Hot cracking susceptibility of boron modified AISI 304 austenitic stainless steel welds

Abstract

The hot cracking susceptibility of welds made on AISI 304 stainless steel modified with from 0·2 to 1·0 wt-%B has been investigated. Varestraint tests showed that the hot cracking susceptibility is high for boron additions of about 0·2%, but is decreased when the boron content is increased to ≥0·5%. Steels containing about 0·2%B were found to have a wide solidification temperature range and their high temperature ductility was low compared with boron free AISI 304 steel and the other boron modified steels. Ferrite precipitation was inhibited in the 0·2%B steels and the formation of low melting point grain boundary films was thereby promoted. Increasing the boron content to ≥0·6% reduces the coefficient of thermal expansion and narrows the solidification temperature range. In addition, crack refilling was observed, resulting in improved hot ductility and high resistance to hot cracking. It is concluded that in structures where weld restraint forces are not high, hot cracking is not likely to occur if boron additions of >0·6% are made to AISI 304 stainless steel. In T-type and Fisco weld cracking tests, in which the weld restraint forces are close to those experienced by actual structural welds, the boron modified stainless steels show a low hot cracking susceptibility which is not significantly different from that of boron free AISI 304 steel.

MST/1548     

Metallographic analysis of embedded crack in electron beam welded austenitic stainless steel chemical storage tank

An AISI 304L austenitic stainless steel tank used for chemical storage showed cracks during the post weld qualification programme. A crack of 75 mm length embedded within the weld pool was subjected to detailed metallographic analysis. The results revealed that the cracking was due to a shift in the solidification mode from primary ferrite to primary austenite. The residual stress introduced during rolling and forming of material as well as additional contractional strain during welding under fixtured condition, are additional factors which caused cracking.     

The sensitivity of surface crack initiation to surface roughness in low-cycle fatigue at high temperature

Low-cycle fatigue tests have been carried out on AISI 304L stainless steel and Cr---Mo---V steel specimens with two different modes of surface roughness at 823 K. In the case of Cr---Mo---V steel, grain boundary cavities were not formed during the test. Transgranular cracks were formed and then propagated. The number of cycles required for the crack initiation was observed to be a very large fraction of the toral fatigue life. In the case of AISI 304L stainless steel, grain boundary cavities formed and intergranular crack initiation and propagation was also observed to occur. The number of cycles required for crack initiation was negligible in comparison with the total low-cycle fatigue life.     

A study on low magnetic permeability gas tungsten arc weldment of AISI 316LN stainless steel for application in electron accelerator

Low magnetic permeability is an important criterion in selection of the material of construction of beam pipes and vacuum chambers of electron accelerators for safeguarding against distortion of the magnetic field. In the modified design of new 20 MeV/30 mA Injector Microtron for the existing synchrotron radiation sources Indus-1 and Indus-2, AISI 316 LN stainless steel has been identified as the material of construction of its vacuum chamber. Welding of AISI 316LN stainless steel with conventional filler alloys like ER316L and ER317L of AWS A5.9 produces duplex weld metal with 3–8% ferro-magnetic delta ferrite to avoid solidification cracking. The results of the study has demonstrated that GTAW of AISI 316LN SS with high Mn adaptation of W 18 16 5 N L filler produced a crack free non-magnetic weld with acceptable mechanical properties. Moreover, AISI 316LN stainless steel is not required to be solution annealed after the final forming operation for obtaining a low magnetic permeability, thereby avoiding solution annealing of large vacuum chamber in vacuum/controlled atmosphere furnace and associated problems of distortion. Besides Injector Microtron, the study also provides useful input for design of future indigenous accelerators with vacuum chambers of austenitic stainless steel.     

Effect of welding processes on fatigue crack growth behaviour of AISI 409M ferritic stainless steel joints fabricated using duplex stainless steel fillers

The present investigation aims to study the effect of welding processes such as shielded metal arc welding (SMAW), gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) on fatigue crack growth behaviour of the ferritic stainless steel (FSS) conforming to AISI 409M grade. Rolled plates of 4 mm thickness were used as the base material and AISI 2209 grade duplex stainless steel (DSS) was used as filler metal, for preparing single pass butt welded joints. Centre cracked tensile (CCT) specimens were used to evaluate the fatigue crack growth behaviour. From this investigation, it is found that the GTAW joints showed superior fatigue crack growth resistance compared with SMAW and GMAW joints. The reasons for the superior performance were discussed in detail.     

