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Sirohi S, Kumar A, Pandey SM, Purohit P, Fydrych D, Kumar S, Pandey C. Dissimilar autogenous TIG joint of Alloy 617 and AISI 304H steel for AUSC application. Heliyon 2023; 9:e19945. [PMID: 37809790 PMCID: PMC10559579 DOI: 10.1016/j.heliyon.2023.e19945] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2023] [Revised: 08/30/2023] [Accepted: 09/06/2023] [Indexed: 10/10/2023] Open
Abstract
To reduce costs and improve high-temperature performance in Advanced Ultra Super Critical (AUSC) boilers, it is necessary to weld austenitic steel to Inconel alloy. In this study, the autogenous tungsten inert gas (TIG) welding process was used to join Alloy 617 and an austenitic AISI 304H steel plate of thickness 5 mm. Microstructural analysis showed that the microstructure formation was uneven along the weldments, with columnar and cellular dendrites near the interface while the central area of the weld exhibited a combination of columnar, cellular, and equiaxed dendrites. The use of energy dispersive spectroscopy and electron probe micro-analysis unveiled the presence of an unmixed layer at the interface between the weld and AISI 304H steel. Furthermore, a notable variation in the concentration of alloying elements such as Fe, Cr, Ni, Co, and Mo was observed. Within the weld metal, inter-dendritic areas showed the presence of precipitates rich in Cr, Ti, and Mo. Meanwhile, the heat-affected zone (HAZ) of Alloy 617 exhibited the presence of phases like Cr and Mo-rich M23C6 as well as Mo-rich M6C. Hardness tests showed non-uniform hardness along the weldments, with a hardness of 199 ± 6 HV in the weld metal and 225 ± 4 HV in Alloy 617 HAZ, and 207 ± 7 HV in AISI 304H HAZ. The Mo and Cr segregation in the inter-dendritic spaces led to a decline in the tensile properties of the welded parts and resulted in failure from the region of the weld metal.
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Affiliation(s)
- Sachin Sirohi
- Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar, 201204, Uttar Pradesh, India
| | - Amit Kumar
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur, Jodhpur, 342037, Rajasthan, India
| | - Shailesh M. Pandey
- Department of Mechanical Engineering, National Institute of Technology Patna, Patna, 500078, India
| | - Priyambada Purohit
- Faculty of Management Studies, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar, 201204, Uttar Pradesh, India
| | - Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
| | - Sanjeev Kumar
- Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar, 201204, Uttar Pradesh, India
| | - Chandan Pandey
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur, Jodhpur, 342037, Rajasthan, India
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Kumar A, Sirohi S, Pandey SM, Kumar P, Fydrych D, Pandey C. High-Temperature Tensile Behaviour of GTAW Joints of P92 Steel and Alloy 617 for Two Different Fillers. Materials (Basel) 2023; 16:5880. [PMID: 37687573 PMCID: PMC10488703 DOI: 10.3390/ma16175880] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/28/2023] [Revised: 08/18/2023] [Accepted: 08/24/2023] [Indexed: 09/10/2023]
Abstract
This study explores the high-temperature (HT) tensile rupture characteristics of a dissimilar gas-tungsten-arc-welded (GTAW) joint between P92 steel and Alloy 617, fabricated using ER62S-B9 and ERNiCrCoMo-1 fillers. The high-temperature tensile tests were performed at elevated temperatures of 550 °C and 650 °C. An optical microscope (OM) and a field emission scanning electron microscope (FESEM) were utilized to characterize the joint. The high-temperature test results indicated that the specimen failed at the P92 base metal/intercritical heat-affected zone (ICHAZ) rather than the weld metal for the ERNiCrCoMo-1(IN617) filler. This finding confirmed the suitability of the joint for use in the Indian advanced ultra-supercritical (A-USC) program. The fracture surface morphology and presence of precipitates were analysed using an SEM equipped with energy dispersive spectroscopy (EDS). The appearance of the dimples and voids confirmed that both welded fillers underwent ductile-dominant fracture. EDS analysis revealed the presence of Cr-rich M23C6 phases, which was confirmed on the fracture surface of the ER62S-B9 weld (P92-weld). The hardness plot was analysed both in the as-welded condition and after the fracture.
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Affiliation(s)
- Amit Kumar
- Mechanical Department, Indian Institute of Technology Jodhpur, N.H. 62 Nagaur Road, Karwar 342037, India; (A.K.); (C.P.)
| | - Sachin Sirohi
- Mechanical Department, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, India
| | - Shailesh Mani Pandey
- Department of Mechanical Engineering, National Institute of Technology, Patna 800005, India
| | - Pradeep Kumar
- Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India
| | - Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
| | - Chandan Pandey
- Mechanical Department, Indian Institute of Technology Jodhpur, N.H. 62 Nagaur Road, Karwar 342037, India; (A.K.); (C.P.)
