EmergingTrendsandProspectsin WeldingResearch

Dr.G.D.Janaki Ram MaterialsJoiningLaboratory DepartmentofMetallurgicalandMaterialsEngineering I di Institute Indian I tit t of fTechnology T h l Madras M d Chennai 600036

Carbidefreebainite welds
Element C M Mn Si Cr Ni M Mo Co S P Composition (wt.%) Base metal Weld metal 0.3 08 0.8 0.6 0.8 0 25 0.25 0.15 0.15 0.28 1 95 1.95 1.55 1.20 0.95 0 25 0.25 2.05 0.003 0.013

CFBweldmetal
300 200

Preheat:350C Postheat:350C/8h

Carbidefreebainite welds

S Sample l CFB weld A t iti weld Austenitic ld Base material

UTS (MP (MPa) ) Elongation El ti (%) 1110 640 1200 12 18 10

L ti of Location f failure f il Weld metal HAZ -

Carbidefreebainite welds

ASSweld

CFBweld

High Entropy Alloys

Multi-principal elemental alloys (four or more elements) Simple solid solutions due to high configurational entropy JW Yeh, Taiwan Since 1995 Interesting properties High Hi h strength h Phase stability Sluggish Sl i h diff diffusivity i it Excellent oxidation, corrosion and wear resistance

Several different systems and d di diverse properties ti Casting: AlCoCrCuFeNi C CC AlCoCrCuFeMoNiTiVZr CuCoNiCrAlFeTiV Mechanical Alloying: AlFeTiCrZnCu NiFeCrCoMnW CuNiCoZnAlTi CoCrFeNi CoCrFeAl

Yeh et al. 2004

Dissimilarwelding
XYZ

XAYBZ

Canthisbedone?

HEA coatings
Increasing interest in HEAs as coating materials Laser cladding
TiVC TiVCrAlSi AlSi coatings ti on Ti Ti-6Al-4V 6Al 4V (Huang (H et t al. l S Surface f and d Coatings technology, 2011) FeCoNiCrAl2Si coatings on low carbon steel (Zhang et al. Intermetallics, 2011) FeCoNiCrCu coatings on low carbon steel (Zhang et al., Materials and Design, 2011)

Plasma spray
NiCoFeCrSiAlTi coatings on austenitic stainless steel 304 (Wang et al., Materials Chemistry and Physics, 2011)

Magnetron sputtering
TiAlCrSiV nitride coatings on mild steel (Lin et al al., Surface and Coatings technology, 2007)

Laserdeposition,CrCrFeNi
NiCoCrFe mechanicallyalloyedpowder Successfullaserdepositiononalloy316L substrates(300W,15mm/s) / Soundinterface,nocracking Highentropycharacterretained

CoCrFeNicoating g

316Lsubstrate

CoCrFeNipowder

CoCrFeNicoating

TIGwelding, CoCrNiCuAl l

SS/TiPipeWelding
SiteweldingofSSpipestoTipipesinnuclear powerplants Goodcorrosionresistanceinnitricacid Fusionweldingisruledout Solidstateweldingonsiteisimpractical Solidstateweldedjoininginsertcanhelp
Fusionweld SSpipe
Solidstateweld

Fusionweld Tipipe

SS/Tiinsert

SS/TiPipeWelding
Howtoproducethejoininginsert?
Frictionwelding
Initialexperimentswithpipes,morecomplications ReasonablygoodweldsbetweenSSandTirods Goodintension tension,butnotinbending Intermetallicformationcouldnotbeprevented
SS SS Ti Ti

SS/TiPipeWelding
IN625interlayercouldnothelpmuch

Ti

IN625 IN625 Ti SS

SS/TiPipeWelding
Idea1:Resistancebuttwelding SSand dTirods d with ithanwithout ith tIN625i interlayer t l Sparkplasmasinteringmachine(850C/10kN/2minutes) Goodintension,butnotinbending

Ti

SS IN625 Ti

SS/TiPipeWelding
Idea2
Compositionallygraded insert SSandTipowders Sparkplasmasintering
100Ti
75Ti+25SS 50SS+50Ti 725Ti+75SS 100SS

C Compositional ii lgradation d i

Continuousintermetallic layercanbeavoided SmootherchangeinCTE

SPSsetupforpowderconsolidation

SS/TiPipeWelding
100%SS 100%Ti

(a)

(b)

(c)

Ti

Ti SS SS Ti SS

MicrostructuresofacompositionallygradedSS/Tijoininginsert(800C,5minutes,25kN)

SS/TiPipeWelding
25SS/75Ti Ti

SS

 Idea3

SS/TiPipeWelding
SS 30

Combinesolidstatebondingwiththreading Sparkplasmasinteringmachine(800C,15kN,5minutes)
SS SS

15 Ti

30

21

Ti

Ti

SS/TithreadedpipejointafterSPSbondingandmachining

SS

Ti

SS/TithreadedpipejointafterSPS bondingandmachining

AfterfusionweldingSSandTipipe extensionstotheinsert

AdditiveManufacturing g
Mostprocessesinvolvefusion Solidificationcracking Crackinginsolidstate(brittlemicrostructure+ residualstresses) Metallurgicalincompatibility Ascastmicrostructure(segregation)

