Welding and Joining of Metallic Materials: Microstructure and Mechanical Properties

In the conditions of an energy crisis, an important issue is the increase in energy efficiency and productivity of welding and hardfacing processes. The article substantiates the perspective of using exothermic additives introduced into core filler for flux-cored wire arc welding processes as a relatively cheap additional heat source, reducing energy consumption when melting filler materials, and increasing the deposition rate. The mixture design (MD) was selected as the design method to optimize the average values of current and voltage, as well as arc stability parameters depending on core filler composition. This article studies the influence of the introduction of exothermic addition (EA), as well as the ratios CuO/C and CuO/Al on arc stability for the FCAW S process. Parameters characterizing arc stability were determined using an oscillograph, and from the obtained oscillograms, an analysis was conducted on arc voltage and welding current signals during flux-cored arc welding. It was determined that various methods can be used to evaluate arc stability, which can be divided into two groups: graphical (current and voltage cyclograms, box plots with frequency histograms, ellipse parameters plotted on current, and voltage cyclograms) and statistical (standard variation and coefficients of variation for welding current and arc voltage). In this paper, a comprehensive evaluation of arc stability depending on the composition of the cored wire filler was carried out. It was determined that the most stable current parameters were observed for the flux-cored wire electrode with an average exothermic addition content at the level of EA = 26.5–28.58 wt.% and a high carbon content (low values of CuO/C = 3.75). Conversely, the lowest values of arc stability (CV(U) and Std(U)) were observed during hardfacing with a flux-cored wire electrode with a high CuO/Al ratio ≥ 4.5 and a content of exothermic addition in the core filler below the average EA < 29 wt.%. Mathematical models of mean values, standard deviation, coefficient of variation for welding current, and arc voltage were developed. The results indicated that the response surface prediction models had good accuracy and prediction ability. The developed mathematical models showed that the ratio of oxidizing agent to reducing agent in the composition of exothermic addition (CuO/Al) had the greatest influence on the welding current and arc voltage characteristics under investigation. The percentage of exothermic mixture in the core filler (EA) only affected the average welding current (Iaw) and the average arc voltage (U_aw). The graphite content expressed through the CuO/C ratio had a significant impact on welding current parameters as well as the coefficient of variation of arc voltage (CV(U)). Two welding parameters were selected for optimization: the mean welding current (I_aw) and the standard deviation of arc voltage (Std(U)). The best arc stability when using exothermic addition CuO-Al in the core filler was observed at CuO/Al = 3.6–3.9, CuO/C = 3.5–4.26, and at an average EA content of 29–38 wt.%. The significant influence of the CuO/Al and CuO/C ratios on arc voltage parameters can also be explained by their impact on the elemental composition of the welding arc (copper, cupric oxide (CuO), and Al₂O₃). The more complete this reaction, the higher the amount of easily vaporized copper (Cu) in the arc plasma, enhancing arc stability. The influence of core filler composition on the microstructure of deposited metal of the Fe-Cr-Cu-Ti alloy system was investigated. Full article

The Laser Beam Welding (LBW) of aluminum alloys has attracted significant interest from industrial sectors, including the shipbuilding, automotive and aeronautics industries, as it expects to contribute to significant cost reduction associated with the production of high-quality welds. To comprehend the behavior of welded structures in regard to their damage tolerance, the application of fracture mechanics serves as the instrumental tool. However, the methods employed overlook the changes in the microstructure within the Heat-Affected Zone (HAZ), which leads to the degradation of the mechanical properties of the material. The purpose of this study is to simulate microhardness evolution in the HAZ of AA2198-T351 LBW. The material represents the latest generation of Al-Cu-Li alloys, which exhibit improved mechanical properties, enhanced damage tolerance behavior, lower density and better corrosion and fatigue crack growth resistance than conventional Al-Cu alloys. In this work, the microhardness profile of LBW AA2198 was measured, and subsequently, through isothermal heat treatments on samples, the microhardness values of the HAZ were replicated. The conditions of the heat treatments (T, t) were selected in line with the thermal cycles that each area of the HAZ experienced during welding. ThermoCalc and DICTRA were employed in order to identify the strengthening precipitates and their evolution (dissolution and coarsening) during the weld thermal cycle. The microstructure of the heat-treated samples was studied employing LOM and TEM, and the strengthening precipitates and their characteristics (volume fraction and size) were defined and correlated to the calculations and the experimental conditions employed during welding. The main conclusion of this study is that it is feasible to imitate the microstructure evolution within the HAZ through the implementation of isothermal heat treatments. This implies that it is possible to fabricate samples for fatigue crack growth tests, enabling the experimental examination of the damage tolerance behavior in welded structures. Full article

Superduplex stainless steels (SDSS) are known for their combination of good mechanical properties and excellent corrosion resistance, enabled by the microstructural balance between austenite and ferrite and an amount of alloying elements. Their application in welded components is, however, limited by the possibility of the precipitation of intermetallic phases and microstructural misbalance, which might hinder their properties, especially in the heat-affected zone (HAZ). This work introduces a methodology that relies simultaneously on physical and numerical simulations to study the HAZ in a UNS S32750 SDSS. Dimensions of the fusion zone and thermal cycles were calibrated for a numerical model using preliminary welding trials. Numerically simulated cycles for each heat input (HI) were physically reproduced in a Gleeble^® simulator, and the heat-treated samples were characterized and compared with real specimens welded using the same parameters. Thermal curves resulting from the numerical simulations were successfully replicated by the Gleeble^®, indicating adequate application of the desired HI. The hardness and microstructural results from simulated and welded specimens were also found to be quite similar. Therefore, the proposed methodology showed itself adequate not only for the study of duplex stainless steels, but also of materials with similar thermal and mechanical properties, including the extrapolation of welding parameters. Full article

