Mechanical Properties and Microstructural Characterization of Laser Welded S32520 Duplex Stainless Steel

This paper investigates an experimental design of laser butt welding of S32520 duplex stainless steel, which has been passed out with the help of a pulsed Nd: YAG laser supply. The intention of the present research is to learn the impact of beam diameter, welding speed, and laser power on the superiority of the butt weld. The individuality of butt joints has been characterized in terms of tensile properties, fractography, and hardness. It was noticed that unbalanced particle orientations indirectly produce a comparatively fragile quality in the laser welded joint. The outcome of varying process parameters and interaction effect of process parameters on ultimate tensile strength and micro hardness were studied through analysis of experimental data. With different process parameters, the heat energy delivered to the material was changed, which was reflected in tensile strength measurement for different welded samples. From this present research, it was shown that, up to a certain level, an increase in process parameters amplified the tensile strength, but after that, certain level tensile strength decreased with the increase in process parameters. When process parameters exceeded that certain level, the required amount of heat energy was not delivered to the material, resulting in low bead width and less penetration, thus producing less strength in the welded joint. Less strength leads to more ductile weld joints. Microhardness was higher in the weld zone than in the base region of welded samples. However, the heat affected zone had a high microhardness range.     

Enhancement of Weldability at Laser Beam Welding of 22MnB5 by an Entrained Ultrasonic Wave Superposition

In this paper, the potential of directional ultrasonic wave superposition by moving sound generators for laser beam welding of high-strength steel alloys 1.5528 (22MnB5) is studied. Steel sheets of identical thickness and in form of tailored blanks were joined in butt joint configuration. The influences of the various excitation parameters of the moving sound generators on the ultrasonic coupling and their influence on the distribution of the AlSi coating components within the melting zone and the weld seam characteristics are investigated. Etched cross-sections, scanning electron microscopy, energy dispersive X-ray spectroscopy, and electron backscattering measurements were used as the investigation methods to determine the AlSi distribution in the weld as well as its microstructure. The results presented a series of experiments which show that a suitable superposition of ultrasonic waves by the moving sound generators lead to a more homogeneous distribution of AlSi particles in the melt as well as to a finer microstructure within the weld, which improves the mechanical–technological properties.     

Influence of Welding Speeds on the Morphology,Mechanical Properties,and Microstructure of 2205 DSS Welded Joint by K-TIG Welding

In this paper, 8.0 mm thickness 2205 duplex stainless steel (DSS) workpieces were welded with a keyhole tungsten inert gas (K-TIG) welding system under different welding speeds. After welding, the morphologies of the welds under different welding speed conditions were compared and analyzed. The microstructure, two-phase ratio of austenite/ferrite, and grain boundary characteristics of the welded joints were studied, and the microhardness and tensile properties of the welded joints were tested. The results show that the welding speed has a significant effect on the weld morphology, the two-phase ratio, grain boundary misorientation angle (GBMA), and mechanical properties of the welded joint. When the welding speed increased from 280 mm/min to 340 mm/min, the austenite content and the two-phase ratio in the weld metal zone (WMZ) decreased. However, the ferrite content in the WMZ increased. The proportion of the Σ3 coincident site lattice grain boundary (CSLGB) decreased as the welding speed increased, which has no significant effect on the tensile strength of welded joints. The microhardness of the WMZ and the tensile strength of the welded joint gradually increased when the welding speed was 280–340 mm/min. The 2205 DSS K-TIG welded joints have good plasticity.     

Microstructural Characterization and Mechanical Properties of Laser Beam-Welded Dissimilar Joints between A6000 Aluminum Alloy and Galvanized Steel

This paper presents the laser beam welding process of a lap joint between galvanized steel (Z225) and an aluminum alloy (A6000) from an IPG fiber laser. Welding of steel to aluminum has become popular in the automotive industry as a means of reducing the total vehicle body mass. This approach reduces fuel consumption and, ultimately, carbon emissions. Laser welding parameters used to control heat input for the study were laser power ranging between 800 and 1200 W, as well as laser welding speeds between 2 and 4 m/min. Distinct features of the dissimilar joints were microscopically examined. The SEM-EDS technique was employed to study the intermetallic phases along the Fe-Al interface. The outcome revealed the presence of “needle-like phases” and “island-shaped phases” at high heat inputs. Traces of both Fe₂Al₅ and FeAl₃ phases were detected. For low heat input, there was evidence of insufficient fusion. Weld width was influenced by welding parameters and increased with an increase in heat input. Mechanical properties of the joints indicated that the microhardness values of the weld joints were higher than those of both base metals. The maximum tensile shear strength obtained was 1.79 kN for a sample produced at 1200 W and 3 m/min.     

