Welding Effect at the Heat Affected Zone by Joining a Gray Cast Iron with Stainless Steel E308-16

Different investigations of the union of dissimilar materials such as stainless steel and different castings have been carried out, but rapid cooling immediately after welding has not been considered, in this work it was investigated how rapid cooling affects the metallurgical microstructure and consequently the mechanical properties. The effect of welding parameters on the microstructure and mechanical properties of the joint between dissimilar metals, an E-308-16 austenitic stainless steel and Gray Cast Iron was also analyzed. Gray cast iron samples (GCI) were fabricated, welded and cooled. The main welding parameters studied in this work are the welding technique and the type of filler electrodes. Flux-coated electrode E-308-16 was applied for this different joint. An experimental study was carried out for the analysis of welded joints of similar and dissimilar steels. The microstructure of the welded joints was analyzed using an optical microscope, in the base metals, heat affected zone (HAZ) and filler metal. The mechanical properties of the welded joints were evaluated by Vickers microhardness and tensile strength tests. The hardness profile showed differences in hardness between the base metals, the heat affected zone and the filler metal. The metallurgical microstructures observed along the welded areas corresponded to the profile. The hardness differences determined the effect on the mechanical and metallurgical characteristics of the welded samples as a result of the cooling rate differences. This research work is important because it allows us to analyze the possibility of reworking pieces of dissimilar materials by welding or, failing that, to determine if this may or may not be possible.

Microstructural zones and tensile characteristics of friction stir welded joint of TC4 titanium alloy

TC4 titanium alloy was friction stir welded using a W-Re pin tool,and the defect-free weld was produced with proper welding parameters.The joint consists of stir zone,heat affected zone and base material.The stir zone is characterized by equiaxed dynamically recrystallized α phases and transformed β phases with fine α+β lamellar microstructure.The microstructure of the heat-affected zone is similar to that of the base material,but there is an increase in the volume fraction of β.Transverse tensile strength of the joint is 92% that of the base material,and the joint is fractured in the stir zone and the fracture surface possesses typical plastic fracture characteristics.The stir zone is the weakest part of the joint,through which the tensile characteristics of the TC4 joint can be explained.

Effect of welding parameters on the heat-affected zone of AISI409 ferritic stainless steel

One of the main problems during the welding of ferritic stainless steels is severe grain growth within the heat-affected zone （HAZ） In the present study, the microstmctural characteristics of tungsten inert gas （TIG） welded AISI409 ferritic stainless steel were investigated by electron backscattered diffraction （EBSD）, and the effects of welding parameters on the grain size, local misorientation, and low-angle grain boundaries were studied. A 3-D finite element model （FEM） was developed to predict the effects of welding parameters on the holding time of the HAZ above the critical temperature of grain growth. It is found that the base metal is not fully recrystallized. During the welding, complete recrystallization is followed by severe grain growth. A decrease in the number of low-angle grain boundaries is observed within the HAZ. FEM results show that the final state of residual sWains is caused by competition between welding plastic strains and their release by recrystallization. Still, the decisive factor for grain growth is heat input.

INFLUENCE OF LOCAL BRITTLE ZONE ON THE FRACTURETOUGHNESS OF HIGH-STRENGTH LOW-ALLOYEDMULTIPASS WELD METALS

In this paper, toughness properties and microstructurc of low-alloyed multipass welds with yield strength above 700MPa have 6een studied using the weld thermal simulation and throughout thickness CTOD fracture mechanics tests. Impact testing of thermal simulated specimens showed that the primary weld metal and the fine gmmed weld metal had good toughness, while the coarse grained weld metal had the lowest toughness value as the local brittle zone (LBZ) in multipass weld metals. Cleavage fracture in CTOD testing of thick multipass weld metals was initiated from martensite-austenite (MA) phases in the LBZ. MA phases were distributed at the prior austenite grain boundaries and around ferrite grains. As the size of the local brittle zone along the fatigue crack front increases, CTOD frncture toughness of multipass weld metals decreases. The weakest link theory was used to evaluate effect of the local brittle zone on fracture toughness of thick multipass weld metals. The estimated curves agree well with the eaperimental data.

Study on shape factor of the fusion-solidification zone of electron beam weld

The concept of shape factors of the fusion-solidification zone is proposed to describe the weld cross section geometry. According to these shape factors, the electron beam weld fusion-solidification zone is divided into four typical shapes and the classification criterion for these typical shapes is suggested. An integrated parameter n, combining the line power density of electron beam and material thermal properties is proposed to describe the relative power input, and another integrated parameter n2 combing the accelerating voltage and focusing current is proposed to reflect the power distribution in the keyhole. A series of new expressions, which can reflect the influence of focusing current, accelerating voltage, beam current, and material thermal properties, are developed to predict the fusion-solidification zone shape based on experimental results nonlinear fitting of n1 and n2.

