Eliminating the Brittleness Constituent to Enhance Toughness of the High-Strength Steel Weld Heat-Affected Zone Using Electropulsing.

The evolution of the martensite-austenite (MA) constituent in the heat-affected zone (HAZ) of high-strength steel FH690 welds when subjected to electropulsing (EP) treatment was investigated herein, with the aim of eliminating brittle MA to enhance toughness. The features induced by EPT were correlated with the microstructure and fractography through scanning electron microscopy and electron backscatter diffraction analyses, together constituting an impact property evaluation. The Charpy V-notch impact results showed EPT could improve toughness of the HAZ from 34.1 J to 51.8 J (the calibrated value was 46 J). Examinations of EP-treated microstructure showed a preferred Joule heating: at the site of the MA constituent, the cleavage fractography introduced by the MA constituent was substituted with ductile dimples with various sizes. Decreases in grain size of 40% and 47% for the matrix and the retained austenite, respectively, were achieved; while for regions without the MA constituent, microstructural modification was negligible. The temperature rise at sample surface was less than 60 °C. The mechanism behind this favorable Joule heating for the MA constituent was correlated with the electrical properties of the MA constituent in contrast with martensite matrix. The toughness enhancement of the HAZ was thus attributed to the elimination of the coarse MA constituent. The present investigation suggested that electropulsing, characterized as a narrow-duration current, is a promising method for preferred elimination of brittle factors and thus improving the toughness of HAZ of high-strength steel within a limited region with a width less than 2 mm.

Solidification Crack Evolution in High-Strength Steel Welding Using the Extended Finite Element Method.

High-strength steel suffers from an increasing susceptibility to solidification cracking in welding due to increasing carbon equivalents. However, the cracking mechanism is not fully clear for a confidently completely crack-free welding process. To present a full, direct knowledge of fracture behavior in high-strength steel welding, a three-dimensional (3-D) modeling method is developed using the extended finite element method (XFEM). The XFEM model and fracture loads are linked with the full model and the output of the thermo-mechanical finite element method (TM-FEM), respectively. Solidification cracks in welds are predicted to initiate at the upper tip at the current cross-section, propagate upward to and then through the upper weld surface, thereby propagating the lower crack tip down to the bottom until the final failure. This behavior indicates that solidification cracking is preferred on the upper weld surface, which has higher weld stress introduced by thermal contraction and solidification shrinkage. The modeling results show good agreement with the solidification crack fractography and in situ observations. Further XFEM results show that the initial defects that exhibit higher susceptibility to solidification cracking are those that are vertical to the weld plate plane, open to the current cross-section and concentratedly distributed compared to tilted, closed and dispersedly distributed ones, respectively.