1 s2.0 S2214785320358120 Main PDF
1 s2.0 S2214785320358120 Main PDF
1 s2.0 S2214785320358120 Main PDF
a r t i c l e i n f o a b s t r a c t
Article history: Dissimilar weldments of Monel 400 and UNS S32750 are widely used in pressure vessels and marine
Received 13 July 2020 industries where the weldments are exposed hot corrosion and can withstand this effect as they offer
Accepted 30 July 2020 excellent corrosion resistance and improve the service life. This research paper aims at investigation
Available online 12 September 2020
on the weldability and welding strength of dissimilar welded joints of UNS S32750 and Monel 400 devel-
oped by pulsed current gas tungsten arc welding technique. ERNiCrMo-4, ERNiCrMo-3 and ER309L fillers
Keywords: were used to join the base metals. Mechanical properties were demonstrated by using tensile test, impact
Super-Duplex Stainless Steel
toughness test and microhardness. The ultimate strength of ERNiCrMo-4 weldment was increased by
Monel 400
PCGTAW
16.2% and 20.2% when compared to ERNiCrMo-3 and ER309L weldments, respectively. The fracture has
Tensile properties occurred under direct tension test in all the cases at the base metal of Monel 400. The superior impact
Impact toughness toughness value (169 J) was observed in ERNiCrMo-4 filler weldment than the ERNiCrMo-3 (144 J) and
Microhardness ER309L (76 J) filler weldments. The average hardness number of ERNiCrMo-4 filler weldment (318
HV0.1) was higher than those of ERNiCrMo-3 (306 HV0.1) and ER309L (286 HV0.1) filler weldments.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Manufacturing Material Science and Engineering.
1. Introduction zone. The filler metal and the selection of welding technique play
an important role in joining the dissimilar metals to produce sound
Super-Duplex Stainless Steels (SDSS) being versatile that shows weldments [4]. In selection of filler metal for joining dissimilar
a wide range of applications in chemical processing industries, plates, the main requirements are phase structures should be same
pulp and paper machineries, petrochemical, oil and gas industries. as the base metal and should have good fatigue and corrosion
Possessing the equal percentages of both ferrite and austenite resistance [5]. The alloying elements of filler effect formation of
phase structures, SDSS exhibits a reliable corrosion resistance that new phases near the fusion zone, elemental micro-segregation,
been formulated in various corrosive environments [1]. As a result microstructures and hence the quality of weld structures [6].
of processing, SDSS lay out a dual-phase microstructure which is Devendranath et al. [7] developed dissimilar metal joint of SDSS
formulated compositionally resulting in the presence of equal UNS S32750 and AISI316L by using two different fillers namely,
amount of ferrite content and austenite content. These are most ERNiCrMo-3 and ER2553. The results revealed that the equal
often chosen when corrosion resistance is required and substituted amount of both ferrite and austenite phase structures are observed
for austenitic steel alloys in industry applications where pitting with improved hardness value at fusion zone when ER2553 filler is
and stress corrosion cracking are the concerns [2]. Monel 400, employed. Also, suggested that ER2553 filler is most suitable for
Ni-based alloy, has applications in the boiler heat pumps, petro- these dissimilar weldments for improving tensile properties.
chemical and marine industries. The alloy exhibit its toughness Ramkumar et al. [8] studied the effect of fillers on dissimilar metal
and hot corrosion resistance at high temperature [3]. During dis- joints of AISI 430 and AISI 904L stainless steels and concluded that
similar welding, some of the problems encountered are related to the improved mechanical properties have been observed when Ni-
the weld quality, especially the solidification cracks near the weld based filler is employed. Devendranath et al. [9] investigated on
similar weldments of SDSS UNS S32750 by using two different fil-
ler wires namely, ERNiCrMo-4 and ER2553. The results indicated
⇑ Corresponding author.
that the high impact toughness and tensile strength properties
E-mail address: balram3072@gmail.com (B. Yelamasetti).
https://doi.org/10.1016/j.matpr.2020.07.686
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Manufacturing Material Science and Engineering.