Fatigue crack growth from stage I to stage II in a corrosive environment

How a corrosive environment such as a 3.5% NaCl aqueous solution would affect the transition of fatigue crack initiation mode from stage I (shear mode) cracking to stage II (normal mode) cracking was investigated, using notched specimens of HT80 and SNCM439 steels (corresponding to AISI 4340 steel).The experimental result that the transition of fatigue crack growth from stage I to stage II was accelerated in a hydrogen-related environment was discussed in terms of hydrogen induced dislocation multiplication near a crack tip. The microstructures immune to environmental damage were examined, using a precipitate-hardened steel.     

Stress corrosion cracking of AISI 321 stainless steel in acidic chloride solution

The stress corrosion cracking (SCC) of AISI 321 stainless steel in acidic chloride solution was studied by slow strain rate (SSR) technique and fracture mechanics method. The fractured surface was characterized by cleavage fracture. In order to clarify the SCC mechanism, the effects of inhibitor KI on SCC behaviour were also included in this paper. A study showed that the inhibition effects of KI on SCC were mainly attributed to the anodic reaction of the corrosion process. The results of strain distribution in front of the crack tip of the fatigue pre-cracked plate specimens in air, in the blank solution (acidic chloride solution without inhibitor KI) and in the solution added with KI measured by speckle interferometry (SPI) support the unified mechanism of SCC and corrosion fatigue cracking (CFC).     

Failure analysis of H13 working die used in plastic injection moulding

The present study is focused on the failure of a die used in plastic injection moulding. The die was made from AISI H13 steel and was intended for the production of plastic cups used for the outer closure of cylindrical aluminium cans in coffee packaging. The appearance of the die provides a clear picture of degradations. Extended corrosion damage on various areas of the metallic part and a wide crack can be observed by the naked eye. Hardness measurements and chemical analysis eliminated the probability of faulty material selection or improper heat treatment. Visual inspection, macro-examination and microscopic observations of representative failed parts revealed that the failure was caused by corrosion that led to the total cracking of the die. The design deficiency and improper cooling conditions generated a complex fatigue-corrosion cracking mechanism that lead to the damage of the die after half of it’s predicted service life.     

Failure Investigation of Stainless Steel Adaptor

Adaptors used in check valve inlet pressure sensors were fabricated from austenitic stainless steel. Recently, during pretest operation and during hydrogen pressurization of an engine, a leak was noticed through the adaptor. Subsequent to disassembly, the leak was attributed to a crack in the adaptor. Detailed metallurgical investigations were carried out to understand the cause of cracking. Synergistic effect of chloride ions present in marine environment, the presence of residual stresses and sensitized grains of the material led to intergranular stress corrosion cracking. This article highlights details of investigation.     

Cracking of Aluminum Alloy Rivets Used in Space Application: A Metallurgical Investigation

Adaptors used in check valve inlet pressure sensors were fabricated from austenitic stainless steel. Recently, during pretest operation and during hydrogen pressurization of an engine, a leak was noticed through the adaptor. Subsequent to disassembly, the leak was attributed to a crack in the adaptor. Detailed metallurgical investigations were carried out to understand the cause of cracking. Synergistic effect of chloride ions present in marine environment, the presence of residual stresses and sensitized grains of the material led to intergranular stress corrosion cracking. This article highlights details of investigation.     

冷喷涂304不锈钢涂层的弯曲力学行为研究

采用冷喷涂(CGDS)技术在IF钢基体上制备304不锈钢涂层.用SHIMADZU液压伺服疲劳试验机对304不锈钢涂层样品进行三点弯曲实验,用扫描电子显微镜来研究冷喷涂304不锈钢涂层的断裂行为.结果表明:冷喷涂304不锈钢涂层的断裂行为为脆性断裂;裂纹萌生于涂层表面,随着载荷和力矩的增加,裂纹向涂层内部扩展,裂纹在涂层...     

