HW-6 Chap 9 dan 10

9.1 (a) Construct pseudo-binary phase diagrams for 55% and 74% Fe. Mark on the diagrams the approximate
compositions of 310 (essentially Fe–25 Cr–20 Ni) and 304 (essentially Fe–18Cr–8Ni) stainless steels. (b) From the
diagrams and the approximate compositions, indicate the primary solidification phases.

9.2 A 308 stainless-steel filler (essentially Fe–20Cr–10Ni) is used to weld 310 stainless steel. What is the primary
solidification phase if the dilution ratio is about 60%?

9.3 A 304 stainless-steel sheet with a composition given below is welded autogenously with the GTAW process.
The shielding gas is Ar-2% N2, and the nitrogen content of the weld metal is about 0.13%. The contents of other
alloying elements are essentially the same as those in the base metal.
(a) Calculate the ferrite numbers for the base metal and the weld metal.
(b) The weld metal exhibits the primary solidification phase of austenite, and the ferrite content measurements
indicate essentially zero ferrite number. Is the calculated ferrite number for the weld metal consistent with the
observed one? (Composition: 18.10Cr, 8.49Ni, 0.060C, 0.66Si, 1.76Mn, 0.36Mo, 0.012S, 0.036P, and 0.066N.)

9.4 A significant amount of ferrite is lost in a 316 stainless steel weld after being subjected to three post-weld
thermal cycles with a 1250°C peak temperature, which is just below the g + d two-phase region of about 1280 to
1425°C. Sketch a curve of ferrite number vs. temperature from 900 to 1400°C and explain it.

9.5 Kou and Le (9) quenched 309 stainless steel during autogenous GTAW. The weld metal side of the quenched
pool boundary showed dendrites of d-ferrite but the weld pool side showed dendrites of primary austenite.
Explain why.

9.6 It has been observed in welding austenitic stainless steel with a teardrop-shaped weld pool that the weld metal
solidifies with primary ferrite except near the centerline, where it solidifies as primary austenite. Sketch a curve of
the growth rate R versus the distance y away from the weld centerline. How does your result explain the ferrite
content change near the centerline?

10.1 With the help of Schaeffler’s diagram, show that martensite can form in the fusion zone at 70 mm from the
fusion boundary of the weld shown in Figure 10.11. PROBLEMS 261

10.2 Butt welding of 5052 aluminum (Al–2.5Mg) with a single-V joint is carried out with 5556 filler (Al–5.1Mg).
The dilution ratio of the first pass is 80%. In the second pass 40% of the material comes from the filler wire, 40%
from the base metal, and 20% from the first pass. Calculate the compositions of the two passes, assuming uniform
mixing in both.

10.3 Suppose that in the previous problem the workpiece composition is Fe–25Cr–20Ni and the filler composition is
Fe–20Cr–10Ni. What is the difference in the ferrite content between the two passes based on Schaeffler’s diagram

10.4. Consider the pseudo-binary-phase diagram shown in Figure 10.3a. Sketch the Ni and Cr concentration profiles
across a dendrite arm for an alloy that has a composition just to the left of point b.

10.5. Consider welding Ni to Ti. Can macro-segregation occur in LBW? Why or why not? Is the chance of macro-
segregation higher or lower in GTAW than in LBW?

10.6. Explain why gas porosity can be severe in the GTAW of powder metallurgy alloy Al–10Fe–5Ce (Figure
10.16a). Explain why gas porosity can be significantly less with DCEN than with AC.

10.7. Consider banding in the YAG laser weld of 304 stainless steel (Figure 10.6). What could have caused banding
in this weld? Is the growth rate higher during dendritic or planar-like solidification and why?
Answer :
9.1
(a) SS310 (Fe-25Cr-20Ni) SS304(Fe–18Cr–8Ni)

(b) For SS310, solidification occurs as primary austenite. The microstructure consists of austenite dendrites (light
etching; mixed-acids etchant) and interdendritic d-ferrite (dark etching; mixed-acids etchant) between the primary
and secondary dendrite arms. For SS304, solidification occurs as primary ferrite. The microstructure consist of
austenite and d-ferrite.

