Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Nickel-based superalloys are extensively used in the crucial hot-section components of industrial gas turbines,aeronautics,and astronautics because of their excellent mechanical properties and corrosion resistance at high temperatures.Fusion welding serves as an effective means for joining and repairing these alloys;however,fusion welding-induced liquation cracking has been a challenging issue.This paper comprehensively reviewed recent liquation cracking,discussing the formation mechanisms,cracking criteria,and remedies.In recent investigations,regulating material composition,changing the preweld heat treatment of the base metal,optimizing the welding process parameters,and applying auxiliary control methods are effective strategies for mitigating cracks.To promote the application of nickel-based superalloys,further research on the combination impact of multiple elements on cracking prevention and specific quantitative criteria for liquation cracking is necessary.

Low-temperature purification process of metallurgical silicon

The removal of B and P consumes most of heat energy in Si metallurgical purification process for solar-grade Si. Metal-liquating purification of metallurgical grade silicon （MG-Si）, also called Si-recrystallization from metal liquid, was a potential energy-saving method for the removal of B and P efficiently, since Si could be melted at lower temperature by alloying with metal. The selection criteria of metal-liquating system was elaborated, and Al, Sn and In were selected out as the optimum metallic mediums. For Sn-Si system, the segregation coefficient of B decreased to 0.038 at 1 500 K, which was much less than 0.8 at the melting point of Si. The mass fraction of B was diminished from 15×10^-6 to 0.1×10^-6 as MG-Si was purified by twice, while that of most metallic elements could be decreased to 0.1×10^-6 by purifying just once. During the metal-liquating process, the formation of compounds between impurity elements and Si was also an important route of impurity removal. Finally, one low-temperature metallurgical process based on metal-liquating method was proposed.

Liquation cracking in laser beam welded joint of ZK60 magnesium alloy

The ZK60 magnesium alloy plates were welded by laser beam welding (LBW) and the microstructures in the partially melted zone (PMZ) of welded joints were investigated. For the as-cast alloy, the eutectoid mixtures along grain boundaries (GBs) in the PMZ are liquefied during welding, and their re-solidified materials present hypoeutectic characters, which lead to more severe segregation of the Zn element along GBs, and thus enhance the cracking tendency of the PMZ. The main reasons for liquation cracking of PMZ are described as that the absence of liquid at the terminal stage of solidification leads to the occurrence of shrinkage cavities in PMZ, from which liquation cracking initiates, and propagates along the weakened GBs under the tensile stress originating from solidification shrinkage and thermal contraction. Lower heat input can reduce the cracking tendency, and the plastic processing such as rolling also contributes to the mitigation of PMZ liquation cracking by reducing the size of eutectoid phases and changing their distribution in the base metal.

Geohazards Induced by the Lushan Ms7.0 Earthquake in Sichuan Province, Southwest China:Typical Examples, Types and Distributional Characteristics

Geohazards induced by the Lushan Ms 7.0 earthquake on April 20, 2013 mainly have four types： collapse, landslide, slope debris flow, and sand-soil liquefaction. These geohazards mainly occurred near the epicenter, on steep slopes or below cliffs in high mountain and deep valley areas, and at or near fault ends. They have no obvious relationships to active faults, but their relationships to the weathering degree and structures of rock and rock mass are obvious. Compared with the Wenchuan Ms 8.0 earthquake on May 12, 2008, the Lnshan earthquake is relatively little in the impact force and the throwing amount. All of these should be related to the magnitude of this earthquake, not very large but not very little. This character of the Lushan earthquake would make some processes uncompleted so as to bring about some concealed geohazards. Finally, in order to deal with challenges presented by such conceal geohazards, some brief recommendations are put forward.

Liquation cracking in the heat-affected zone of IN939 superalloy tungsten inert gas weldments

The main aim of this study was to investigate liquation cracking in the heat-affected zone(HAZ)of the IN939 superalloy upon tungsten inert gas welding.A solid solution and age-hardenable filler metals were further studied.On the pre-weld heat-treated samples,upon solving the secondaryγ′particles in the matrix,primaryγ′particles in the base metal grew to"ogdoadically diced cubes"of about 2μm in side lengths.The pre-weld heat treatment reduced the hardness of the base metal to about HV 310.Microstructural studies using optical and fieldemission scanning electron microscopy revealed that the IN939 alloy was susceptible to liquation cracking in the HAZ.The constitutional melting of the secondary,eutectic,and Zr-rich phases promoted the liquation cracking in the HAZ.The microstructure of the weld fusion zones showed the presence of fine spheroidalγ′particles with sizes of about 0.2μm after the post-weld heat treatment,which increased the hardness of the weld pools to about HV 350 and 380 for the Hastelloy X and IN718 filler metals,respectively.Application of a suitable solid solution filler metal could partially reduce the liquation cracking in the HAZ of IN939 alloy.