Weldability and properties of martensitic/austenitic stainless steel joints

Abstract

A series of studies has been carried out to examine the weldability and properties of dissimilar steel joints using martensitic and austenitic stainless steels F6NM (OCr13Ni4Mo) and AISI 347, respectively. This type of joint requires good mechanical properties, corrosion resistance, and a stable magnetic permeability in addition to a good weldability. Weldability tests include weld thermal simulation of the martensitic steel to investigate the influence of weld thermal cycles and post-weld heat treatment (PWHT) on the microstructure and mechanical properties of the heat affected zone (HAZ); implant testing to examine the tendency for cold cracking of martensitic steel; and rigid restraint testing to determine hot crack susceptibility of the multipass dissimilar steel joints. The simulation results indicated that the toughness of the martensitic steel HAZ did not change significantly after the weld thermal cycles. The implant test results indicated that welds produced using nickel based filler show no tendency for cold cracking, whereas welds produced using martensitic or ferritic filler show such a tendency. Based on the weldability tests, a welding procedure (tungsten inert gas welding for root passes with HNiCrMo-2B wire followed by manual metal arc welding using ENiCrFe-3B coated electrode) was developed and a PWHT at 600°C for 2 h was recommended. Joints produced using the developed welding procedure are not susceptible to hot and cold cracking. After PWHT the joints exhibit both satisfactory mechanical properties and stress corrosion cracking resistance.

MST/1955     

An evaluation of the crack growth and fracture properties of AISI 403 modified 12 Cr stainless steel

The plane strain fracture toughness, $\text{K}{}_{\mathrm{Ic}}$, and fatigue crack growth rate material properties were developed for three heats of AISI 403 modified 12 Cr stainless steel. Valid (per ASTM requirements) fracture toughness tests were conducted in the temperature range ?200°F to 175°F. In addition, both the room temperature air environment plus 520°F, 1200psi distilled water environment fatigue crack growth rate material properties are presented. Finally, a hypothetical example problem is included which demonstrates the application of fracture mechanics technology to an AISI 403 modified 12 Cr stainless steel turbine rotor.     

On the stress corrosion cracking mechanisms of austenitic stainless steels

In this paper, experimental results on stress corrosion cracking in austenitic stainless steels are described. Crack growth data in sodium chloride solution for AISI 304 steel obtained for different metallurgical conditions, acoustic emission data recorded during crack growth and fractographic observations have been discussed with a view to identifying the operating mechanism. Some of the experimental observations such as crack propagation occurring in discontinuous jumps of the order of a few microns, lowering of the threshold stress intensity andJ-integral values on sensitization and cold working, typical transgranular fractographic features, transition in mode of fracture from transgranular to intergranular in sensitized conditions and activation energies of the order of 50 to 65 kJ/mol can all be accounted by hydrogen embrittlement mechanism. Hydrogen generated at the crack tip by corrosion reaction diffuses ahead of the crack tip under hydrostatic stress and influences the deformation process at the crack tip and also leads to the brittle component of the crack advance in jumps.     

ARTIFICIAL RETARDATION OF FATIGUE CRACK GROWTH BY THE INFILTRATION OF CRACKS BY FOREIGN MATERIALS

The effects of inducing artificial crack closure into fatigue cracks in AISI 304 stainless steel by infiltrating foreign materials have been investigated. The foreign materials used include pure epoxy resin and resin mixed with 0.3  μm and 4  μm TiO2 , 4  μm Fe, as well as 18  μm AISI 316L stainless steel. In all the cases studied, different degrees of crack growth retardation have been achieved. When the particle size was small enough or when the prop-opening load for infiltration was large enough, crack arrest occurred. Crack retardation and arrest were mainly caused by the infiltrated material rather than the propping load. A rigid-wedge model was found to have limited value in predicting the possible outcome of an infiltration. On the other hand, the degree of crack closure immediately on resumption of a test after infiltration could tell whether the treatment was going to be successful or not.     

