Embrittlement Fracture Behavior and Mechanical Properties in Heat-Affected Zone of Welded Maraging Steel.

In welded maraging steels, mechanical properties, particularly ductility and toughness, are often compromised in the heat-affected zone (HAZ). This study focuses on 300-grade maraging steel bars, solution annealed at 1123 K for 1.5 h (5.4 ks) and welded using gas tungsten arc welding, followed by a post-weld heat treatment at 753 K for 13.33 h (48 ks). In situ observations during three-point bending tests on HAZ samples featuring coarsened prior austenite grain sizes were conducted to examine damage behavior and the crack path near the crack tip. The main crack initiated at the peak applied load during the bending test and, upon further loading, exhibited significant deflection and extension accompanied by numerous microcracks and localized crack branching. Distinctive damage features, such as transgranular cracking across block regions, intense intergranular cracking along packet boundaries with a pronounced shear component, and crowding of microcracks ahead of the crack tip, were observed in the HAZ sample during the in situ test. The interaction between the main crack tip and microcracks and its influence on the local crack propagation driving force was discussed using fracture mechanics. Experimental results, including tensile fracture surface observations and in situ images, along with analysis of the stress anti-shielding effect by microcracks, suggest that the HAZ sample exhibits embrittlement fracture behavior with lower ductility and toughness compared to the base metal sample.

Investigation of thermal effects of laser micromachining for APT and TEM specimen preparation: A modeling and experimental study.

Laser micromachining can serve as a coarse machining step during sample preparation for high-resolution characterization methods leading to swift sample preparation. However, selecting the right laser parameters is crucial to minimize the heat-affected zone, which can potentially compromise the microstructure of the specimen. This study focuses on evaluating the size of heat-affected zone in laser annular milling, aiming to ascertain a minimal scan diameter that safeguards the inner region of micropillars against thermal damage. A computational model based on the finite element method was utilized to simulate the laser heating process. To validate the simulation results, a picosecond pulsed laser is then used to machine the micropillars of Al and Si. The laser-machined samples were subjected to surface and microstructural analysis using Scanning Electron Microscope (SEM) and Electron Backscatter Diffraction (EBSD) scans. The length of heat affected zone obtained from simulations was approximately 6 µm for silicon and 12 µm for aluminum. The diameter of micropillars formed with laser machining was 10 µm for silicon 26 µm for aluminum. The core of the pillars was preserved with less than one degree of microstructural misorientations making it suitable for further processing for preparing specimens for techniques like APT and TEM. For silicon micropillars, the preserved central region has a diameter of 6 µm and for aluminum its around 20-24 µm. Additionally, the study determines the minimum scan diameter that can be achieved using the given laser machining setup across a range of common materials.

The Influence of the Second Phase on the Microstructure Evolution of the Welding Heat-Affected Zone of Q690 Steel with High Heat Input.

Q690 steel is widely used as building steel due to its excellent performance. In this paper, the microstructure evolution of the heat-affected zone of Q690 steel under simulated high heat input welding conditions was investigated. The results show that under the heat input of 150-300 kJ/cm, the microstructures of the heat-affected zone are lath bainite and granular bainite. The content of lath bainite gradually decreased with the increase in heat input, while the content of granular bainite steadily increased. The proportion of large-angle grain boundaries decreased from 51.1% to 40.3%. Overall, the average size of original austenite increased, and the precipitates changed from Ti (C, N) to Cr carbides. During the cooling process, the nucleation position of bainitic ferrite was from high to low according to the nucleation temperature, and in order of inclusions at grain boundaries, triple junctions, intragranular inclusions, bainitic ferrite/austenite phase boundaries, twin boundaries, grain boundaries, and intragranular inclusions at the bainitic ferrite/austenite phase interface. The growth rate of bainitic ferrite nucleated at the phase interface, grain boundary, and other plane defects was faster, while it was slow at the inclusions. Moreover, it was noted that the Mg-Al-Ti-O composite inclusions promote the nucleation of lath bainitic ferrite, while the Al-Ca-O inclusions do not facilitate the nucleation of bainitic ferrite.

