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Original Article
Abstract
This research aims to optimize the process parameters of plasma arc welding for welding of dissimilar metals: austenitic
stainless steel SS-304 L and low carbon steel A-36. It investigates the effect of welding current and welding speed on the
quality of the welded joints. The quality characteristics like bead geometry, microstructure, hardness, ferrite measure-
ment and tensile test are considered for qualification of the welded samples. Welded specimens were prepared both with
and without filler material. These specimens were mechanically tested and analyzed using metallographic techniques.
Based on the results, suitable welding parameters were found to be 45 A and 2 mm/s for samples prepared with and
without filler wire. An all-martensitic weld zone structure was obtained for direct fusion. However, a complex hetero-
geneous microstructure was obtained by using austenitic stainless steel filler wire E 309 L. Hardness of directly fused
sample was observed to be significantly higher compared to filler wire sample.
Keywords
Plasma arc welding, dissimilar metal welding, microstructure, hardness, tensile testing
Table 1. Welding parameters for PAW (PWH/-3 A). in PAW is constricted in nozzle, which makes it more
directional and confined.23 Also the electrode in PAW
Parameters Values is not in direct contact with weld pool; hence, the
Shielding gas flow rate 10 LPM possibility of tungsten inclusion is minimized and
Purging gas flow rate 10 LPM the life of electrode increases.26 Moreover, PAW is
preferred over other conventional processes due to
Plasma gas flow rate 0.5 LPM
its greater energy concentration, deeper and narrower
Nozzle to plate distance 6 mm
penetration achievement and greater arc stability.27
Filler wire 309 L The practical PAW process is widely appreciated in
Holding time after welding 1 min the aerospace, chemical, naval, nuclear industries,
Joint design Square groove joint etc.24 Prasada et al. investigated the weld quality char-
Shielding gas High purity argon acteristics of pulsed current micro-plasma arc welded
Plasma gas High purity argon austenitic stainless steels and considered weld pool
Electrode used 9-1783 geometry, microstructure, grain size, hardness and
Orifice diameter 0.46 mm tensile properties as weld quality characteristics.
Torch position Vertical It was established that SS 304L attained better weld
Operation type Automatic quality characteristics at same welding conditions as
Pilot arc 5 amp compared to SS 316 L, SS 316Ti, SS 321.21 Reddy
et al. analyzed the microstructure of post weld heat
Mode of operation Fusion mode
treated DMW joint between type 316 L and C-steel by
Plate thickness 2 mm
GTAW process and found that martensite is found in
the HAZ of C-steel with autogeneous welding pro-
cess.28 Sánchez-Tovar et al. studied the micro-
plasma arc welded stainless steels SS 316 L and
problem associated with DMW between CS and SS found that the microstructure of the SS is modified
with an austenitic SS filler metal is the carbide pre- due to the micro-PAW procedure.27 Pouranvari and
cipitation due to higher carbon content of carbon coworkers., studied similar and dissimilar resistance
steel.19 Many researchers reported that the in-service spot welding of low carbon and austenitic stainless
failures of dissimilar weldments are due to weak tran- and determined that pull out failure location for CS/
sition joint.20,21 SS is the base metal of low carbon side. It was also
The selection of suitable welding process is also concluded that increased welding current widened
essential in order to control such critical welds. The fusion-zone side which resulted in martensite forma-
high-power density methods like laser, electron beam tion.29 It has been observed from the published litera-
and plasma arc welding (PAW) are becoming prom- ture review that no systematic work is done to find the
inent as these processes exhibit quick fusion of both role of PAW process parameters on dissimilar metal
metals even if they have quite different melting tem- welding. Dissimilar metal welding is highly critical as
peratures.22–24 PAW is an arc welding process that many issues arise during welding such as the carbon
exhibits joining of metals by heating them with a con- migration from the higher carbon containing alloy
stricted arc established between tungsten electrode steel to relatively low carbon alloy steel. The differ-
and the metals.22,25 PAW is advantageous as the arc ences in thermal expansion coefficients also play
Fatima et al. 3
Table 2. Chemical composition (wt%) of type 304 L stainless steel, low carbon steel A-36, E-309 L.
Composition %
C Si Mn P S Cr Ni Mo Cu N Fe
Austenitic stainless 0.017 0.37 1.79 0.028 0.010 18.1 8.0 0.40 0.34 0.06 bal
steel 304 L
Low carbon 0.16 0.08 0.49 0.017 0.034 – – – – – bal
steel A-36
E-309 L 0.035 0.53 1.5 0.024 0.021 23.45 12.6 – – – bal
Table 3. Mechanical properties of metals of interest in welding applications involving dissimilar metals.45,51–55
Austenitic
stainless Low carbon Titanium Al Inconel
Property steel 304 L steel A-36 (grade 1) Ti-6Al-4 V 6082-T6 Al7075-T6 718
Speed (mm/sec 3
0
10 15 20 25 30 35 40 45
Current (A)
Figure 2. Effect of welding current and speed of PAW on acceptable weld zone of SS-304 L and A-36 with filler wire 309 L.
3
Speed (mm/sec)
0
10 15 20 25 30 35 40 45
Current (A)
Lack of Fusion Lack of Penetration Good Weld Excessive Penetration
Figure 3. Effect of welding current and speed of PAW on acceptable weld zone of SS-304 L and A-36 without filler wire 309 L.
Fatima et al. 5
Figure 4. Weld configuration of (a) incomplete fusion, (b) lack of penetration (c) sound weld (d) excessive penetration/over burn.
Table 5. Bead width, penetration and weld profile of the selected samples.