Softened zone formation and joint strength properties in dissimilar friction welds

The mechanical properties of dissimilar MMC/AISI 304 stainless steel friction welds with and without silver interlayers were examined. The notch tensile strengths of MMC/AISI 304 stainless steel and MMC/Ag/AISI 304 stainless steel friction welds increased when high friction pressures were applied during the joining operation. The higher notch tensile strengths of dissimilar MMC/AISI and MMC/Ag/AISI 304 stainless steel friction welds resulted from the formation of narrow softened zones in MMC material immediately adjacent to the bondline. The influence of softened zone width and hardness (yield strength) on the notch tensile strengths of dissimilar welds was analysed using finite element modelling (FEM). FEM in combination with the assumption of a ductile failure criterion was used to calculate the notch tensile strengths of dissimilar joints. The key assumption in this work is that dissimilar weld failure wholly depended on the characteristics (mechanical properties and dimensions) of the softened zone formed in MMC material immediately adjacent to the bondline. The modelling results produced based on this assumption closely correspond with the actual notch tensile strengths of dissimilar MMC/Ag/AISI 304 stainless steel and MMC/Ag/AISI 304 stainless steel friction welds.     

高强不锈钢绞线网增强工程水泥基复合材料弯曲性能试验

为了研究高强不锈钢绞线网增强工程水泥基复合材料(Engineered cementitious composites,ECC)的受弯性能,考虑纵向高强不锈钢绞线配筋率、ECC抗压和抗拉强度等影响因素,对设计的8个高强不锈钢绞线网增强ECC试件进行四点弯曲试验.结果 表明,随着纵向高强不锈钢绞线配筋率增大,其开裂荷载基本...     

Investigation on cracking mechanism of austenite stainless steel during in situ tension in transmission electron microscope

Twin-roll strip casting technology is a new one to produce austenite stainless steel strip directly. However, during this process, the cracking occurs usually on the surface of the steel strip. The technique of in situ tension in transmission electron microscope was used to observe and analyze the crack initiation and propagation in austenite stainless steel produced by twin-roll strip casting technology in this work. The results show that the crack initiates in dislocation free-zone firstly and then propagates along the direction vertical to the tensile force. The crack may propagate in continuous propagation way and discontinuous one respectively. When the shear stress on the close-packing face and the normal stress on the secondary close-packing face are at the same side of the tensile force, the cracks propagate continuously. However, when the shear stress on the close-packing face and the normal stress on the secondary close-packing face are in two sides, the cracks propagate discontinuously.     

Effect of ultrasonic nanocrystal surface modification on the characteristics of AISI 310 stainless steel up to very high cycle fatigue

Effects of ultrasonic nanocrystal surface modification (UNSM) on the very high cycle fatigue response of AISI 310 stainless steel have been investigated. The higher impact force used in UNSM treatment showed a higher fatigue life improvement. The fatigue life improvement was higher in crack initiation from the surface of specimens. The subsurface crack initiation depth in the alloy increased with increase in the fatigue failure cycles. It was concluded that UNSM treatment can increase the life of the alloy significantly up to very high cycle fatigue.     

Characterization of Weld Solidification Cracking in a Duplex Stainless Steel

Weld solidification cracking in the duplex stainless steel SAF 2205 has been investigated and compared with that of alternate duplex and austenitic stainless steels. Varestraint weld-ability testing showed SAF 2205 to exhibit a lower cracking susceptibility than that of the duplex stainless steel Ferralium 255 but greater than that of a Type 304 austenitic stainless steel which solidified as ferrite and exhibited Ferrite Number 8 (FN 8) in the weld fusion zone. The high augmented strain levels required to induce cracking in these three alloys during Varestraint testing indicated a high resistance to solidification cracking at strain levels normally encountered in structural weldments. Cracking susceptibilities of the duplex and Type 304/FN-8 stainless steels were appreciably lower than that of a Type 304L stainless steel which solidified entirely to austenite and exhibited less than FN 1 in the weld fusion zone.

Microstructural characterization of SAF 2205 using conventional black-and-white and two different color metallography techniques showed solidification cracks to be associated with ferrite grain boundaries. Color metallography was also effective in revealing the fusion zone solidification structure and delineating second phases, including inter- and intragranular austenite and fine Cr₂N precipitates. Fractographic analysis of solidification crack surfaces from SAF 2205 Varestraint samples revealed dendritic and flat topographies, and confirmed a solidification versus solid-state cracking mechanism.