Microstructure Evolution and Mechanical Properties of 20%SiCp/Al Joint Prepared via Laser Welding

SiC particles-reinforced Al matrix composites (SiC_p/AMCs) have been widely used in the aerospace structural components. In this work, 20 vol% SiC_p/2A14 joint was fabricated by laser welding technology. The effects of different laser power/welding velocity on the 20 vol% SiC_p/2A14 joint forming, microstructure evolution and mechanical properties were studied in detail. The results showed that, under the same heat input, the high power/high welding velocity was beneficial to reduce the porosity of SiC_p/2A14 joint and inhibited the formation of brittle phase of Al₄C₃. At 8 kW-133 mm/s welding parameters, the maximum tensile strength of the SiC_p/2A14 joint reached 199 MPa, which is ~64% higher than that of the SiC_p/2A14 joint prepared at 4 kW-66 mm/s welding parameters. By analyzing the fracture morphology and SEM image of SiCp/2A14 joint section, it is was found that the porosity of weld and Al₄C₃ brittle phase were the important factors limiting the strength of SiCp/2A14 joint. This work provides a reference for the process window design of laser welding SiC_p/2A14 composites.     

Microstructure and Tensile Property of Laser Cladding Assisted with Multidimensional High-Frequency Vibration

Laser cladding is a promising surface modification technology to fabricate high-performance parts. However, defects such as porosity, cracks and residual tensile stress are easily produced in laser cladding, leading to significant property reduction and poor reliability. In this study, laser cladding with multidimensional high-frequency vibration was investigated. The effects of multidimensional high-frequency vibration on the improvement of microstructure and mechanical properties were analyzed and discussed based on the vibration-assisted laser cladding experiments. In addition, a numerical model was conducted to help understand the significance of the vibration on flow field and temperature field. Results show that 3D vibration led to the primary dendrite spacing reduction from 11.1 to 6.8 μm, microhardness increase from 199 to 221 HV_0.2, and a nearly 110% improvement in the elongations. The findings of this study confirmed the significant benefits of multidimensional high-frequency vibration applied in laser cladding and provided a basis to uncover the underlying mechanisms of multidimensional vibration on the rapid melting and solidification.     

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy

Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.     

Microstructure and Tensile Behavior of Laser Arc Hybrid Welded Dissimilar Al and Ti Alloys

Fiber laser-cold metal transfer arc hybrid welding was developed to welding-braze dissimilar Al and Ti alloys in butt configuration. Microstructure, interface properties, tensile behavior, and their relationships were investigated in detail. The results show the cross-weld tensile strength of the joints is up to 213 MPa, 95.5% of same Al weld. The optimal range of heat input for accepted joints was obtained as 83–98 J·mm⁻¹. Within this range, the joint is stronger than 200 MPa and fractures in weld metal, or else, it becomes weaker and fractures at the intermetallic compounds (IMCs) layer. The IMCs layer of an accepted joint is usually thin and continuous, which is about 1μm-thick and only consists of TiAl₂ due to fast solidification rate. However, the IMCs layer at the top corner of fusion zone/Ti substrate is easily thickened with increasing heat input. This thickened IMCs layer consists of a wide TiAl₃ layer close to FZ and a thin TiAl₂ layer close to Ti substrate. Furthermore, both bead shape formation and interface growth were discussed by laser-arc interaction and melt flow. Tensile behavior was summarized by interface properties.     

Effects of Laser Forming on the Mechanical Properties and Microstructure of DP980 Steel

Due to its high strength and good plasticity, dual-phase (DP) steel is widely used for manufacturing the structural and reinforcement components of automobiles. Therefore, it is urgent to investigate the mechanical properties and microstructure variation in DP steel after deformation, especially those subjected to hot-forming processes. In this study, the mechanical properties and microstructure of laser-formed DP980 steel plates under different laser parameters were investigated by means of monotonic tensile tests, microhardness tests, and metallographic tests. The results showed that both yield strength and tensile strength increased with increasing laser line energy in the range of 5~19 J/mm due to the increasing volume content of martensite laths. Elongation was slightly improved after the laser-forming process due to the existence of residual austenite. The average microhardness of the heat-affected zone also increased with an increase in laser line energy and reached a maximum of 412.8 HV_0.2—an improvement of 23.5% compared to that of the parent material.     