Effect of Welding Current on Corrosion Resistance of Heat-Affected Zones of HDR Duplex Stainless Steel.

This paper examines the corrosion behavior of the welding heat-affected zone (HAZ) of HDR (high chromium, duplex, corrosion-resistant) duplex stainless steel, which currently faces corrosion-related challenges in marine seawater systems. The corrosion behavior of the HAZ was studied using microstructure analysis, polarization curve experiments, and double-loop potentiodynamic reactivation experiments. The results show that (1) the covering welding current can promote the formation of austenite in the HAZ, and that the covering welding current has no strict correspondence with the formation of austenite; (2) increasing the welding gap properly can facilitate the formation of austenite; (3) increasing the covering welding current enhances the material's pitting resistance, and a covering welding current of 70 A, coupled with a covering welding current of 100 A, represents a reasonable choice in terms of achieving a stronger pitting resistance; (4) in terms of intergranular corrosion resistance, increasing the covering welding current is not conducive to the intergranular corrosion resistance of the material, as the covering current will promote the precipitation of the secondary phase at the grain boundary, thus reducing its intergranular corrosion resistance; and (5) reducing the welding current appropriately contributes to improving the stability of the grain boundary.

Effect of Fusion Boundary Microstructure on Flow-Accelerated Corrosion Cracking.

Flow-accelerated corrosion (FAC) preferentially attacks the downstream heat-affected zone of the root-pass weld in steam pipe systems. A detailed characterization identifies the fusion boundary as the initiation location for the attack. Alloying elements are found depleted along the weld fusion boundary, and multiple welding thermal cycles and repetitive austenite-to-ferrite phase transformations result in an increased proportion of grains with Goss {110}<001> texture along the fusion boundary. The synergistic effects of chemical segregation and the Schmid factor may contribute to the preferential initiation of FAC cracks along the root weld fusion boundary, making it the weakest link for FAC attack in steam pipe girth welds.

Effect of powder composition, PTAW parameters on dilution, microstructure and hardness of Ni-Cr-Si-B alloy deposition: Experimental investigation and prediction using machine learning technique.

The implementation of hard-facing alloy on the existing materials caters the need for high-performance surfaces in terms of wear and high temperatures. The present research explore the effect of Plasma Transferred Arc Welding (PTAW) parameters and powder composition on dilution, microstructure and hardness of the commonly used hard-facing alloy Ni-Cr-Si-B powder. The hard-facing alloy was deposited with three weight proportions of boron (2.5 %, 3 % and 3.5 %). The statistical-based Grey Relational Analysis (GRA) followed by a Machine Learning Algorithm (MLA) was implemented to identify the ideal parameters and degree of significance of each parameter and for the prediction of the responses. The dilution percentage, microstructure analysis, and phase detection were estimated through elemental analysis, Scanning electron Microscopy (SEM) and X-ray Diffraction Analysis (XRD) respectively. The experimental and modelling results revealed that 400 mm/min of scanning speed, 8 gm/min of powder delivery, 14 mm of stand-off distance, and 120 A of current were the optimal parameters along with 3.5 wt% of boron powder composition to yield a better dilution, microstructure and hardness.

Suppressing Metal Nanoparticle Ablation with Double-Pulse Femtosecond Laser Sintering.

As a branch of laser powder bed fusion, selective laser sintering (SLS) with femtosecond (fs) lasers and metal nanoparticles (NPs) can achieve high precision and dense submicron features with reduced residual stress, due to the extremely short pulse duration. Successful sintering of metal NPs with fs laser is challenging due to the ablation caused by hot electron effects. In this study, a double-pulse sintering strategy with a pair of time-delayed fs-laser pulses is proposed for controlling the electron temperature while still maintaining a high enough lattice temperature. We demonstrate that when delay time is slightly longer than the electron-phonon coupling time of Cu NPs, the ablation area was drastically reduced and the power window for successful sintering was extended by about two times. Simultaneously, the heat-affected zone can be reduced by 66% (area). This new strategy can be adopted for all the SLS processes with fs laser and unlock the power of SLS with fs lasers for future applications.