B. Yelamasetti et al. / Materials Today: Proceedings 46 (2021) 272–278 273
were observed when ERNiCrMo-4 filler is employed. Rahmani et al. and hence with in a frequency range of 0.5–5 Hz has to be selected
[10] evaluated the weld quality, mechanical properties and metal- with 40–60% duty ratio. The low pulse frequency PCGTAW process
lurgical aspects of two dissimilar metals UNS S30403 and UNS has shown that the welding arc can become stable during the peak
S32750 with Gas Tungsten Arc Welding (GTAW) technique using and background intervals [18]. Tseng et al. [19] investigated on
two different fillers ER 2594 and ER309L. The studies concluded effects of frequency and spacing on angular distortions of stainless
that impact strength and hardness value of duplex filler welded steel welded joints. By maintaining lower pulse spacing during
joints are better than those of austenitic filler welded joints. Zhou PCGTAW technique has enhanced the heat energy density of the
et al. [11] employed the GTAW technique to develop the dissimilar heat source and hence reduced the distortions in steel joints. Bal-
weldments of UNS S32750 and UNS S31254 by using two Ni-based ram et al. [20] developed the similar joint of stainless steels by
filler wires. Multi-pass welding is used to join these dissimilar using PCGTAW technique at low pulse frequency (4 Hz) and
12 mm thick plates. The results indicated that the Ni-based filler reports indicated that the residual stresses developed near the
ERNiCrMo-13 filler is recommended for improving the corrosion fusion zone are greatly reduced in PCGTAW weldments as com-
resistance and mechanical properties. pared to that of GTAW weldments. Karunakaran et al. [21] reported
Fusion welding technique has been widely used for the fabrica- the effect of main current on size of weld beads and thermal cycles
tion of offshore industries, nuclear industries, pressure vessels and of Aluminum weldments, in PCGTAW grain refinement is observed
petrochemical equipment [12]. As the constant heat input is given in welded joints with enhanced mechanical properties. The
during the GTAW technique, high amount of heat is released which mechanical and metallurgical properties are improved in PCGTAW
results in formation of coarse grain structure and segregation of fil- in comparison of CCGTAW during joining of duplex steels and Aus-
ler alloying elements near the weld zone [13,14]. The problems tenitic steel weldments. Results revealed that equal amount of
found in the GTAW technique can be minimized by altering the austenite phases and ferrite phases present near the weld zone
arc characteristics from high to low levels. The pulsed current while employing PCGTAW resulted in improved mechanical prop-
GTAW (PCGTAW) technique is widely used in fusion welding pro- erties. From the above literature review, looking at the advantages
cess that have been identified to have several advantages over the in replacement for 300 series stainless steel with Monel, not much
GTAW technique. The most often benefits of PCGTAW over GTAW work has been done on combination welds of Monel 400 with SDSS
are reduced heat input rates to the weldment that resulted in S32750.
decrease in porosity, micro-segregation, weld bead shape and size, The present research focuses on selection of suitable filler wire
distortion and residual stresses [15,16]. During main current (Im) for the joining of dissimilar metals of UNS S32750 and Monel 400
the base metals are heated and fusion will occur, while dropping using PCGTAW technique. Three filler wires namely, ERNiCrMo-4,
current from high level to low level, the weld zone is allowed to ERNiCrMo-3 and ER309L were selected to join the base metals.
cool the molten pool. The overlapping of weld spot during The welding condition and process parameters of PCGTAW tech-
multi-pass welding process and bead geometry mainly depends nique were used same for three filler weldments. The weld quality
on frequency [17]. Higher pulse frequencies in PCGTAW technique and joining strength of dissimilar weldments of UNS S32750 and
practically do not result in thermal cycles between high and low Monel 400 were studied by conducting XRT and mechanical
levels and thus produce same thermal cycles of GTAW technique testing.
Table 1
Chemical composition of base metals UNS S32750 and Monel 400.
Table 2
Chemical composition of filler wires ERNiCrMo-4, ERNiCrMo-3 and ER309L.
Filler Fe Ni Si Cu Cr C Mn S P Mo Others
ERNiCrMo-3 5.0 49.5 0.5 0.5 21.5 0.1 0.5 0.005 0.022 9.0 Co-9.1, Nb-3.5, Ti-0.4, Al-0.4
ERNiCrMo-4 5.45 57.1 0.03 0.05 15.9 0.02 0.5 0.003 0.007 16.9 Ti-0.10, V-0.18, Co-0.36, W-3.4
ER309L 62.3 12.2 0.53 Nil 23.4 0.03 1.5 0.021 0.02 Nil Nil
Table 3
Mechanical properties of base metals SDSS S32750 and Monel 400.
Base metal Impact strength (J) Hardness (HV) Proof stress, MPa UTS, MPa % Reduction in area %age of elongation
UNS S32750 203 284 579 925 50.18 39
Monel 400 62 162 254 514 46.72 35
Table 4
Welding parameters used for each pass in PCGTAW technique.
