,在热模拟试验机上测定了1000MPa级低碳微合金高强钢焊接过程中的临界点Ac1和Ac3,绘制出该钢在不同冷却速率下的焊接连续冷却转变曲线(SH-CCT曲线),研究了冷却速率对焊接热影响区粗晶区(CGHAZ)组织和硬度的影响规律,揭示了不同冷却速率下焊接热影响区的相变过程及组织特征,同时获得了奥氏体晶粒平均尺寸随t8/5的变化关系。研究结果表明,在焊接条件下,该钢的奥氏体化温度要比平衡状态下的奥氏体化温度显著升高;该钢在相当宽的冷却速率范围内发生中温转变,获得贝氏体组织;在较快的冷却速率(≥40℃/s)下,焊接热影响区组织以马氏体为主;随着冷却时间t8/5的增加,硬度逐渐下降,最高硬度HV10为425。在试验条件下,奥氏体晶粒粗化程度并不显著。     

Reduced Dwell-Fatigue Resistance in a Ni-Base Superalloy After Short-Term Thermal Exposure

The effect of short-term thermal exposure on microstructure and dwell-fatigue resistance of Ni-base superalloy 718Plus was investigated. Contrary to previous studies performed after long-term exposure, an increase in the dwell-fatigue crack growth rate was observed, which was connected to a small increase in the size of the hardening precipitates. The proposed controlling mechanism was the stress relaxation rate at the crack tip, and based on this a schematic model for the development of the properties during exposure is presented.     

Atom-Probe Tomographic Investigation of Austenite Stability and Carbide Precipitation in a TRIP-Assisted 10 Wt Pct Ni Steel and Its Weld Heat-Affected Zones

Newly developed low-carbon 10 wt pct Ni-Mo-Cr-V martensitic steels rely on the Ni-enriched, thermally stable austenite [formed via multistep intercritical Quench-Lamellarization-Tempering (QLT)-treatment] for their superior mechanical properties, specifically ballistic resistance. Critical to the thermal stability of austenite is its composition, which can be severely affected in the weld heat-affected zones (HAZs) and thus needs investigations. This article represents the first study of the nanoscale redistributions of C, Ni, and Mn in single-pass HAZ microstructures of QLT-treated 10 wt pct Ni steels. Local compositions of Ni-rich regions (representative of austenite compositions) in the HAZs are determined using site-specific 3-D atom-probe tomography (APT). Martensite-start temperatures are then calculated for these compositions, employing the Ghosh-Olson thermodynamic and kinetics approach. These calculations predict that austenite (present at high temperatures) in the HAZs is susceptible to a martensitic transformation upon cooling to room temperature, unlike the austenite in the QLT-treated base-metal. While C in the QLT-treated base-metal is consumed primarily in MC and M₂C-type carbide precipitates (M is Mo, Cr, V), its higher concentration in the Ni-rich regions in the HAZs indicates the dissolution of carbide precipitates, particularly M₂C carbide precipitates. The role of M₂C carbide precipitates and austenite stability is discussed in relation to the increase in microhardness values observed in the HAZs, relative to the QLT-treated base-metal. Insights gained from this research on austenite stability and carbide precipitation in the single-pass HAZ microstructures will assist in designing multiple weld cycles for these novel 10 wt pct Ni steels.     

Unravelling Microstructure Evolution and Grain Boundary Misorientation in Coarse-Grained Heat-Affected Zone of EH420 Shipbuilding Steel Subject to Varied Welding Heat Inputs

Microstructure evolution and grain boundary misorientation in coarse-grained heat-affected zone of EH420 shipbuilding steel have been investigated at different welding heat inputs. As heat input increases, main constituents transform from lath bainites to granular bainites, and to acicular ferrites as a result of reduced cooling rate. Corresponding fraction of high angle grain boundaries decreases from 28.24 to 20.04 pct as heat input is raised from 50 to 150 kJ/cm but reverses to 29.04 pct at 200 kJ/cm.     

Effects of Thermal History and Microstructure on Segregation of Phosphorus and Alloying Elements in the Heat-Affected Zone of a Low Alloy Steel

The grain boundary segregation of phosphorus and alloying elements in the heat-affected zone (HAZ) of a low alloy steel was studied quantitatively with atom probe tomography. Non-equilibrium segregation mainly occurred during welding and subsequent fast cooling, leading to remarkable segregation of P, C, Mn, and Mo. The segregation of these four types of solutes showed similar microstructure-dependence at this stage, in which the segregation levels are higher in coarse-grained HAZ and intercritically reheated coarse-grained HAZ than in fine-grained HAZ. After simulated aging, P and Mn showed further enrichment at grain boundaries through equilibrium segregation, while desegregation was observed for C and Mo. In addition, it seems that precipitation of Mo at dislocations was greatly promoted during aging, which probably also contributed to the increase of P and Mn at grain boundaries.     

Improved Fracture Toughness and Resistance to Fatigue Crack Propagation in ESR Steels

Abstract

Two types of alloy steels (En 24 and En 52 steels) have been electro slag refined and the improvement in their mechanical properties has been assessed. ESR has improved the tensile ductility, plane strain fracture toughness, room temperature CVN energy, fatigue strength and has decreased fatigue crack growth rates. The K _lc values for the ESR steel are nearly twice those estimated in the unrefined steel. Fatigue crack growth rates in region I and region III are found to be decreased considerably in the ESR steel while they are unaffected in region II. The improvement in the mechanical properties has been explained in terms of the removal of large sized nonmetallic inclusions and reduction in sulfur content in the ESR steel.

Résumé

Deux types d'aciers alliés (En 24 et En 52) ont été affinés par refusion sous laitier (ESR) et l'amélioration de leurs propriétés mécaniques a été évaluée. Le procédé ESR a amélioré la ductilité en traction, la ténacité en déformation plane, l' énergie CEV à température ambiante, la résistance à la fatigue et a diminué les taux de croissance des fissures de fatigue. Les valeurs de K_lc des aciers ESR sont presque le double de celles estimees pour les aciers non affinés. Les taux de propagation des fissures de fatigue dans les domaines I et III sont considérablement moins élevés dans les aciers ESR alors qu'ils ne sont pas affectés dans la région II. L'amélioration des propriétés mécaniques a été expliquée en termes de l'enlèvement des inclusions non métalliques de taille importante et de la réduction de la teneur en soufre des aciers ESR.