The effect of thermomechanical welding on the microstructure and mechanical properties of S700MC steel welds.

Grain refinement by plastic deformation during conventional TIG welding can help to compensate for the loss of mechanical properties of welded joints. The thermomechanical welding (TMW) tests were performed on S700MC steel with different combinations of TIG arc energy and high frequency hammering over three target cooling times (t8/5 = 5s, 15s, and 25s). Additionally, the effect of initial microstructures on the weld joint quality was analysed by testing three materials conditions: hot-rolled (as-received) and cold-rolled with 10% and 30% thickness reductions, respectively. The effects of plastic deformation and the mechanical vibration on the grain refinement were studied separately. Optical microscopy, electron backscattered diffraction, and Vickers hardness were used to characterise the weld microstructure heterogeneity. The weld width and depth and the mean grain size were correlated as the function of cooling time t8/5. The results show that the weld dimensions increase with increasing the t8/5. The weld microstructures transformed from the mixed martensite and bainite into mixed ferrite and bainite with increasing the t8/5 time, and the related mean grain size increased gradually. The TMW welds exhibit smaller grains compared to TIG welds due to the coupled effects of mechanical vibration and plastic deformation. The mechanical vibration contributes to weld metal homogenisation, accelerating TiN precipitation in the fusion zone. The proposed TMW process can refine the weld microstructure of S700MC steel, enhancing its mechanical properties.

The Dominant Role of Recrystallization and Grain Growth Behaviors in the Simulated Welding Heat-Affected Zone of High-Mn Steel.

Single-pass-welding thermal cycles with different peak temperatures (Tp) were reproduced by a Gleeble 3800 to simulate the heat-affected zone (HAZ) of a Fe-24Mn-4Cr-0.4C-0.3Cu (wt.%) high manganese austenitic steel. Then, the effect of Tp on the microstructure and mechanical properties of the HAZ were investigated. The results indicate that recrystallization and grain growth play dominant roles. Based on this, the HAZ is proposed to categorize into three zones: the recrystallization heat-affected zone (RHAZ) with a Tp of 700~900 °C, the transition heat-affected zone (THAZ) with a Tp of 900~1000 °C, and the coarse grain heat-affected zone (CGHAZ) with a Tp of 1000~1300 °C. The recrystallization fraction was 29~44% in the RHAZ, rapidly increased to 87% in the THAZ, and exceeded 95% in the CGHAZ. The average grain size was 17~19 µm in the RHAZ, slightly increased to 22 µm in the THAZ, and ultimately increased to 37 µm in the CGHAZ. The yield strength in the RHAZ and THAZ was consistent with the change in recrystallization fraction, while in the CGHAZ, it satisfied the Hall-Petch relationship with grain size. In addition, compared with the base material, the Charpy impact absorbed energy at -196 °C decreased by 22% in the RHAZ, but slightly increased in the CGHAZ. This indicates that the theory of fine grain strengthening and toughening is not entirely applicable to the HAZ of the investigated high-Mn steel.

ANN Prediction of Laser Power, Cutting Speed, and Number of Cut Annual Rings and Their Influence on Selected Cutting Characteristics of Spruce Wood for CO2 Laser Processing.

In this work, we focus on the prediction of the influence of CO2 laser parameters on the kerf properties of cut spruce wood. Laser kerf cutting is mainly characterized by the width of kerf and the width of the heat-affected zone, which depend on the laser power, cutting speed, and structure of the cut wood, represented by the number of cut annual rings. According to the measurement results and ANN prediction results, for lower values of the laser power (P) and cutting speed (v), the effect of annual rings (ARs) is non-negligible. The results of the sensitivity analysis show that the effect of v increases at higher energy density (E) values. With P in the range between 100 and 500 W, v values between 3 and 50 mm·s-1, and AR numbers between 3 and 11, the combination of P = 200 W and v = 50 mm·s-1, regardless of the AR value, leads to the best cut quality for spruce wood. In this paper, the main goal is to show how changes in the input parameters affect the characteristics of the cutting kerf and heat-affected zones for all possible input parameter values.

Study of the Relationship between Entropy and Hardness in Laser Cutting of Hardox Steel.