Pass Welding arc Arc voltage, V Welding torch speed (mm/min) Heat input rates (kJ/mm)
current, A
Ip Ib
Root pass: Pass-1 170 80 14 ± 2 80 0.807
Filling pass: Pass-2 170 80 13 ± 2 92 0.685
Capping pass:Pass-3 170 80 13 ± 2 84 0.75
274 B. Yelamasetti et al. / Materials Today: Proceedings 46 (2021) 272–278
2. Materials and experimentation by weight % of base and fillers is shown in Tables 1 & 2. The
mechanical properties of base metals UNS S32750 and Monel
The base metals of size 160 150 5 mm, UNS S32750 and 400 are listed in Table 3. PCGTAW technique was employed to join
Monel 400, were sliced into equal size specimens of the base metals by using three filler wires namely, ERNiCrMo-4,
150 80 5 mm by using wire cut EDM technique. The chemical ERNiCrMo-3 and ER309L. The heat input rate of PCGTAW tech-
composition of base metals and filler wires was carried out by nique is calculated by using Eqs. (1) & (2) [14]. The process param-
using spectroscopic technique. The analyzed chemical composition eters of PCGTAW technique are set same for three filler wires and
values are shown in Table 4. The pulse frequency of 4 Hz and 40–
60% duty cycle were selected during PCGTAW process. Before
welding, tack welding process was made to maintain equal root
gap between base metals as well as to avoid misalignment
between base metals. Argon gas was used for shielding of weld
pool with a flow rate of 10 lpm. The pre and post flow time of
gas was maintained at 15 and 10 s, respectively. The fabricated dis-
similar joints of UNS S32750 and Monel 400 are shown in Fig. 1.
V Im
Q PCGTAW ¼ g ð1Þ
s
I b T b þ Ip T p
Im ¼ ð2Þ
Tb þ Tp
Fig. 1. Dissimilar weldments of UNS S32750 and Monel 400 joined by (a) where, Ib and Ip are the background and pulse current; T b and T p
ERNiCrMo-4, (b) ERNiCrMo-3 and (c) ER309L. are the time duration of background current and peak current.
Fig. 2. Weld join configuration (a) 3D Schematic representation of welded joints, (b) Microhardness specimen and (c) Tensile test specimen.
Fig. 3. XRT films of dissimilar weldments joined by (a) ERNiCrMo-4, (b) ERNiCrMo-3 and (c) ER309L.
B. Yelamasetti et al. / Materials Today: Proceedings 46 (2021) 272–278 275
After welding process, the welded joints were inspected by 3.1. Radiography test
employing X-Ray radiography test for examining defects such as
porosity, voids, inclusions, etc. CEREM-235 radiography machine The X-Ray radiography Test (XRT) films of dissimilar weldments
was used to inspect the defects as per the ASME SEC-VIII standards. are shown in Fig. 3. From the visual examination as well as XRT
After NDT analysis, the joints were sliced along transverse direc- film analysis, the welded joints were free from surface and sub-
tion into different welding specimens to evaluate the welding surface defects. From the NDT analysis and visual inspection it is
strength, toughness and microhardness. The weld join configura- clearly observed that the narrow and uniform beads with complete
tion and standard dimensions of testing specimens are shown in fusion was attained by employing of PCGTAW technique (multi-
Fig. 2. The tensile properties of base metals and welded joints were pass welding) in three filler weldments.
evaluated by conducting a tension test according to ASTM stan-
dards. The impact strength of welded joints are evaluated by con- 3.2. Mechanical properties
ducting impact test on Izod impact testing. Further, hardness
values were measured with Vickers hardness tester by setting of 3.2.1. Tensile properties
100 gf load. The tensile stress–strain plot of base plates and weldments of
UNS S32750 and Monel 400 obtained are shown in Figs. 4 & 5.
The average tensile properties are computed by testing three ten-
1000 sile coupons from each welding joint and the values are tabulated
Std. Deviation ±2 in Table 5. Fracture of the tensile specimens in all the cases was
UNS S32750
observed at the parent metal Monel 400, which is an indication
800 Monel 400 of improvement in the resistance of the welded joint towards ten-
Tensile stress (MPa)
500 ERNiCrMo-3
ERNiCrMo-4
400 ER309L 3.2.3. Microhardness
The microhardness value of dissimilar weldments of UNS
300 S32750 and Monel 400 were measured by using Vickers hardness.
The hardness profiles of three filler dissimilar weldments are
200
shown in Figs. 8–10. The average microhardness value and heat
100
affected zone width of dissimilar weldments are computed and
shown in Table 7. From the microhardness profiles, it is identified
0 that the microhardness value of ERNiCrMo-4, ERNiCrMo-3 and
0.0 0.1 0.2 0.3 0.4
ER309L were 318 HV0.1, 306 HV0.1 and 286 HV0.1, respectively.