Study on Microstructural Characterization,Mechanical Properties and Residual Stress of GTAW Dissimilar Joints of P91 and P22 Steels

This article deals with the dissimilar joining of two different grade Cr-Mo steel (2.25Cr-1Mo: P22 and modified 9Cr-1Mo: P91) for power plant application. The dissimilar butt-welded joint was produced for conventional V groove design by using the gas tungsten arc welding (GTAW) process with the application of an ERNiCrMo-3 Ni-based super alloy filler. A microstructure characterization was performed to measure the inhomogeneity in the microstructure and element diffusion across the interface in a welded joint. The experiments were also performed to evaluate the mechanical properties of the dissimilar welded joint in as-welded (AW) and post-weld heat treatment (PWHT) conditions. An acceptable level of the mechanical properties was obtained for the AW joint. After PWHT, a significant level of the element diffusion across the interface of the weld metal and P22 steel was observed, resulting in heterogeneity in microstructure near the interface, which was also supported by the hardness variation. Inhomogeneity in mechanical properties (impact strength and hardness) was measured across the weldments for the AW joint and was reduced after the PWHT. The tensile test results indicate an acceptable level of tensile properties for the welded joint in both AW and PWHT conditions and failure was noticed in the weak region of the P22 steel instead of the weld metal.     

Effect of Oxygen Content on Microstructure and Tensile Properties of a 22Cr-5Al ODS Steel

The high tensile strength and irradiation resistance of oxide dispersion strengthened (ODS) ferritic steels is attributed to the ultrafine and dispersed oxides within the matrix. The high content of oxygen and yttrium is critical for the formation of dense Y-rich oxides. However, only few studies have reported the effect of oxygen content on the microstructure and mechanical properties of ODS steels. Herein, we employed gas atomization reactive synthesis to prepare pre-alloy powders and then hot isostatic pressing (HIP) to consolidate two 22Cr-5Al ODS steels with different oxygen content. Our results showed Y-rich precipitates at and near grain boundaries of the as-HIPed alloys. Moreover, with the oxygen content increasing from 0.04 to 0.16 wt%, more precipitates precipitated in the as-HIPed alloy, and the ultimate tensile strength of the alloy was improved. However, increasing the oxygen content to 0.16 wt% led to formation of stripe and chain precipitates at and near grain boundaries, which caused a partial intergranular fracture of the as-HIPed alloy.     

Dissimilar Laser Welding of Austenitic Stainless Steel and Abrasion-Resistant Steel: Microstructural Evolution and Mechanical Properties Enhanced by Post-Weld Heat Treatment

In this study, ultra-high-strength steels, namely, cold-hardened austenitic stainless steel AISI 301 and martensitic abrasion-resistant steel AR600, as base metals (BMs) were butt-welded using a disk laser to evaluate the microstructure, mechanical properties, and effect of post-weld heat treatment (PWHT) at 250 °C of the dissimilar joints. The welding processes were conducted at different energy inputs (EIs; 50–320 J/mm). The microstructural evolution of the fusion zones (FZ) in the welded joints was examined using electron backscattering diffraction (EBSD) and laser scanning confocal microscopy. The hardness profiles across the weldments and tensile properties of the as-welded joints and the corresponding PWHT joints were measured using a microhardness tester and universal material testing equipment. The EBSD results showed that the microstructures of the welded joints were relatively similar since the microstructure of the FZ was composed of a lath martensite matrix with a small fraction of austenite. The welded structure exhibited significantly higher microhardness at the lower EIs of 50 and 100 J/mm (640 HV). However, tempered martensite was promoted at the high EI of 320 J/mm, significantly reducing the hardness of the FZ to 520 HV. The mechanical tensile properties were considerably affected by the EI of the as-welded joints. Moreover, the PWHT enhanced the tensile properties by increasing the deformation capacity due to promoting the tempered martensite in the FZ.     