MICROSTRUCTURE TRANSFORMATION IN THE WELDING HEAT AFFECTED ZONE OF 800MPa GRADE ULTRA FINE STRUCTURED STEEL

The transformation behavior and microstructure development in the heat affected zone(HAZ) of 800MPa grade ultra fine structured steel was investigated. It was found thatthe HAZ has intermediate temperature transformation characteristics in a wide rangeof cooling rates, with the bainite sheaves consisting of bainite ferrite plates withoutcarbide precipitation and retained austenite in the fast cooling regime. At relativelyhigh cooling rates, which corresponded to low heat inputs, the hardness of the simulatedHAZ was above that of the base metal. When the cooling rate was below 9℃/s, thewelding HAZ would have an obvious softening. The analysis of transformation ratesin continuous cooling processes was completed by numerical differential method. Theresult indicated that the microstructure transformation rate of the HAZ in 800MPagrade ultra fine structured steel changed sharply to slow speeds when the cooling timet_(8/5) is longer than 7s.

Microstructure and toughness of local brittle zone of HSLA steel multipass weld metals

By using thermo-simulation,Auger analysis and Charpy Ⅴ impact test and with the observation of the microstructures in which cleavage crack was initiated,the morphology and toughness of the local brittle zone of C-Mn and Cr-Ni-Mo multipass weld metals have been investigated.The results indicated that the local brittle zone in C-Mn weld metals with low and high Mn％ and Cr- Ni-Mo weld metals is different.With statistical analysis,it has been revealed that the more the local brittle zone and the lower their toughness,the lower the toughness of the entire weld metals.The alloy elements have a noticeable influ- ence on the toughness of the local brittle zone,thereby changing the toughness of weld metals.

Quantitative research on the heat affected zone of weave bead welding for Invar alloy

Quantitative research on the heat affected zone （ HAZ） o f weave bead welding （ WBW） joint fo r Invar alloy is carried out in this paper. Based on the morphology and related data analysis of the weld seam, the width difference o f each layer and the forming mechanism are analyzed. Results show that the bottom layer （ Layer 1 ） has the widest HAZ and the smallest fluctuation, which reaches 1 200 ｜jLm. HAZ width o f layer 2 to 5 is relatively narrower which is basically below 600 jjim, while the amplitude fluctuation is greater. The main reason lies in the welding path. The long straight welding without weave causes the base metal near the groove fully melts which causes by the long straight welding without weave, while welding with weave leads to the uneven and inadequate melting of metal near groove.

Residual Stresses and Micro-Hardness Testing in Evaluating the Heat Affected Zone’s Width of Ferritic Ductile Iron Arc Welds

Shielded Metal Arc Welding (SMAW) in Ductile Irons (DI) is often required by foundries for practical manufacturing reasons. The mechanical properties of the welded structures are strongly dependent on their HAZ’s width. A model based on the behaviour of the ferritic matrix of high-Si DIs in order to make an approach in measuring their HAZ’s width is developed in this study. A series of thermal treatments on 3.35 and 3.75 wt% Si as-cast DIs and spot SMAWs is applied on these materials. The applied SMAWs are done on non-preheated and preheated samples (150℃ - 300℃). For welding we modify the amperage (100 - 140A). The micro-hardness Vickers changes in the ferrite of the as-cast samples and inside the HAZ of the welded ones can be attributed to the existence of residual stresses (RS) in the ferritic matrix and assist in estimating the HAZ’s width.

Study on laser welded heat-affected zone in new ultralow carbon bainitic steel

800 MPa grade ultralow carbon bainitic （NULCB） steel is the recently developed new generation steel, which was produced by thermo mechanical controlled processing ＆ relaxation-precipitation controlling transformation （TMCP＆RPC） tech- nique. The microstructure and the mechanical properties of the heat-affected zone （HAZ） in NULCB steel under laser welding conditions were investigated by using a Gleeble-1500 thermal simulator. The experimental results indicate that the simplex microstructure in the HAZ is granular bainite that consists of bainite-ferrite （BF） lath and M-A constituent when the cooling time from 800 to 500℃ （t8/5） is 0.3-30 s, and the M-A constituent consists of twinned martensite and residual austenite. As t8/5 increases, the hardness and tensile strength of HAZ decreases, but they are higher than that of the base metal, indicating the absence of softened zone after laser welding. The impact toughness of HAZ increases at first and then decreases when t8/5 increases. The impact energy of HAZ is much higher than that of the base metal when t8/5 is between 3 and 15 s. It indicates that excellent low temperature toughness can be obtained under appropriate laser welding conditions.