The article presents the findings of a study on the machining of 10 mm thick Hardox 400 steel plates using the CO2 laser. The purpose of the investigation was to investigate the relationship between the entropy and the hardness of machined surfaces. For this purpose, a new mathematical model is established to estimate the entropy, and its influence on the hardness is determined. The mathematical model is statistically and experimentally validated. An entropy variation ΔS = -330 mJ/K between 2 K is found, causing a decrease in hardness compared to the standard value. The influences of input parameters (laser power, cutting speed, and auxiliary gas pressure) on hardness are determined. It is demonstrated that the surface hardness is strongly influenced by the auxiliary gas pressure. The combination of laser power P = 4200 W with gas pressure p = 0.45 bar at average cutting speed v = 1400 mm/min leads to a hardness of 38 HRC, extending the life and wear resistance of the cut parts.

Effects of Ambient Temperature on the Mechanical Properties of Frictionally Welded Components of Polycarbonate and Acrylonitrile Butadiene Styrene Dissimilar Polymer Rods.

Rotary friction welding (RFW) has no electric arc and the energy consumption during welding can be reduced as compared with conventional arc welding since it is a solid-phase welding process. The RFW is a sustainable manufacturing process because it provides low environmental pollution and energy consumption. However, few works focus on the reliability of dissimilar polymer rods fabricated via RFW. The reliability of the frictionally welded components is also related to the ambient temperatures. This work aims to investigate the effects of ambient temperature on the mechanical properties of frictionally welded components of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) dissimilar polymer rods. It was found that the heat-affected zone width increases with increasing rotational speeds due to peak welding temperature. The Shore A surface hardness of ABS/PC weld joint does not change with the increased rotational speeds. The Shore A surface hardness in the weld joint of RFW of the ABS/PC is about Shore A 70. The bending strength was increased by about 53% when the welded parts were placed at 60-70 °C compared with bending strength at room temperature. The remarkable finding is that the bending fracture position of the weldment occurs on the ABS side. It should be pointed out that the bending strength can be determined by the placed ambient temperature according to the proposed prediction equation. The impact energy was decreased by about 33% when the welded parts were placed at 65-70 °C compared with the impact energy at room temperature. The impact energy (y) can be determined by the placed ambient temperature according to the proposed prediction equation. The peak temperature in the weld interface can be predicted by the rotational speed based on the proposed equation.

Study of Residual Stresses and Austenite Gradients in the Surface after Hard Turning as a Function of Flank Wear and Cutting Speed.

This paper investigates the influence of cutting speed and flank wear on the depth profile of residual stresses, as well as the fraction of retained austenite after hard turning of quenched bearing steel 100Cr6. Residual stress and retained austenite profiles were studied for the white layer, heat-affected zone thickness, and XRD sensing depth. It was found that the influence of flank wear on the white layer and heat-affected zone thickness predominates. On the other hand, residual stresses are affected the cutting speed and the superimposing contribution of flank wear. Moreover, these aspects also alter microhardness in the affected regions. The study also demonstrates that information concerning residual stresses and the austenite fraction is integrated into the white layer, and the heat-affected zone in the surface is produced by the insert of low flank wear since the XRD sensing depth is more than the thickness of the white layer. On the other hand, the pure contribution of the white layer or the heat-affected zone to residual stress and the austenite fraction can be investigated when the affected surface region is thick enough.

Pulsed Laser Spot Welding Thermal-Shock-Induced Microcracking of Inconel 718 Thin Sheet Alloy.

This paper investigates the change in solidification microcrack susceptibility under the influence of thermal-shock-induced effects for pulsed laser spot welding molten pools with different waveforms, powers, frequencies, and pulse widths. During the welding process, the temperature of the molten pool under the effect of thermal shock changes sharply, triggering pressure waves, creating cavities in the molten pool paste area, and forming crack sources during solidification. The microstructure near the cracks was analyzed using a SEM (scanning electron microscope) and EDS (electronic differential system), and it was found that bias precipitation occurred during the rapid solidification of the melt pool, and a large amount of Nb elements were enriched in the interdendritic and grain boundaries, which eventually formed a liquid film with a low melting point, known as a Laves phase. When cavities appear in the liquid film, the chance of crack source formation is further increased. Using a slow rise and slow fall waveform is good for reducing cracks; reducing the peak laser power to 1000 w is good for reducing cracks in the solder joint; increasing the pulse width to 20 ms reduces the degree of crack damage; reducing the pulse frequency to 10 hz reduces the degree of crack damage.

