Development and Evaluation of Dissimilar Gas Tungsten Arc-Welded Joint of P92 Steel/Inconel 617 Alloy for Advanced Ultra-Supercritical Boiler Applications

Kumar, Amit; Pandey, Chandan

doi:10.1007/s11661-022-06723-0

Cited by 58 publications

(34 citation statements)

References 58 publications

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“…Deep hole drilling (DHD) is a semi-destructive method used for measuring the through-thickness residual stresses based on strain relaxation methodology. This method estimates the locked-in stresses from the deformation of a reference hole following material removal [ 37 , 38 , 39 ]. The DHD process mainly involves four steps: (1) drilling of a reference hole; (2) measuring the hole diameter by an air probe; (3) trepanning the reference hole using EDM; and (4) re-measuring the hole diameter by an air probe [ 40 , 41 ].…”

Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on the arc welding process in which wire is melted by an electric arc and deposited layer by layer. Due to the cost and rate benefits over powder-based additive manufacturing technologies and other alternative heat sources such as laser and electron beams, the process is currently receiving much attention in the industrial production sector. The gas metal arc welded (GMAW) based WAAM process provides a higher deposition rate than other methods, making it suitable for additive manufacturing. The fabrication of mild steel (G3Si1), austenitic stainless steel (SS304), and a bimetallic sample of both materials were completed successfully using the GMAW based WAAM process. The microstructure characterization of the developed sample was conducted using optical and scanning electron microscopes. The interface reveals two discrete zones of mild steel and SS304 deposits without any weld defects. The hardness profile indicates a drastic increase in hardness near the interface, which is attributed to chromium migration from the SS304. The toughness of the sample was tested based on the Charpy Impact (ASTM D6110) test. The test reveals isotropy in both directions. The tensile strength of samples deposited by the WAAM technique measured slightly higher than the standard values of weld filament. The deep hole drilling (DHD) method was used to measure the residual stresses, and it was determined that the stresses are compressive in the mild steel portion and tensile in austenitic stainless steel portion, and that they vary throughout the thickness due to variation in the cooling rate at the inner and outer surfaces.

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Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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“…The alloy consists of fine Cr-rich (M 23 C 6 ) carbides Mo-rich (M 6 C) carbides, along with coarse Ti (C, N). 35 The HAZ shows a similar microstructure along with grain growth which was due to the multi-pass heating effect of welding thermal cycle (Figure 13(b)). Figure 13(c) and (d) shows the interface of the weld metal and Inconel 617 alloy HAZ.…”

Section: Materials Characterizationmentioning

confidence: 93%

Residual stresses study in butt welded joint of Inconel 617 alloy and effect of post weld heat treatment on residual stresses

Kumar

Dey

Pradhan

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Distribution of weld-induced residual stress plays a significant effect on the service life of a welded component. The accumulation of high residual stress accelerates the crack propagation even if the crack is of microscopic level, reducing the service life of the welded component. Prior understanding of residual stress distribution can aid in the design of a component with an adequate factor of safety and reduce the probability of failure. In the present study, two separate circumferential butt welded pipes were fabricated using Alloy 617 and then subjected to post weld heat treatment) at 720°C and 980°C. The deep hole drilling method was used to measure the distribution of residual stress. The fabrication of the welded joint was done using the hot-wire TIG welding process. High welding speeds are possible with hot-wire tungsten inert gas (TIG) welding because it uses less heat than conventional TIG welding. Using hot-wire TIG welding, the welded joint's mechanical properties, such as hardness, are improved in addition to its metallurgical properties. The computational approach is provided to analyze temperature and residual stress fields in multi-pass TIG welds with different passes. Based on ABAQUS FEA software, a coupled thermomechanical computational approach was developed to analyze the residual stress distribution on the welded joint. A 3D finite element model for Alloy 617 tube was created to estimate the welding stress field in two separate multi-pass welded joints. Mixed hardening model (kinematic and isotropic) was used during the numerical analysis. The effectiveness of the computational approach was verified with experimental measurements. The magnitude of hoop and axial residual stresses were observed to be maximum at a depth of 6 mm from the upper surface. The stress gradient in the welded zone and heat-affected zone is dramatically reduced by 70–80% of the as-welded condition during the post weld heat treatment at 980°C.

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“…In the multi-pass fusion welding process, a nonhomogeneous temperature distribution due to heating and cooling during the welding process leads to the inhomogeneity in microstructure along welded joint, accumulation of the residual stresses inside and around the weld metal, and variation in mechanical properties. [5][6][7][8] Residual stresses, typically functioning as a driving factor for fracture development, might enhance the probability of timedependent failure. 9 The solidification cracking, liquation cracking in heat affected zone (HAZ) of Inconel 617 alloy, and hot cracking are serious issues of the ENiCrCoMo-1electrode.…”

Section: Introductionmentioning

confidence: 99%

Metallurgical characterization and high-temperature tensile failure of Inconel 617 alloy welded by GTAW and SMAW—a comparative study

Sirohi

Kumar

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Two types of the weld joint of Inconel 617 alloy were produced using gas tungsten arc welding (GTAW) and shielded metal arc welding (SMAW) processes with ERNiCrCoMo-1 filler metal and ENiCrCoMo-1 electrode, respectively. The weld metal showed the segregation of the principle alloying elements like Mo and Cr along the inter-dendritic spaces, triggering the formation of secondary phases. The microstructure characterization of the interface ensured the high dilution, which could be attributed to the closeness in melting point and chemistry of base and filler metal. Microhardness variation, tensile testing at room and high temperature, and Charpy impact test were conducted to investigate the effect of the Mo segregation in the weld zone and heterogeneity in the microstructure of weldments on the mechanical behavior of both the welded joints. The cross-weld tensile tests were conducted at room temperature and 550°C. The tensile test samples failed from the weld zone for each condition with a tensile strength value close to the base metal, which ensured the applicability of the joint for end service. The tensile strength of GTAW-RT, GTAW-HT, SMAW-RT, and SMAW-HT were measured as 766 ± 22 MPa, 570 ± 5 MPa, 760 ± 7 MPa, and 600 ± 8 MPa, respectively. A non-uniform hardness plot was witnessed with the hardness of the GTAW-weld and SMAW-weld zone of 257 ± 8 HV and 285 ± 5 HV, respectively, in the transverse direction. The impact toughness of the weld zone was 84 ± 2 J and 48 ± 4 J for GTAW and SMAW weld zone. The average impact toughness of the GTAW-weld zone was approximately 42% higher than the value of the SMAW-weld zone. In a nutshell, it can be concluded that the welded joint of Inconel 617 produced using the GTAW process with ERNiCrCoMo-1 filler had the best metallurgical and mechanical properties.

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Development and Evaluation of Dissimilar Gas Tungsten Arc-Welded Joint of P92 Steel/Inconel 617 Alloy for Advanced Ultra-Supercritical Boiler Applications

Cited by 58 publications

References 58 publications

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Residual stresses study in butt welded joint of Inconel 617 alloy and effect of post weld heat treatment on residual stresses

Metallurgical characterization and high-temperature tensile failure of Inconel 617 alloy welded by GTAW and SMAW—a comparative study

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