Weldability and liquation cracking behavior of ZhS6U superalloy during electron-beam welding

The weldability of the ZhS6U nickel-based superalloy, which is prone to solidification cracking during electron-beam welding(EBW) repair processes, was investigated. The effects of two different pre-weld heat-treatment cycles on the final microstructure before and after welding were examined. Welds were made on flat coupons using an EBW machine, and the two heat-treatment cycles were designed to reduce γ′ liquation before welding. Microstructural features were also examined by optical and scanning electron microscopy. The results showed that the change in the morphology and size of the γ′ precipitates in the pre-weld heat-treatment cycles changed the ability of the superalloy to release the tensile stresses caused by the matrix phase cooling after EBW. The high hardness in the welded coupons subjected to the first heat-treatment cycle resulted in greater resistance to stress release by the base alloy, and the concentration of stress in the base metal caused liquation cracks in the heat-affected zone and solidification cracks in the weld area.

HAZ CRACKING AND HOT DUCTILITY OF Ni_3AI CONTAINING Zr ALLOY

The HAZ cracking test in EB welding condition and hot ductility test show that the cracking mechanism is the formation of Ni - Ni5Zr eutectic which is resulting from the enrichment of Zr in grain boundaries during welding.In order to eliminate HAZ cracks the diffusion and recrystalization anealing treatment after cast and during cold rolling should be conducted in vacuum or protecting atmosphere and at the same time a slow welding speed is necessary.

Microstructure characteristics and liquation behavior of fiber laser welded joints of Mg-5Zn-1Mn-0.6Sn alloy sheets

Fine-grained Mg?5Zn?1Mn?0.6Sn alloy sheets of2mm in thickness were welded by fiber laser welding.The appearanceand microstructures of the welding joints and liquation behaviors in the partially melted zone(PMZ)were investigated.The resultsshow that,with the lower welding power and higher welding speed,the width and depth of the joints decrease.Moreover,some poresare detected at a very high welding speed.There are two kinds of liquation phenomena in the PMZ.One is the liquation networkalong grain boundaries associated with the liquation of substrate and segregation-induced liquation,the other is the molten poolinvolved with the liquation of the residual second phases at the boundaries.However,the liquation of substrate and thesegregation-induced liquation are the main liquation mechanism in the PMZ.

Main Mineralization Mechanism of Magmatic Sulphide Deposits in China

Before intruding, primary magmas have undergone liquation and partial crystallization atdepth; as a result the magmas are partitioned into barren magma, ore-bearing magma, ore-richmagma and ore magma, which then ascend and are injected into the present locations once ormultiple times, thus forming ore deposits. The above-mentioned mineralizing process is knownas deep-seated magmatic liquation-injection mineralization. The volume of the barren magma isgenerally much larger than those of the ore-bearing magma, ore-rich magma and ore magma. Inthe ascending process, most of the barren magma intrudes into different locations or outpoursonto the ground surface, forming intrusions or lava flows. The rest barren magma, ore-bearingmagma, ore-rich magma and ore magma may either multiple times inject into the same space inwhich rocks and ores are formed or separately inject into different spaces in which rocks and oresare formed. The intrusions containing such deep-seated magmatic liquation-injection depositshave a much smaller volume, greater ore potential and higher ore grade than that of in-situmagmatic liquation deposits. Consequently this mineralizing process results in the formation oflarge deposits in small intrusions.

Magmatic Sulfide Ni-Cu Deposits in China

Deep seated magmatic liquation injection deposits form a major type of magmatic sulfide deposit in China. The reserves of nickel and copper in this type of deposit may attain several hundred thousand tons (e.g.Hongqi 7 and Karatunggu) to nearly ten million tons (e.g.Jinchuan). Those deposits can be classified as large or superlarge deposits. The ore grade is relatively high, commonly with w (Ni)>1 %. The mineralized intrusions are small in size, generally only 0.0 n km 2 to 0. n km 2, with the largest one not exceeding a few km 2. Before intruding, the primary magmas have undergone liquation and partial crystallization at depth; as a result, the magmas have partitioned into barren magma, ore bearing magma, ore rich magma and ore magma, which then ascended and injected into the present locations once or multiple times, to form ore deposits. The above mentioned mineralizing process is known as deep seated magmatic liquation injection mineralization. The volume of the barren magma is generally much larger than those of the ore bearing magma, ore rich magma and ore magma. In the ascending process, most of the barren magma intruded into different locations or outpoured onto the ground surface, forming intrusions or lava flows. The rest barren magma, ore bearing magma, ore rich magma and ore magma may either multiple times inject into the same place in which rocks and ores are formed or separately inject into different spaces to form rocks and ores. Such deep seated magmatic liquation injection deposits have a much smaller volume, greater ore potential and higher ore grade than those of in situ magmatic liquation deposits. Consequently, this mineralizing process leads to the formation of large deposits in small intrusions.

Improving the Quality of Thermocouple Wire Made of Platinum-rhodium Alloys

For the manufacture of S-type thermocouple the so-called thermocouple wire of platinum and platinum-rhodium alloy is used.One of the main technical requirements for the quality of the wire,according to State Standard of Russia(GOST 10821),is the uniformity of its largest thermoelectric force(Thermo-emf) in the length different sections.It was found that a determining impact on the uniformity of the wire thermo-emf is the distribution of rhodium along the length of the wire.The impact of platinum-rhodium melt crystallization conditions on the inhomogeneity of wire manufactured from it.It was suggested that the chemical inhomogeneity of the wire is related to the liquation phase of platinum-rhodium alloy.