High-temperature creep properties of fine grained heat-affected zone in P92 weldment

The simulated fine grained heat-affected zone (FGHAZ) specimens for P92 welded joints were prepared by heat treatment, then the creep tests were carried out at 650 ℃ under the applied stress of 90-120 MPa to investigate high-temperature creep behavior of FGHAZ. The results show that the creep property of FGHAZ is much inferior to that of the base metal, which exhibits the much higher steady creep rate and shorter time to creep fracture. The power law equation can describe the steady creep rate dependence on applied stress, indicating that the stress exponent n of FGHAZ is distinguished between two regions with n=15.1 at high stresses (more than 100 MPa) and n=8.64 at lower stresses. Based on Monkman-Grant equation, the relationship between the secondary creep rate and time to rupture is obtained to evaluate the creep life of FGHAZ with the applied stress above 100 MPa.

Effect of Zr-Ti combined deoxidation on impact toughness of coarse-grained heat-affected zone with high heat input welding

In this study, the effects of Zr-Ti combined deoxidation and AI deoxidation on the impact toughness of coarse- grained heat-affected zone in high-strength low-alloy steels were investigated. More fine oxides were formed in the Zr-Ti-killed steel than in Al-killed steel. It was also found that more acicular ferrite grains were formed in the coarse-grained heat-affected zone in the Zr-Ti-killed steel than in Al-killed steel. The impact toughness of coarse-grained heat-affected zone of Zr-Ti-kiUed steel was higher than that of Al-killed steel. The good impact toughness was attributable to the pinning effect of fine oxides and the formation of acicular ferrite grains on fine oxides.

基于Roe-Siegmund循环内聚力模型焊趾疲劳裂纹萌生仿真

为建立焊趾疲劳裂纹萌生行为仿真方法,基于Roe-Siegmund循环内聚力模型对ABAQUS进行二次开发,形成用于反映疲劳累积损伤的VUMAT子程序,依据文献方法及试验数据获取Q345焊接区域材料的内聚力参数,通过Voronoi图法和内聚力单元法生成具有疲劳累积损伤特性和晶粒特征的微观模型,并与宏观对接焊缝模型合并,进行多尺度疲劳裂纹萌生仿真模拟,获得裂纹萌生路径、临界循环次数及晶粒力学响应特征.结果表明,此方法能够自发地选择符合实际情况的裂纹萌生位置以及短裂纹扩展路径,完成对焊接区域材料微观断裂过程的模拟,不同仿真组获取的临界循环次数存在于一定的分布范围内,模型中的累积内聚力长度需通过试验数据进行拟合.

蜂窝与K418B高温合金电阻定位焊工艺研究

目的获得蜂窝电阻定位焊的最佳工艺参数并提高焊接接头的力学性能。方法通过正交试验法,对15mm×10mm×4.2mm的GH3536蜂窝和15mm×10mm×2.5mm的K418B基板进行系列电阻焊实验,主要的焊接工艺控制参数包括焊接电流、焊接时间和焊接压力。对焊接接头进行了抗拉强度测试,系统分析了工艺参数对接头力学性能的影响;通过光学显微镜和扫描电镜(SEM)对拉伸试样的断口形貌和失效形式进行了观测;采用电镜配套的能谱(EDS)探头对焊接接头的界面元素进行了分析。结果GH3536蜂窝与K418B基板定位焊系列接头的最高平均抗拉载荷为123.76N。接头界面处的K418B基板为细小等轴晶组织。基板与蜂窝之间存在宽度约2μm的界面层,其成分与基板相近。接头断口焊合区面积随电流的增大而增大,且在高电流下焊合区焊痕呈蝴蝶状分布。结论在电阻定位焊工艺参数中,焊接电流对接头强度的影响最为显著,其次为焊接压力,焊接时间的影响程度相对较弱。得到的最优参数组合如下:焊接时间为2 ms,焊接电流为4.5kA,焊接压力为17.5N。在该参数下能够获得最高的接头平均抗拉载荷(123.76N)。

基于渐进损伤模型的热固性复合材料电阻焊接头强度的尺寸效应研究

研究了拉剪载荷下热固性复合材料电阻焊接头强度的尺寸效应,揭示了不同搭接尺寸对焊接强度和焊接界面渐进损伤行为的影响规律。为了研究焊接界面的渐进损伤行为,引入双线性内聚力单元,进而建立焊接接头的有限元模型,然后通过电阻焊接的拉剪试验验证了模型的准确性。在此基础上,建立了不同搭接尺寸的数值模型并对其进行研究。研究结果表明,增大搭接长度或者宽度可以提高接头结构的承载能力,但是当搭接长度较长时,在搭接区域边缘易发生翘曲失效,降低了接头单搭接剪切强度,而宽度则对接头的剪切强度影响很小。