316L stainless steel joined to mild steel is widespread in several applications to reach a requested good association of mechanical properties at a lower cost. The activating tungsten inert gas (ATIG) weld was carried out using a modified flux composed of 76.63% SiO₂ + 13.37% Cr₂O₃ + 10% NaF to meet standard recommendations in terms of limiting the root penetration. Modified optimal flux gave a depth of penetration 1.84 times greater than that of conventional tungsten inert gas (TIG) welds and a root penetration of up to 0.8 mm. The microstructure of the dissimilar joints was investigated using a scanning electron microscope and EDS analysis. The mechanical properties of the weld were not affected by the modified flux. The results show that the energy absorbed in the fusion zone in the case of ATIG weld (239 J/cm²) is greater than that of TIG weld (216 J/cm²). It was found that the weld bead obtained with the optimal flux combination in ATIG welding can better withstand sudden loads. The obtained UTS value (377 MPa) for ATIG welding was close to that of TIG welding (376 MPa). The average Vickers hardness readings for ATIG welds in the fusion zone are up to 277 HV, compared to 252 HV for conventional TIG welding. Full article

Small differences in the contents of surface active elements can change flow direction and thus heat transfer, even for different batches of a given alloy. This study aims to determine the effects of sulfur on weld bead morphology in the laser process. The paper presents the results related to the weld bead shape of two thin AISI 304 industrial stainless steel casts. One cast contains 80 ppm (0.008%) of sulfur, considered as a high sulfur content, and the other one contains 30 ppm (0.003%) sulfur, which can be considered low sulfur. The welds were executed using a CO₂ laser. The effects of laser power (3.75, 3.67, 6 kW), welding speed (1.25, 2.40, 2.45, 3.6 m/min), focus point position (2, 7, 12 mm), and shield gas (Helium, mixed 40% helium + 60% argon and mixed 70% helium + 30% argon) with a flow rate of 10 L/min on the depth of the weld (D) and the aspect ratio (R = D/W) were investigated using RSM (response surface methodology). The experimental results show that the transfer of energy from the laser beam to the workpiece can be total in cases where the selected welding parameters prevent plasma formation. For the 304 HS cast, the focus point is the major factor in determining the depth of penetration, and its contribution is up to 52.35%. However, for 304 LS, the interaction between shield gas and focus point seems to play an important role, and the contribution of their interaction raises to 28% in relation to the laser depth of the weld. Moreover, the study shows that sulfur plays a surface-active role only in the case of partial penetration beads, so that a 56% partially penetrated weld supports the hypothesis of its surface-active role in the formation of the weld pool. However, a penetration of only 36% confirms the effects of a sulfur surface-active when the bead is fully penetrated. Full article

Friction welding of aluminum alloys holds immense potential for replacing riveted joints in the structural sections of the aeronautical and automotive sectors. This research aims to investigate the effects on the microstructural and mechanical properties when AA5083 H116 joints are subjected to rotary friction welding. To evaluate the quality of the welds, optical and scanning electron microanalysis techniques were utilized, revealing the formation of sound welds without porosity. The microstructural examination revealed distinct weld zones within the weldment, including the dynamically recrystallized zone (DRZ), thermo-mechanically affected zone (TMAZ), heat-affected zone (HAZ), and base metal (BM). During the friction-welding process, grain refinement occurred, leading to the development of fine equiaxed grains in the DRZ/weld zone. Tensile testing revealed that the weldment exhibited higher strength (YS: 301 ± 6 MPa; UTS: 425 ± 7 MPa) in the BM region compared to the base metal (YS: 207 ± 5 MPa; UTS: 385 ± 9 MPa). However, the weldment demonstrated slightly lower elongation (%El: 13 ± 2) compared to the base metal (%El: 15 ± 3). The decrease in ductility observed in the weldment can be attributed to the presence of distinct weld zones within the welded sample. Also, the tensile graph of the BM showed serrations throughout the curve, which is a characteristic phenomenon known as the Portevin–Le Chatelier effect (serrated yielding) in Al-Mg alloys. This effect occurs due to the influence of dynamic strain aging on the material’s macroscopic plastic deformation. Fractography analysis showcased a wide range of dimple sizes, indicating a ductile fracture mode in the weldment. These findings contribute to understanding the microstructural and mechanical behavior of AA5083 H116 joints subjected to rotary friction welding. Full article

This research study investigates the influence of sampling direction on the microstructure and mechanical properties of dissimilar joints formed by friction stir welding (FSW). The specimens were cut in two directions: perpendicular (transverse) and parallel (longitudinal) to the FSW joint. The tests conducted included X-ray diffraction (XRD), macrostructure, microstructure, tensile, microhardness, and fractography analysis. Different phases were noted in the XRD patterns and explained, with the aluminum phase being the dominating one. The results further showed that the transverse dissimilar joint exhibited higher microhardness compared to the longitudinal dissimilar joint, which is consistent with the respective grain sizes. Moreover, the ultimate tensile strength of the longitudinal joint exceeded that of the transverse joints, showing a substantial 47% increase. Similarly, the elongation of the joints followed a similar trend, with the longitudinal joint displaying a significant 41% increase in elongation compared to the transverse joint. Fractographic analysis revealed ductile fracture behaviour in all joints. Full article