SolidStateProcessesforMaterialAddition
Ultrasonicwelding(UC/UAM) Othercandidateprocesses: Frictionwelding welding,frictionstir welding,frictionsurfacing Ourfocus:Frictiondeposition
Approach1:Layerwise 1a:withtranslation 1b:withouttranslation Approach2:Linewise Multipleoverlappingtracks makeupalayer Sound S dinter i track kbonding b di CNCmachiningforlayershaping

Uniquecapabilities
Standardengineering g gmaterials( (rods, ,bars) ) Wroughtmicrostructure,finegrainsize Dissimilarmetals Thicklayers,highdepositionrates Fullyenclosedinternalcavities

BoratedStainlessSteels
D Developed l dfor f neutronshielding hi ldi purposes. Propertiesdependonboron contentandboridemorphology. ASTMA887coverseight d ff different types( (0.2to2.25wt%. boron);GradeAandGradeBin eachtype. yp GradeAmaterials(PMroute) showfine,uniformlydistributed b id better borides b tt ductility d tilit and d toughnessthanGradeB materials.

304B7GradeA

304B4GradeB

Weldability
Attractivemechanicalproperties,butpoorfusion weldability Solidificationendwithaeutecticreaction: L +boride Widesolidificationrange Interdendritic eutecticnetwork(poorductility andtoughness) Excellentboridestability
1075C/4h 1125C/4h

Fusionzonemicrostructure,304B4TIGweld

1175C/4h

1225C/4h

Microstructuresafterisothermaltreatments

304B4,DSCscan(onheating)

FrictiondepositionofASTM304B4GradeB
Cylindricalsamplesformicroscopy,tensile,andimpacttests Consumablerods:10mmdia 304B4GradeBrods(rotatingside) Substrate:15mmdia AISI304rods(stationaryside) p spindle p rotationspeed, p 8kN frictionforceand1mmburnoff Parameters:800rpm Layerthicknessaftermachining:~0.6mm Composition(wt.%)
C Cr Ni B Mn Si S P Fe 0.02(0.08) 18.5 (1820) 12.5(1215) 1.15(11.24) 1.3(2) 0.5(0.75) 0.008(0.03) 0.02(0.045) Balance

Impactspecimens:5x5x55mm (ASTME23)

Tensilespecimens:10mmgaugelength,3mmgaugewidth, 2mmthickness,40mmtotallength(ASTME8)

Microstructures

Frictiondeposit

Consumablerod

Frictiondeposit

Peaktemperatureduringfrictiondeposition:11201130C(noboridemeltingorcoarsening) Frictiondeposition(i)Finegrainsize(dynamicrecrystallization),(ii)Fineborideparticlesand uniformdistribution(plasticdeformation,fragmentation,redistribution)

Layerswithinalayer

Edgeofafrictiondepositedsample
Progressivematerialtransferindiscretelayers Rotationalplanekeepsmoving Processterminationinvolvesshearattherotationalplane Initialheatingduetofriction,thenadiabaticheatingduetosevereplasticdeformation

Mechanicalproperties
Specimen 304B4-Grade B bulk material (specified) 304B4-Grade 304B4 Grade B bulk material (obtained) 304B4-Grade B friction deposit Yield Strength (MPa) 205 250 330 Tensile Ultimate Tensile Strength (MPa) 515 620 700 % Elongation (10 mm GL) 16 20 28 Charpy V-Notch V Notch Impact Energy (5 x 5 mm) (J) 5 11 Hardness (BHN) 217 222 230

Bulkmaterial

Frictiondeposit

Bulkmaterial

Frictiondeposit

Tensilefracturesurfaces Fractureline

Impactfracturesurfaces

Frictiondepositionresultedinimproved strength,ductility,andtoughness(finer grainsize,finerandmoreuniformly distributedborides)

Inconel 718,friction d deposits it

Inconel 718, f friction d deposits

Asdeposited

Afterdirectaging

Inconel 718,frictiondeposits
Property 0 2%PS(MPa) 0.2% (MP ) UTS(MPa) %Elongation Rupturelife(hours) Specified 1035 1275 12 23 Bulk material Tensile 1150 1410 22 Stressrupture(650C/690MPa) >100 2030 1200 1440 14 Frictiondeposits

AlCualloyAA2014,frictiondeposits

Processparameters
Friction force:8kN Spindlerotationspeed:800rpm Traversespeed:1mm/s 20mmdia consumablerods

Microstructural Characterization

Consumable rod

Friction surfaced deposit

Hardnessstudies
Frictiondeposit(AD),toplayer:94106HV Frictiondeposit(AD),bottomlayer:7282HV Frictiondeposit(DA):8590HV Frictiondeposit(STA):132138HV Alloy2014T6: T6 125HVminimum

Asdeposited

STA:485C/1h/WQ+180C/10h

ThankYou!