600
500 WF01
hardness ( VHN)
400 DF01
SS-304L A-36 WF02
300
DF02
200 DF03
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Locaon at weld joint
Fatima et al. 7
Figure 6. (a) Parent SS metal, (b) fusion zone with SS (c) weld zone (d) fusion zone with CS (e) parent CS metal.
003
1000
900
(a) 800
FeKa
700
FeLa
600
Counts
CrLl CrLa
500
400
300
FeKb
FeLl
FeKesc
CKa
CrKa
CrKb
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
005
1000
900
(b)
800
FeLa NiLl
FeKa
700
600
CrLl CrLa FeLl
Counts
500
CrKa
400
FeKb
300
CrKb
FeKesc
NiKa
NiLa
CKa
NiKb
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
1000
FeKa
900
(c)
800
FeLa NiLl
700
600
CrKa
CrLl CrLa FeLl
Counts
500
400
FeKb
300
CrKb
FeKesc
NiKa
NiLa
NiKb
CKa
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
Figure 7. SEM micrographs along with EDS spectra of (a) SS HAZ, (b) Weld zone, (c) CS HAZ.
during high-temperature service. Moreover, the same ferrite content as in base SS alloy; however,
amount of ferrite controls the corrosion and stress all the samples are within the desired limit
corrosion resistance. The weld solidification of FN 30.
cracking may increase with increasing ferrite
content above approximately FN 30.38 Hence, the
quantity of ferrite in the welds must be
Microstructure analysis
minimized during welding of austenitic steel Metallography of both 304 L SS and low CS A-36 was
joints to avoid material degradation during ser- carried out. Etching was performed according to
vice.39 Table 6 shows the total ferrite number in ASTM standard E-407. Freshly prepared 2% Nital
parent SS and weld zones. It is observed that (98 ml C2H5OH, 2 ml HNO3) was used for etching
the samples welded with E-309 L have almost CS while Glyceregia (10 ml HNO3, 20 ml HCL,
Fatima et al. 9
Figure 8. (a) Parent SS metal, (b) fusion zone with SS, (c) weld zone, (d) fusion zone with CS, (e) parent CS metal.
10 ml CH3COOH and 30 ml Glycerine) was employed transformation occurring in this zone. Figure 7(b) indi-
as etchant for SS. Out of five qualified weld sam- cates the microstructure of fusion zone with a complex
ples, two were selected, i.e. one with filler (WF) and heterogeneous structure. The matrix consists of pearlite
the other without filler (DF). Samples WF01 and with carbide at prior austenite grain boundaries. Also,
DF01, both at 45 A and 2 mm/s were selected con- some portion of martensite is expected to be present as
sidering the economical factor associated with high- suggested by Schaeffler diagrams.41 In case of using
speed welding. austenitic SS filler wire 309 L, the diffusion of alloying
Figure 6(a) shows optical micrograph of the parent elements is controlled and the weld zone retains the
SS material for the WF01 sample. Figure 6(c) shows chromium and nickel equivalent to the composition
the dendritic structure of the fusion zone, while the of austenitic SS base metal. Figure 7(c) indicates the
interface between the fusion zone and the SS HAZ HAZ of CS. It consists of ferrite and pearlite structure.
can be observed in Figure 6(b). It is observed that The corresponding EDS spectra of zone a, b and c are
the interface is not very sharp; therefore, a broad shown along with structures. The elemental distribu-
and diffuse fusion zone is produced for stainless tion of SS HAZ and weld zone is similar. The spectra
steel. In addition fine dendritic structure seen in the reveal the high peaks of Fe, Cr, Ni, in weld zone and
weld zone can be attributed to the very high cooling SS HAZ, whereas CS HAZ does not consist of Cr and
rates in the fusion zone.40 On the other hand, Figure Ni peaks.
6(d) shows the interface of CS HAZ with the fusion Similar to sample 1 (WF01), the microstructure
zone, where a very sharp fusion line is observed. of sample 2 (DF01) was studied using optical
Figure 6(e) shows the structure of parent CS metal. microscopy and SEM. Figure 8(b) shows the inter-
The CS structure consists of equiaxed ferrite (white face of SS HAZ with fusion zone, whereas, Figure
areas) and pearlite (dark areas). In the light of above 8(d) shows the interface of CS HAZ with fusion
observations, it is clear that full penetration joint was zone. Figure 8(c) reveals the dendrite structure of
produced by using filler wire at 45 A, 2 mm/s and with weld zone. Full penetration joint was produced by
0.5 LPM plasma gas flow rate. direct fusion at 45 A, 2 mm/s and with 0.5 LPM
Figure 7(a) to (c) shows SEM images along with plasma gas flow rate. Similar to sample 1,
compositional analysis for SS HAZ, fusion zone and Micrographs of sample 2 did not reveal any defects
CS HAZ for the WF 01 sample. SS HAZ (Figure 7(a)) such as micro cracks or porosity in the welded
revealed the austenitic microstructure with no phase sample.
1000
FeKa
900
(a) 800
FeLa NiLl
700
600
CrKa
CrLl CrLa FeLl
Counts
500
400
FeKb
300
CrKb
FeKesc
NiKa
NiLa
NiKb
CKa
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
003
1000
(b) 900
800
700
FeKa
FeLa
600
Counts
500
400
300
FeKb
FeKesc
CrKb
CrKa
CKa
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
005
1000
(c)
FeKa
900
800
FeLa NiLl
700
600
CrLl CrLa FeLl
Counts
500
CrKa
400
FeKb
300
FeKesc
NiKa
CrKb
NiLa
CKa
NiKb
200
100
0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
Figure 9. SEM micrographs along with EDS spectra of (a) SS HAZ, (b) weld zone, (c) CS HAZ.
Fatima et al. 11
Fatima et al. 13
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