Finite Element Simulation and Experimental Assessment of Laser Cutting Unidirectional CFRP at Cutting Angles of 45° and 90°.

Laser cutting of carbon fibre-reinforced plastics (CFRP) is a promising alternative to traditional manufacturing methods due to its non-contact nature and high automation potential. To establish the process for an industrial application, it is necessary to predict the temperature fields arising as a result of the laser energy input. Elevated temperatures during the cutting process can lead to damage in the composite's matrix material, resulting in local changes in the structural properties and reduced material strength. To address this, a three-dimensional finite element model is developed to predict the temporal and spatial temperature evolution during laser cutting. Experimental values are compared with simulated temperatures, and the cutting kerf geometry is examined. Experiments are conducted at 45° and 90° cutting angles relative to the main fibre orientation using a 1.1 mm thick epoxy-based laminate. The simulation accurately captures the overall temperature field expansion caused by multiple laser beam passes over the workpiece. The influence of fibre orientation is evident, with deviations in specific temperature data indicating differences between the estimated and real material properties. The model tends to overestimate the ablation rate in the kerf geometry, attributed to mesh resolution limitations. Within the parameters investigated, hardly any expansion of a heat affected zone (HAZ) is visible, which is confirmed by the simulation results.

A Parameterized Leblond-Devaux Equation for Predicting Phase Evolution during Welding E36 and E36Nb Marine Steels.

High heat input welding can improve welding efficiency, but the impact toughness of the heat-affected zone (HAZ) deteriorates significantly. Thermal evolution in HAZ during welding is the key factor affecting welded joints' microstructures and mechanical properties. In this study, the Leblond-Devaux equation for predicting phase evolution during the welding of marine steels was parameterized. In experiments, E36 and E36Nb samples were cooled down at different rates from 0.5 to 75 °C/s; the obtained thermal and phase evolution data were used to construct continuous cooling transformation diagrams, which were used to derive the temperature-dependent parameters in the Leblond-Devaux equation. The equation was then used to predict phase evolution during the welding of E36 and E36Nb; the quantitative experimental phase fractions of the coarse grain zone were compared with simulated results to verify the prediction results, which are in good agreement. When heat input is 100 kJ/cm, phases in the HAZ of E36Nb are primarily granular bainite, whereas for E36, the phases are mainly bainite with acicular ferrite. When heat input increases to 250 kJ/cm, ferrite and pearlite form in both steels. The predictions agree with experimental observations.

Physical Simulation and Numerical Simulation of Flash Butt Welding for Innovative Dual Phase Steel DP590: A Comparative Study.

In this study, the microstructure and performance of newly designed dual-phase steel (DP590) after joining by flash butt welding (FBW) for vehicle wheel rims was analysed and compared by two simulations, i.e., physical simulation and numerical simulation, due to the high acceptance of these two methodologies. Physical simulation is regarded as a thermal-mechanical solution conducted by the Gleeble 3500 simulator and which can distribute the heat-affected zone (HAZ) of the obtained weld joint into four typical HAZs. These are coarse-grained HAZ, fine-grained HAZ, inter-critical HAZ and sub-critical HAZ. A combination of ferrite and tempered martensite leads to the softening behaviour at the sub-critical HAZ of DP590, which is verified to be the weakest area, and influences the final performance due to ~9% reduction of hardness and tensile strength. The numerical simulation, relying on finite element method (FEM) analysis, can distinguish the temperature distribution, which helps us to understand the relationship between the temperature distribution and real microstructure/performance. Based on this study, the combination of physical and numerical simulations can be used to optimise the flash butt welding parameters (flash and butt processes) from the points of temperature distribution (varied areas), microstructure and performance, which are guidelines for the investigation of flash butt welding for innovative materials.

