Electrochemical Impedance Analysis on Cryogenically Treated Dissimilar Metal Welding of 316L Stainless Steel and Monel 400 Alloy Using GTAW
Abstract
:1. Introduction
- Gas tungsten arc welding of SS 316L and Monel 400 alloy using ENiCrFe-5 filler material;
- Post-weld heat treatment (annealing) and cryogenic treatment on weld specimens;
- Potentiodynamic and electrochemical analyses for corrosion resistance of the treated specimens;
- SEM and EDS analysis of the corroded specimens to understand the results obtained in the corrosion tests.
2. Materials and Methods
2.1. Materials
2.2. Welding and Post-Weld Treatments
2.3. Optical Microscopy, EDS, and SEM
2.4. Polarization Analysis and Electrochemical Impedance Spectroscopy Analysis
3. Results
3.1. Optical Microscopy, EDS, and SEM
- SS 316L HAZ of the CT specimen has revealed annealing twins and grain refinement (Figure 3a). The grain size number was in the range of 11 to 13 (smaller is coarser), as per ASTM E112. The area fraction of carbide precipitates was found to be 2.52%, with an average carbide precipitate size of 1.335 µm.
- Figure 3b shows the optical image of SS 316L weld fusion zone, which has the grain number 13. Carbide precipitates for 2.68% of its area, with an average precipitate size of 2.78 µm, was observed.
- Migrated grain boundaries were observed at the weld zone in Figure 3c for the CT specimen. Similar results were presented by and Devendranath Ramkumar et al. in 2015 for SS/Inconel dissimilar metal welding [22]. Carbide precipitation was observed at 6.27%, with an average precipitate size of 3.811 µm. The grain size number was noted to be close to 8.
- Epitaxial growth in weld fusion zone was noted in Figure 3d for the CT specimen. Epitaxial growth was detected prominently at the fusion boundary of ERNiCrFe-5 weld with Monel 400. This phenomenon was also reported by Farahani et al. during welding of Inconel 617 alloy [23]. The epitaxial growth normally occurs in the weld and base materials which have a similar crystal microstructure. The grain size number of 14 was observed for the microstructure.
- Figure 3e of the CT specimen shows Monel 400 HAZ, which has a grain size number from 11 to 13.
- Figure 3f shows the optical image of SS 316L HAZ for the HT specimen, which has grain size number ranging from 13 to 14. The average carbide precipitate size was observed to be 1.73 µm, with 2.46% of precipitates with respect to area.
- Partially melted zones on the weld fusion are shown in Figure 3g for the SS 316L weld fusion zone of the HT specimen, which has grain size number ranging from 12 to 14. The average carbide precipitate size was observed to be 3.045 µm, with 3.97% area fraction of carbide precipitates.
- Weld region of the HT specimen has inter-dendritic network of the elements consisting of Ni, Cr, Fe, Cu, and Nb in Figure 3h. The grain size number is 7 and average carbide precipitate size was observed to be 4.66 µm, with 3.86% of carbide precipitates.
- Weld fusion of Monel was seen in Figure 3i for the HT specimen, which has a size grain number of 13.
- Grain coarsening is noticed in Monel 400 HAZ for the HT specimen, as seen in Figure 3j, with grain size number in the range of 11 to 14.
3.2. Polarization Analysis and Electrochemical Impedance Spectroscopy Analysis
3.2.1. Weld Zone
3.2.2. SS 316L HAZ
3.2.3. Monel 400 HAZ
3.2.4. SS 316L Base
3.2.5. Monel 400 Base
4. Discussion and Conclusions
- Polarization analysis and Electrochemical Impedance Spectroscopy Analysis are powerful techniques to investigate the corrosion resistance of dissimilar metal welds. In the present study, the results have similar trends.
- Chloride attack at localized location as corrosion is a serious problem of stainless steels when they are exposed to chloride solutions in 316L/Monel 400 dissimilar metal welds.
- Cryogenic treatment resulted in better corrosion resistance when compared to the conventional annealing. The Jcorr values decreased up to 41 times for the cryo-treated specimens, and the corrosion rate of the weld zone was as low as 0.003 × 10−6 mm/yr, resulting in a 97% reduction in corrosion rate. The electrical equivalent circuit selected matches with the phase angle plot.