Effect of Initial Temperature on the Microstructure and Properties of Stellite-6/Inconel 718 Functional Gradient Materials Formed by Laser Metal Deposition

Stelite-6/Inconel 718 functionally gradient materials (FGM) is a heat-resisting functional gradient material with excellent strength performance under ultra-high temperatures (650–1100 °C) and, thus, has potential application in aeronautic and aerospace engineering such as engine turbine blade. To investigate the effect of initial temperature on the microstructure and properties of laser metal deposition (LMD) functional gradient material (FGM), this paper uses the LMD technique to form Stelite-6/Inconel 718 FGM at two different initial temperatures: room temperature and preheating (300 °C). Analysis of the internal residual stress distribution, elemental distribution, microstructure, tensile properties, and microhardness of 100% Stelite-6 to 100% Inconel 718 FGM formed at different initial temperatures in a 10% gradient. The experimental results prove that the high initial temperature effectively improves the uneven distribution of internal residual stresses. Preheating slows down the solidification time of the melt pool and facilitates the escape of gases and the homogeneous diffusion of elements in the melt pool. In addition, preheating reduces the bonding area between the gradient layers, enhancing the metallurgical bonding properties between the layers and improving the tensile properties. Compared with Stellite-6/Inconel 718 FGM formed at room temperature, the mean yield strength, mean tensile strength, and mean elongation of Stellite-6/Inconel 718 FGM formed at 300 °C are increased by 65.1 Mpa, 97 MPa, and 5.2%. However, the high initial temperature will affect the hardness of the material. The average hardness of Stellite-6/Inconel 718 FGM formed at 300 °C is 26.9 HV (Vickers hardness) lower than that of Stellite-6/Inconel 718 FGM formed at 20 °C.     

Microstructure and Mechanical Properties Analysis of Al/Cu Dissimilar Alloys Joining by Using Conventional and Bobbin Tool Friction Stir Welding

The feasibility of producing welding joints between 6061-T6 aluminum and pure copper sheets of 6 mm thickness by conventional friction stir welding (CFSW) and bobbin tool friction stir welding (BTFSW) by using a slot-groove configuration at the joining surface was investigated. The microstructure of the welded samples was examined by using an optical microscope and X-ray diffraction. Furthermore, the mechanical properties of the weld samples are compared based on the results of the tensile test, hardness measurement, and fractography test. The slot-groove configuration resulted in the presence of a bulk-sized Al block on the Cu side. The microscopic observations revealed the dispersion of fine Cu particles in the stir zone. The presence of intermetallic compounds (IMCs) CuAl₂, which are hard and brittle, lowered the strength of the weld joints. The strength of the weld joints produced with BTFSW was superior to that of the C-FSW. The maximum hardness values of 214 HV and 211 HV are reported at the stir zone for BTFSW and CFSW, respectively. The fracture location of all the joints was at the intersection of the stir zone and the thermomechanically affected zone was on the Cu side.     

High-Power Fiber Laser Welding of High-Strength AA7075-T6 Aluminum Alloy Welds for Mechanical Properties Research

The results disclosed that both the microstructure and mechanical properties of AA7075-T6 laser welds are considerably influenced by the heat input. In comparison with high heat input (arc welding), a smaller weld fusion zone with a finer dendrite arm spacing, limited loss of alloying elements, less intergranular segregation, and reduced residual tensile stress was obtained using low heat input. This resulted in a lower tendency of porosity and hot cracking, which improved the welded metal’s soundness. Subsequently, higher hardness as well as higher tensile strength for the welded joint was obtained with lower heat input. A welded joint with better mechanical properties and less mechanical discrepancy is important for better productivity. The implemented high-power fiber laser has enabled the production of a low heat input welded joint using a high welding speed, which is of considerable importance for minimizing not only the fusion zone size but also the deterioration of its properties. In other words, high-power fiber laser welding is a viable solution for recovering the mechanical properties of the high-strength AA 7075-T6 welds. These results are encouraging to build upon for further improvement of the mechanical properties to be comparable with the base metal.     