Experimental Comparison of Laser Cladding and Powder Plasma Transferred Arc Welding Methods for Depositing Wear-Resistant NiSiB + 60% WC Composite on a Structural-Steel Substrate.

A Ni-based powder composed of NiSiB + 60% WC was deposited onto a structural-steel substrate using two methods: laser cladding (LC) and plasma powder transferred arc welding (PPTAW). The resulting surface layers were analyzed and compared. Both methods resulted in the precipitation of secondary WC phases in the solidified matrix, but the PPTAW clad exhibited a dendritic microstructure. The microhardness of the clads prepared by both methods was similar, but the PPTAW clad showed higher resistance to abrasive wear compared to the LC clad. The thickness of the transition zone (TZ) was thin for both methods, with a coarse-grain heat-affected zone (CGHAZ) and peninsula-like macrosegregations observed in clads from both methods. The PPTAW clad showed a unique cellular-dendritic growth solidification (CDGS) and a type-II boundary at the TZ attributed to its thermal cycles. While both methods resulted in metallurgical bonding of the clad to the substrate, the LC method exhibited a lower dilution coefficient. The LC method also resulted in a larger HAZ with higher hardness compared to the HAZ of the PPTAW clad. The findings of this study indicate that both methods are promising for antiwear applications due to their wear-resistant properties and metallurgical bonding to the substrate. The PPTAW clad may be particularly useful in applications that require higher resistance to abrasive wear, while the LC method may be advantageous in applications that require lower dilution and larger HAZ.

A Methodology for Predicting the Phase Fraction and Microhardness of Welded Joints Using Integrated Models.

Understanding the phase transformation and fraction affected by thermal changes is imperative for ensuring the safety of a welded joint. This study proposes a methodology for predicting the phase transformation and fraction of a welded joint using an integrated model. The integrated model includes a heat transfer model and procedures for predicting phase fraction and microhardness. The heat transfer model was developed to simulate the heat transfer in a welded joint and obtain the thermal cycles. The procedure consists of obtaining the peak temperature, austenite fraction, prior austenite grain size (PAGS), and t8/5 (the cooling time between 800 and 500 °C). A database was constructed based on the continuous cooling transformation (CCT) diagram using PAGS and t8/5 as the variables. The phase fraction was then predicted by considering the PAGS with t8/5 from the database. The predicted phase fraction and microhardness were in good agreement with those determined experimentally, demonstrating the reliability of the methodology. This methodology provides a more realistic understanding of phase transformation and facilitates the prediction of the phase fraction and microhardness under various welding conditions that have experimental limitations.

Effect of Mg Addition on Inclusions in the Welding Heat-Affected Zone of Pressure Vessel Steels.

With the development of the pressure vessel industry, high-energy wire welding has a great future. However, this means higher demands on the weldability of pressure vessel steels. Controlling inclusions via oxidative metallurgy is a reliable method of improving the weldability of pressure vessel steels. Hence, in this paper, experimental steels with different Mg element mass fractions were prepared using vacuum metallurgy. Simulated welding for high-heat input welding was carried out using the Gleeble-2000 welding thermal simulation test machine. The inclusions in the welding heat-affected zone (HAZ) in the experimental steels were observed using an optical microscope (OM) and scanning electron microscope (SEM). The compositions of the inclusions were analyzed using an energy-dispersive spectrometer (EDS). The research results indicated that the addition of Mg could increase the number density of the inclusions in the welding HAZ. With the addition of Mg from 0 to 5 wt.%, the total number density of the inclusions increased from 133 to 687 pieces/mm2, and the number density of the inclusions with a size of 0-5 µm2 increased from 122 to 579 pieces/mm2. The inclusions in the experimental steel welding HAZ with Mg elements were mainly elliptical composite inclusions composed of (Mg-Zr-O) + MnS. Moreover, MnS precipitated on the surface of the Mg-containing inclusions in the welding HAZ. Intragranular acicular ferrite (IAF) nucleation was primarily induced via the minimum lattice mismatch mechanism, supplemented with stress-strain energy and inert interface energy mechanisms.