9.2 Weld metal composition:

(25 x 0.6) + (20 x 0.4) = 23% Cr
(20 x 0.6) + (10 x 0.4) = 16% Ni
From pseudo-binary phase diagrams, the composition of weld metal is in Ni-rich isothermal liquidus. So, the
primary solidification phase is austenite.

9.3
(a) Base metal
Cr eq = 18.10 + 0.36 + (1.5 x 0.66) + (0.5 x 0) = 19.45
Ni eq = 8.49 + (30 x 0.060) + (30 x 0.066) + (0.5 x 1.76) = 13.15
Weld metal:
Cr eq = 19.45
Ni eq = 13.15 + 30 x (0.130 – 0.066) = 15.07
From the diagram above, estimated ferrite number is 0 (zero)

(b) In weld metal Ferrite number that calculated consistent with measurement, is zero (0)

9.4 Below 1250deg C in austenite phase Area, when temperature increase, ferrite dissolve and the number of
ferrite reduce significantly. From 1250 to 1400deg C in austenite + ferrite Area, when temperature increase,
ferrite number increase.

9.5 Higher cooling rate in quenching cause undercooling and solidification in weld pool to primary austenite as
replacement of primary ferrite

9.6 R = V cos alpha

According to the above equation, the growth rate R increases from 0 on the fusion line to the welding speed V at the
center line of the weld. Form of weld pool is teardrop-shaped, the part that remains at the pool boundary is a straight
line (constant alpha) except near the fusion line and the center line. In higher welding speed (v) form of weld pool
teardrop-shaped rather elongation, so angle alpha can decrease suddenly and growth speed R can increase in center
line. Higher growth speed in center line can affect undercooling then solidification of primary austenite occur. When
this happen, Ferrite in weld metal can decrease suddenly in center line of welding.
10.1

At about 70 micrometers from the fusion boundary, the composition averages 6% Cr, 6% Ni, 2% Mn and 86% Fe
Cr eq = 6
Ni eq = 6 + (0.5 x 2) = 7
From Schaffler diagram, we can see that the structure is martensite

10.2
Pass – 1= Dillution ratio = 80%, so the composition of Mg is :
(2.5 x 0.8) + (5.1 x 0.2) = 3.02Mg
Pass – 2
(5.1 x 0.4) + (2.5 x 0.4) + (3.02 x 0.2) = 3.64%Mg
The difference between two passes = 3.64 – 3.02 = 0.62%Mg
10.3
Pass – 1
Cr = (25 x 0.8) + (20 x 0.2) = 24%
Ni = (20 x 0.8) + (10 x 0.2) = 18%
Estimated ferrite number = 0%
Pass – 2
Cr = (20 x 0.4) + (25 x 0.4) + (24 x 0.2) = 22.8%
Ni = (20 x 0.8) + (20 x 0.4) + (18 x 0.2) = 15.6%
Estimated ferrite number = 4%
The difference in the ferrite content between the two passes based on Schaffler’s diagram is about 5%

10.4
The alloy solidifies as primary austenite, with reduced Ni content and increased Cr content from the center line of
the dendrite arm to the boundary between the dendrite arms.

10.5 In LBW welds with different content of Ni to Ti, the cooling rate is faster so that there is time for the Ni and Ti
to fully mix with each other. Macrosegregation can occur in this weld metal. In GTAW there is less chance of
macrosegregation because the cooling rate is lower and there is not enough time for Ni and Ti to mix completely in
the weld pool.

10.6 Oxidation reaction and Al powder hydration during and after powder production with atomization produce
moisture high content. When powder join to PM, the moisture is trapped inside. As a result, there is high porosity in
the PM, as shown below. With DCEN as a substitute for AC in GTAW welding, the electric arc is more limited to
the weld pool surface and the Lorents force is greater for deep penetration and good mixing of the weld pool. Thus,
gas bubbles have a better chance of escaping from the weld pool so that porosity is reduced
10.7

Banding in weld metal cause by up-down growth speed that affect by up-dow heat quantity in weld pool. In YAG
LBW do not occur Lorentz Force, and up-down heat is caused by Marangoni convection, that can oscillating quite
strongly. The oscillating Marangoni convection flow is demonstrated by both experiments and computer simulations
in fluid mechanics. Growth speed should be higher during dendritic solidification in banding rather than in planar
solidification. This is because higher growth speed can increase supercooling so it can change from planar
solidification to dendritic.