Hot-Wire Gas Tungsten Arc Welding Cladding of Super Austenitic Stainless Steel on Low Carbon Steel
Abstract
1. Introduction
2. Materials and Methods
3. Results and Discussions
3.1. Macrostructure
3.2. Microstructure
3.3. Microhardness
3.4. Coefficient of Friction
3.5. Bending Tests
3.6. Corrosion Resistance
4. Conclusions
- Hot-wire GTAW is a method suitable for cladding super austenitic stainless steels onto low-carbon steels. It creates weld beads with excellent surface adhesion, defect-free quality, and mechanical and corrosion resistance appropriate for corrosive environments.
- Hot-wire GTAW decreased dilution from 27% to 19% compared to the traditional CW-GTAW method, enhancing its suitability for cladding applications.
- In both conditions, the microstructure of the clad layer featured elongated columnar dendrite grains that extend from the heat-affected zone, along with a shallow region of equiaxed dendrite grains near the bead surface, similar to what is observed in wire-arc additive manufacturing.
- In both conditions, the HAZ microstructure shows a gradient of hardened phases, featuring higher hardness near the HAZ/FZ interface because of high-carbon martensite, which diminishes towards the unaffected base metal.
- Hot-wire GTAW showed slightly better wear resistance than CW-GTAW, mainly because of its higher hardness across the entire clad layer. Additionally, hot-wire GTAW also exhibited better corrosion resistance compared to CW-GTAW, which is linked to its lower dilution. For both conditions, the corrosion resistance exceeded that of the base metal.
- Both conditions successfully passed the bending test, showing no cracks and maintaining a strong metallurgical bond.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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| C | Si | Mn | Ni | Cr | Mo | Cu | N | |
|---|---|---|---|---|---|---|---|---|
| ASTM 516 Gr. 70 | ≤0.28 | 0.15–0.40 | 0.85–1.2 | - | - | - | - | - |
| AWS ER385 | ≤0.02 | 0.7 | 4.7 | 25.4 | 20 | 6.2 | 1.5 | 0.23 |
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da Cruz, E.J., Junior; Varasquim, F.M.F.A.; Carvalho, F.O.; Santiago, L.F.F.; Gianelli, B.F.; Ventrella, V.A.; Pigato, M.; Calliari, I. Hot-Wire Gas Tungsten Arc Welding Cladding of Super Austenitic Stainless Steel on Low Carbon Steel. Appl. Sci. 2026, 16, 1527. https://doi.org/10.3390/app16031527
da Cruz EJ Junior, Varasquim FMFA, Carvalho FO, Santiago LFF, Gianelli BF, Ventrella VA, Pigato M, Calliari I. Hot-Wire Gas Tungsten Arc Welding Cladding of Super Austenitic Stainless Steel on Low Carbon Steel. Applied Sciences. 2026; 16(3):1527. https://doi.org/10.3390/app16031527
Chicago/Turabian Styleda Cruz, Eli J., Junior, Francisco M. F. A. Varasquim, Fábio O. Carvalho, Luiz F. F. Santiago, Bruno F. Gianelli, Vicente A. Ventrella, Mirko Pigato, and Irene Calliari. 2026. "Hot-Wire Gas Tungsten Arc Welding Cladding of Super Austenitic Stainless Steel on Low Carbon Steel" Applied Sciences 16, no. 3: 1527. https://doi.org/10.3390/app16031527
APA Styleda Cruz, E. J., Junior, Varasquim, F. M. F. A., Carvalho, F. O., Santiago, L. F. F., Gianelli, B. F., Ventrella, V. A., Pigato, M., & Calliari, I. (2026). Hot-Wire Gas Tungsten Arc Welding Cladding of Super Austenitic Stainless Steel on Low Carbon Steel. Applied Sciences, 16(3), 1527. https://doi.org/10.3390/app16031527