焊接热循环峰值温度对1000 MPa级超高强钢热影响区组织性能的影响

为研究1 000 MPa级超高强钢焊接热影响区(HAZ)不同区域的组织性能,采用焊接热模拟技术制备了试验钢在不同热循环峰值温度下的试样,通过夏比冲击试验研究了HAZ不同区域的冲击韧性。结果表明:在亚临界区(SCHAZ)、临界区(ICHAZ)和细晶区(FGHAZ),样品冲击吸收能量、裂纹扩展能量和动态冲击韧度较大,断口上形成较大面积的脚跟形纤维区和剪切唇,微观可看到大小不一的韧窝,样品冲击韧性较好;在粗晶区(CGHAZ),样品各项冲击数据均急剧下降,断口呈宏观脆性断裂,几乎全为放射区,微观下显示准解理断裂特征,表明裂纹扩展时受到的阻力减小,裂纹萌生后稳定扩展的时间减少,失稳扩展较快,样品的冲击韧性恶化,CGHAZ为HAZ中的韧性谷区;组织分析表明,粗大的晶粒和粗大的马氏体板条是导致CGHAZ脆化的主要原因。该结论为探究1 000 MPa级超高强钢在水电工程中的优选研制及工程应用奠定了理论基础。

基于Sysweld的T形管焊接件温度及应力应变场数值模拟分析

采用双椭球体热源分布模型,基于Sysweld软件平台,对常用的暖气运输管道中T形管焊接过程进行数值模拟仿真.首先通过UG建立三维模型并导入Hypermesh进行了网格划分,之后在Sysweld中对焊接过程进行模拟仿真,获得了温度场及应力应变场的分布情况.然后对焊接过程温度云图及焊件整体形变进行了详细的分析.结果表明,热源处的温度达到2 500℃左右,在焊缝周围形成了明显的热影响区;并在焊缝区域出现应力集中情况,其最大应力为277 MPa,在其材料的屈服应力范围内(345 MPa);且在焊缝处出现下凹现象,最大变形量为0.29 mm.此次分析为实际焊接提供理论依据.

1000 MPa级高强钢国产自研实心焊丝焊接工艺研究

针对国产自研的1 000 MPa级高强钢实心焊丝的熔化极气体保护焊工艺进行了系统性试验与分析。深入探讨了焊接电流和预热温度对接头微观组织、硬度分布以及力学性能的影响。研究发现,焊缝金属组织主要由马氏体构成,且随着焊接电流和预热温度的增加,贝氏体的含量相应增加;热影响区(HAZ)呈现出明显的硬化和软化趋势,细分为粗晶区、细晶区和不完全重结晶区;硬度在细晶区达到最高值,临界热影响区最低;在相同的预热温度下,随着焊接电流的增加,焊接接头的抗拉强度和冲击韧性呈现先增加后减少的趋势;而在相同的焊接电流下,抗拉强度和冲击韧性随预热温度变化的规律性不明显。当焊接电流为260 A,预热温度为100℃时,接头的力学性能最优,其抗拉强度高达1 088 MPa,-40℃时的冲击韧性达到47.8 J。

某电厂低压加热器管板与壳体T型焊接接头开裂失效分析

某电厂低压加热器服役5年后,管板和壳体的T型焊缝部位发生严重开裂;通过宏观检查、断口形貌分析、金相组织分析、能谱分析(EDS)、化学成分分析和硬度检测等检验检测,对焊缝开裂原因进行了分析。分析表明:由于焊接热影响区(HAZ)存在对碱应力腐蚀开裂敏感的淬硬马氏体组织,且焊接接头未进行消应力热处理,在碱性环境中,管板焊接热影响区发生了碱脆,支裂纹在焊缝中扩展穿透造成设备失效。对T型焊接接头失效的原因进行分析,对类似场合换热器设计、制造和使用具有借鉴意义。

激光-MAG和MAG焊接Weldox960钢接头的组织与性能对比

分别采用激光-活性气体保护电弧焊(Laser-MAG焊)和MAG焊对Weldox960钢板进行焊接,对比分析了两种工艺焊接接头的显微组织及性能。结果表明:Laser-MAG焊接接头热影响区粗晶区的平均晶粒尺寸较小,为48μm,而MAG焊接接头的为95μm,两种焊接接头的显微组织基本相同,焊缝区组织为细小粒状贝氏体,细晶区组织为细小板条马氏体和粒状贝氏体,部分相变区组织为铁素体+粒状贝氏体;Laser-MAG焊接接头的热影响区宽度小于MAG焊接接头的,软化带也较窄,其拉伸性能和冲击性能均优于MAG焊接接头的,条件疲劳极限为320 MPa,高于MAG焊接接头的。