Microstructure and Selected Properties of Iron–Vanadium Coatings Obtained by the Laser Processing of a VC Pre-Coat Applied on Steel—Single and Multiple Laser Tracks Study

This paper presents the results of the microstructure, mechanical and physicochemical properties of coatings produced by the remelting of a VC pre-coat applied in the form of a paste on 145Cr6 steel. The remelting process was carried out using a diode laser beam. A laser device with a rated power of 3 kW was used. During these tests, a constant laser beam scanning speed of 3 m/min was used. The variable parameter was the laser beam power. Values of 500 W, 900 W and 1100 W were used. In the first stage of this study, single laser tracks were formed, and basic tests, such as on microstructure, microhardness and chemical composition, were performed. In the second stage of this study, multiple laser tracks were prepared using previously selected parameters. On such specimens, it was possible to test the same traits as for single tracks and, additionally, to perform corrosion and wear resistance tests. It was found that the obtained coatings have different properties than the base material. No primary vanadium carbides were found in the melted zone, but the proposed production method contributed to an increase in microhardness and wear resistance.     

Influence of Assembly Gap Size on the Structure and Properties of SUS301L Stainless Steel Laser Welded Lap Joint

The microstructure and properties of laser welding lap joints with different assembly gap sizes are experimentally investigated. The laser weld joint is composed of γ-austenite and δ-ferrite, and the strip ferrite phase is mainly distributed at the austenite grain boundary. The weld metal presents the austenitic-ferritic (AF) solidification mode. When there is a gap between the two plates, a triangular region composed of similar equiaxed crystals can be found, and the size of the cellular crystals in this region decreases significantly. When the assembly gap size increases from 0.1 mm to 0.4 mm, the weld penetration state of the joint changes from full penetration to semi-penetration, and the surface collapse increases. The excessive size of the gap leads to a decrease in the tensile-shear force and fatigue strength of laser welded joints. In order to ensure that the surface morphology and properties of the welded joint meet the quality standard and requirement, the assembly gap should be less than 0.1mm.     

Interlaminar Microstructure and Mechanical Properties of Narrow Gap Laser Welding of 40-mm-Thick Ti-6Al-4V Alloy

Narrow gap laser welding (NGLW) is a common solution for the welding of thick structures. NGLW was carried out on narrow-gap butt joints of 40 mm-thick Ti-6Al-4V alloy plates with a U-shaped groove. The distribution characteristics of the interlaminar microstructure in different height ranges of the joint were investigated, and the evolution behavior and formation mechanism of the interlaminar microstructure of the joint were also revealed. This showed that a large amount of short needle martensite nucleated and grew up near the fusion line and the upper boundary of the remelting zone. The “softening” phenomenon occurred in all welds except the cover layer weld. The microstructure evolution and defect migration, induced by multiple welding thermal cycles in the upper weld forming process, were the main reasons for the “softening” of the lower weld. The tensile strength of each sample changed in the range of 920~990 MPa; the fracture mode of the sample belongs to a transgranular ductile fracture. In addition, compared with the upper part of the joint, the plasticity and toughness of the weld area in the lower part of the joint was improved.     

A Review: Laser Welding of Dissimilar Materials (Al/Fe,Al/Ti,Al/Cu)—Methods and Techniques,Microstructure and Properties

Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.     

Investigation on Microstructure and Properties of Duplex Stainless Steel Welds by Underwater Laser Welding with Different Shielding Gas

Taking {"type":"entrez-protein","attrs":{"text":"S32101","term_id":"422005","term_text":"pir||S32101"}}S32101 duplex stainless steel as the research object, underwater laser wire filling welding technology was used for U-groove filling welding. The influence of different shielding gas compositions on the ferrite content, microstructure, mechanical properties and pitting corrosion resistance was studied by simulating a water depth of 15 m in the hyperbaric chamber. The results show that, under the same process parameters, the size and proportion of austenite in the weld when using pure nitrogen as the shielding gas are larger than those protected by other shielding gases. In a mixed shielding gas, the increase in nitrogen content has little effect on the strength and toughness of the weld. Regardless of the shielding gas used, the base metal was the weakest part of the weld. At the same time, intermetallic inclusions have an adverse effect on the impact toughness of the weld. The pitting corrosion resistance of the welds depends on the Cr₂N content in the heat-affected zone. The precipitation and enrichment of Cr₂N causes local chromium deficiency, which is the main factor for the weak pitting corrosion ability of the heat-affected zone. Pure nitrogen protection has a better corrosion resistance than other gas protection.