- Among the zones identified for dissimilar welds, corrosion rate is lowest for weld zone and highest for SS 316L HAZ. The corrosion rate for Monel base, Monel HAZ, and SS 316L base are in between them and are almost in the same range as observed in both polarization and electro chemical impedance analyses.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
Abbreviations
BM | Base metal zone |
CT | Cryo-treated specimen |
DCEN | Direct Current Electrode Negative |
DCT | Deep cryogenic treatment |
DMW | Dissimilar metal welding |
EDS | Energy dispersion X-ray Spectroscopy |
EIS | Electrochemical impedance spectroscopy |
GTAW | Gas Tungsten Arc Welding |
HAZ | Heat Affected Zone |
HT | Heat-treated specimen |
LPM | Liters per minute |
SMAW | Shielded metal arc welding |
SS | Stainless steel |
WM | Weld metal zone |
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Material | C | Cr | Fe | Mn | Ni | P | S | Si | Mo | Cu | Ti | Co | Nb |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
SS 316L | 0.03 | 17 | 65.64 | 2 | 12 | 0.045 | 0.03 | 0.75 | 2.5 | 0 | - | - | - |
Monel 400 | 0.3 | - | 2.5 | 2 | 63 | - | 0.024 | 0.5 | - | 31.676 | - | - | - |
ENiCrFe-5 | 0.04 | 14–17 | 6–10 | 1.0 | 70 (min) | 0.03 | 0.015 | 0.35 | - | 0.5 | 0.12 | 1.5 |
wt % | SS HAZ after Corrosion | Weld after Corrosion | Monel HAZ after Corrosion | |||
---|---|---|---|---|---|---|
Component | CT | HT | CT | HT | CT | HT |
Cr | 5.6 | 4.8 | 10.6 | 11.5 | - | 0.7 |
Fe | 19.7 | 12.1 | 9.1 | 11 | - | 2.4 |
Mn | 1.9 | 2.5 | 1.5 | 2.9 | - | 1.2 |
Ni | 3.9 | 4.4 | 34.5 | 22.1 | 21.86 | 28.2 |
Mo | - | - | - | 0.5 | - | - |
Cu | 1.2 | 0.8 | 4 | 2.9 | 10.48 | 12.7 |
Ti | - | - | 1.4 | 0.6 | - | - |
Cl | 16.2 | 26.2 | - | 6.5 | 1.81 | 10.5 |
Nb | - | - | 1.7 | 1.9 | - | - |
Na | 18.5 | 24.6 | 2.3 | 11.8 | 6.79 | 16.4 |
Specimen | Zones | Area | Ecorr | Jcorr | Icorr | Tafel Slope | Corrosion Rate | Polarization Resistance | |
---|---|---|---|---|---|---|---|---|---|
cm2 | V | µA/cm2 | µA | βa | βc | (mm/yr) × 10−6 | (M ohm) | ||
Specimen CT | SS 316L Base | 0.48 | 0.165 | 7.53 | 6.85 | 0.053 | −0.166 | 0.079 | 2.54 |
SS 316L HAZ | 0.94 | 0.104 | 56.49 | 51.36 | 0.096 | −0.146 | 0.589 | 0.49 | |
Weld Zone | 1.02 | 0.090 | 0.32 | 0.29 | 0.296 | −0.692 | 0.003 | 313.10 | |
Monel HAZ | 1.80 | 0.111 | 2.05 | 1.86 | 0.151 | −0.098 | 0.020 | 13.80 | |
Monel 400 Base | 0.90 | 0.099 | 1.48 | 1.34 | 0.066 | −0.073 | 0.014 | 11.20 | |
Specimen HT | SS 316L Base | 1.04 | 0.182 | 257.04 | 233.67 | 0.028 | −0.175 | 2.679 | 0.04 |
SS 316L HAZ | 1.03 | 0.183 | 562.34 | 511.22 | 0.098 | −0.134 | 5.861 | 0.05 | |
Weld Zone | 1.07 | 0.062 | 13.55 | 12.32 | 0.095 | −0.257 | 0.141 | 2.45 | |
Monel HAZ | 1.09 | 0.135 | 39.08 | 35.53 | 0.105 | −0.277 | 0.378 | 0.93 | |
Monel 400 Base | 1.01 | 0.094 | 19.05 | 17.32 | 0.049 | −0.190 | 0.184 | 0.99 |
Specimen | SPECIMEN CT | SPECIMEN HT | ||||
---|---|---|---|---|---|---|
Zones | R1 | R2 | P1 | R1 | R2 | P1 |
Ohm | Ohm | Farads | Ohm | Ohm | Farads | |
Weld | 6.99 | 1915.5 | 0.0000621 | 6 | 1188 | 0.00012 |
Monel Base | 5.64 | 990.1 | 0.00027 | 4.25 | 742 | 0.00023 |
Monel HAZ | 4.03 | 741.29 | 0.00025 | 5.54 | 704 | 0.00029 |
SS Base | 5.54 | 704.28 | 0.00029 | 9.84 | 610 | 0.00015 |
SS HAZ | 1.98 | 375 | 0.0015 | 4.9 | 555 | 0.0009 |
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Mani, C.; Karthikeyan, R.; Kannan, S. Electrochemical Impedance Analysis on Cryogenically Treated Dissimilar Metal Welding of 316L Stainless Steel and Monel 400 Alloy Using GTAW. Metals 2019, 9, 1088. https://doi.org/10.3390/met9101088
Mani C, Karthikeyan R, Kannan S. Electrochemical Impedance Analysis on Cryogenically Treated Dissimilar Metal Welding of 316L Stainless Steel and Monel 400 Alloy Using GTAW. Metals. 2019; 9(10):1088. https://doi.org/10.3390/met9101088
Chicago/Turabian StyleMani, Cherish, R Karthikeyan, and Sathish Kannan. 2019. "Electrochemical Impedance Analysis on Cryogenically Treated Dissimilar Metal Welding of 316L Stainless Steel and Monel 400 Alloy Using GTAW" Metals 9, no. 10: 1088. https://doi.org/10.3390/met9101088