Tensile strain (mm/mm) The average hardness value of ERNiCrMo-4 filler weldment and
ERNICrMo-3 filler weldment was observed to be higher than the
Fig. 5. Tensile stress–strain plot of weldments of UNS S32750 and Monel 400.
base metals UNS S32750 (284HVÞand Monel 400 (160 HV). The
Table 5
Tensile properties dissimilar weldments of UNS S32750 and Monel 400.
Filler wire weldment Proof stress, MPa UTS, MPa % Reduction in area %age of elongation Fracture location
ERNiCrMo-4 378 624 50.18 31.68 Monel 400
ERNiCrMo-3 348 537 56.72 24.10 Monel 400
ER309L 323 519 56.03 23.43 Monel 400
276 B. Yelamasetti et al. / Materials Today: Proceedings 46 (2021) 272–278
Fig. 6. Fracture location under tension test of dissimilar welded joints developed by (a) ERNiCrMo-4, (b) ERNiCrMo-3 and (c) ER309L.
Table 6
drop in hardness value about HAZ of dissimilar UNS S32750 and
Impact toughness value of dissimilar weldments of UNS S32750 and Monel 400. Monel 400 was observed in both ERNiCrMo-4 and ERNiCrMo-3 fil-
ler weldments when compared to fusion zones of the same weld-
Filler weldments ERNiCrMo-4 ERNiCrMo-3 ER309L
ments. The fusion zone of ER309L weldment has shown a lower
Impact toughness 169 J 144 J 76 J hardness when compared to the base metal UNS S32750. The aver-
age microhardness value near the HAZ of Monel 400 has improved
Fig. 7. Impact test samples of dissimilar joints developed by (a) (a) ERNiCrMo-4, (b) ERNiCrMo-3 and (c) ER309L.
350 350
ERNiCrMo-4
Hardness Value (HV0.1)
300 300
250 250
200 200
150 150
UNS S 32750 HAZ Fusion zone HAZ Monel 400
100 100
-10 -8 -6 -4 -2 0 2 4 6 8 10
350 350
ER309L
Hardness Value (HV0.1)
250 250
200 200
UNS S 32750 HAZ Fusion zone HAZ Monel 400
150 150
100 100
-10 -8 -6 -4 -2 0 2 4 6 8 10
Distance from weld line (mm)
Fig. 10. Vickers microhardness profiles of dissimilar weldments developed by ER309L filler.
Table 7
Comparison of width and average Vickers hardness value of dissimilar weldments.
in ERNiCrMo-3 weldments due to the presence of high strength The tensile properties of ERNiCrMo-4 filler weldment were
alloying elements. From the Table 7 it is observed that the HAZ found to be superior to the other two filler weldments
width of the ERNiCrMo-4 weldment is reduced on either sides of (ERNiCrMo-3 and ER309L). The proof stress of ERNiCrMo-4 filler
the base metals compared to that of ERNiCrMo-3 and ER309L weldment was increased by 8.9% and 17.3% when compared to
weldments. ERNiCrMo-3 and ER309L filler weldments, respectively.
The average microhardness of ERNiCrMo-4 filler weldment was
higher than the other two filler weldments. The microhardness
4. Conclusion value of ERNiCrMo-4 weld zone was increased by 4% and 10%
when compared to ERNiCrMo-3 and ER309L filler weldments,
From the experimental research, the dissimilar weldments of respectively.
SDSS UNS S32750 and Monel 400 are developed successfully by The higher toughness value was observed when ERNiCrMo-4 fil-
using PCGTAW process employing ERNiCrMo-4, ERNiCrMo-3 and ler was employed when compared to ERNiCrMo-3 and ER309L
ER309L as fillers. The following conclusions are listed from the fillers.
results; The PCGTAW technique resulted in good weldability and
enhanced weld strength when ERNiCrMo-4 filler wire was
The X-ray radiography results has shown that all the filler weld- employed for joining dissimilar metals of UNS S32750 and
ments were free from micro/macro defects. Monel 400.
278 B. Yelamasetti et al. / Materials Today: Proceedings 46 (2021) 272–278
Declaration of Competing Interest joint, J. Mater. Eng. Perform. 23 (2014) 3745–3753, https://doi.org/10.1007/
s11665-014-1136-z.
[11] Z. Zhou, J. Löthman, Dissimilar welding of super-duplex and super-austenitic
The authors declare that they have no known competing finan- stainless steels, Weld. World 61 (2017) 21–33, https://doi.org/10.1007/
cial interests or personal relationships that could have appeared s40194-016-0408-7.
[12] R.N. Mhetre, S.G. Jadhav (2012) Finite element analysis of welded joints. 116–
to influence the work reported in this paper.
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