THE EFFECT OF BORON AND CARBON ADDITION ON WELDABILITY OF DS TMS-75 SUPERALLOY

Four alloys TMS-75 (Base), Base+B, Base+C and TMD-103 (Base+B+C) with varying levels of B, C were directionally solidified (DS), and their weldability was investigated by bead-on-plate electron beam welding. It was found that cracking occurred in the weld-metal, as well as in the heat affected zone (HAZ). Both γ/γ' and/or γ/carbide eutectic contributed to the weld-metal cracking, and the γ/γ' eutectic was found to be mainly responsible for cracking in HAZ. However, constitutional liquation of carbides seems to have made some contribution also. The B addition had a detrimental effect on HAZ cracking susceptibility, while C addition improved it appreciably even in the presence of B. In addition, no obvious differences were observed in cracking susceptibility of weld-metal in the four alloys. The cracking modes and mechanisms underlying the effect of B and C addition on weldability could be explained on the basis of microstructures of the four alloys.

EXPERIMENTAL RESULTS OF LIQUATION OF TUNGSTEN-AND TIN-BEARING GRANITIC MAGMAS SATURATED WITH WATER AND THEIR METALLOGENIC SIGNIFICANCE

Systematical experimental study has been carried out on liquation (liquid seperation) of granitic silicate melt containing tungsten and tin at the conditions of 850℃ and 150 MPa. The experiments were conducted in rapid quenched high-pressure vessel system.Two kinds of glass, used as starting meterial, were made from Dengfuxian coarse porphyritic biotite granite enriched in W (0. 45 wB% ) and Sn (0. 50 wB%) and Dachang granular biotitemuscovite granite enriched in W (0. 16 wB% ) and Sn (0. 13 wB%). The results of the experiments indicate that the quenched product glass contains no newly-formed minerals through observation under 200 times microscope and with determination of the X-rays diffraction. The final glass of each run consists of both lightedolor and dark-color parts which represent two phases of liquid-separated melt. The color of the light gIass varies with the composition of the systems. In the granite-KF-H2O and granite-NaCl-H2O systems, the light glass is colorless.In the granite-KP-H2O system, the light part is lightly brown. In the Rranite-LiF-H2O system, the light glass appears milkwhite. The color of the dark glass hardly varies with the different compositions of the systems, and appears darkbrown or grew-black. In tbe quenched glass, the dark part is dominant and takes a portion of more than 80 percent. The data of the compositions for the two portions of glass contains relatively much silica and less Fe2O3,FeO, TiO2, MgO, CaO. On the contact line between two phases of glass, there does not exist gradually varying zone of the composition, which indicates that complete liquid separation has taken place.

Local melting mechanism and its effects on mechanical properties of friction spot welded joint for Al-Zn-Mg-Cu alloy

Local melting and the eutectic film and liquation crack formation mechanisms during friction spot weld- ing （FSpW） of Al-Zn-Mg-Cu alloy were studied by both experiment and finite element simulation. Their effects on mechanical properties of the joint were examined. When the welding heat input was high, the peak temperature in the stir zone was higher than the incipient melting temperature of the Al-Zn-Mg-Cu alloy. This resulted in local melting along the grain boundaries in this zone. In the retreating stage of the welding process, the formed liquid phase was driven by the flowing plastic material and redistributed as a ＂U-shaped＂ line in the stir zone. In the following cooling stage, this liquid phase transformed into eutectic films and liquation cracks. As a result, a new characteristic of＂U＂ line that consisted of eutectic films and liquation cracks is formed in the FSpWjoin. This ＂U＂ line was located in the high stress region when the FSpW joint was loaded, thus it was adverse to the mechanical properties of the FSpW joint. During tensile shear tests, the ＂U＂ line became a preferred crack propagation path, resulting in the occurrence of brittle fracture.

Numerical simulation of solidification and liquation behavior during welding of low-expansion superalloys

Low-expansion superalloys are susceptible to weld solidification cracks and heat,affected zone （HAZ）microflssures. To predict solidification cracking, QBasic procedures were developed and solidification reaction sequence, type, and amount of eutectic product were caiculated As manifested, primary solidification is followed by L→（Y＋ NbC） and L → （Y＋ Laves） eutectic reaction sequentially for G H903 and GH907; hence, the terminal eutectic constitue Y/Laves, While for GH909, intsare made up of Y/NbC and Y/only reaction L → （Y ＋ Laves） occurs and more Y/Laves eutectic forms. Therefore, GH909is more sensitive to solidification cracking. To predict HAZ liquation, cracking Visual FORTRAN procedures were developed, and constitutional liquation of NbC was simulated. As shown, solid dissolution of NbC prior to liquation decreases, and initial liquid film increases with the rate of thermal cycle. Higher rate of thermal cycle promotes the melting of the matrix adjacent to the liquid film and postpones the solidification of the at the eutectic n size and peak rifled indirectly by hot ductility tests.