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Kumar A, Pandey SM, Sirohi S, Fydrych D, Pandey C. P92 steel and inconel 617 alloy welds joint produced using ERNiCr-3 filler with GTAW process: Solidification mechanism, microstructure, mechanical properties and residual stresses. Heliyon 2023; 9:e18959. [PMID: 37636414 PMCID: PMC10447995 DOI: 10.1016/j.heliyon.2023.e18959] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/07/2023] [Revised: 07/12/2023] [Accepted: 08/03/2023] [Indexed: 08/29/2023] Open
Abstract
The objective of the current study was to analyse the microstructure, mechanical characteristics, and residual stresses of a dissimilar welded joint (DWJ) made of P92 steel and the Inconel alloy 617 (IN617) using the gas tungsten arc welding (GTAW) method. The ERNiCr-3 filler was selected to produce the conventional V groove (VG) and narrow V groove (NVG) butt joint. The filler deficient zones in the weldments, such as the filler deficient beach, i.e. unmixed zone (UZ), peninsula, and island, as well as the distinct heat-affected zone (HAZ), were visible near the interface of ERNiCr-3 filler weld and P92 steel due to the distinct differences in the chemical composition, microstructure, and mechanical properties between the filler and P92 base metal (BM). A very narrow partial melted zone (PMZ) and almost negligible UZ and HAZ were noticed at the interface of IN617 and ERNiCr-3 weld metal and it occurred mainly due to the similarity in microstructure and melting point. The austenitic microstructure of ERNiCr-3 filler weld was accompanied by precipitates enriched with Ti and Nb along with the inter-dendritic space. At room temperature, the mechanical properties of both the groove joints were evaluated, and the test results indicated that the welded joint satisfied the standard requirements for AUSC power plants' boiler applications. The tensile test results showed the failure from ERNiCr-3 filler weld with a tensile strength of 627 ± 2 MPa and 636 ± 3 MPa for VG and NVG welded joints, respectively. A poor weld metal impact toughness in comparison to the BMs was attributed to the presence of the brittle Ti(C, N) and Nb(C) particles in the interdendritic space. The impact toughness for the NVG weld joint was measured higher than for the VG weld joint. A significant hardness deviation was measured along the weldments that might be due to heterogeneous microstructure, i.e. UZ, HAZ, delta ferrite, and weld metal. To impart the ductility and temper the martensite in P92 HAZ, post-weld heat treatment (PWHT) was also performed, and a studied their effect on microstructure evolution across the weldments and mechanical properties. Groove design also showed a significant effect on residual stress variation. The work highlights the groove geometry, welding procedure, evolution of the microstructure along the weldments, mechanical characteristics, and residual stress variation of DWJ of P92 steel and IN617 alloy. In comparison to conventional VG joints, the NVG joints exhibited superior mechanical properties and lower residual stress values.
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Affiliation(s)
- Amit Kumar
- Department of Mechanical Engineering, IIT Jodhpur, Jodhpur, 342037, India
| | | | - Sachin Sirohi
- Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, Uttar Pradesh, India
| | - Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gdańsk 80-233, Poland
| | - Chandan Pandey
- Department of Mechanical Engineering, IIT Jodhpur, Jodhpur, 342037, India
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Fydrych D, Kubit A, Slota J, Kowalczyk A. Technologies for Joining and Forming Thin-Walled Structures in the Construction of Transportation Vehicles. Materials (Basel) 2023; 16:4594. [PMID: 37444908 DOI: 10.3390/ma16134594] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/14/2023] [Accepted: 06/16/2023] [Indexed: 07/15/2023]
Abstract
The pursuit of COx reduction has progressed the construction of transport systems produced using various types of materials to ensure weight reduction while maintaining sufficient functional and quality features [...].
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Affiliation(s)
- Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, 80-233 Gdańsk, Poland
| | - Andrzej Kubit
- Department of Manufacturing and Production Engineering, Rzeszow University of Technology, 35-959 Rzeszów, Poland
| | - Ján Slota
- Institute of Technology and Materials Engineering, Technical University of Košice, 040 01 Košice, Slovakia
| | - Agnieszka Kowalczyk
- Department of Chemical Organic Technology and Polymeric Materials, Faculty of Chemical Technology and Engineering, West Pomeranian University of Technology in Szczecin, 70-322 Szczecin, Poland
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Ahmed MMZ, El-Sayed Seleman MM, Fydrych D, Çam G. Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review. Materials (Basel) 2023; 16:ma16082971. [PMID: 37109809 PMCID: PMC10143485 DOI: 10.3390/ma16082971] [Citation(s) in RCA: 9] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/21/2023] [Revised: 03/30/2023] [Accepted: 04/05/2023] [Indexed: 05/27/2023]
Abstract
The use of the friction stir welding (FSW) process as a relatively new solid-state welding technology in the aerospace industry has pushed forward several developments in different related aspects of this strategic industry. In terms of the FSW process itself, due to the geometric limitations involved in the conventional FSW process, many variants have been required over time to suit the different types of geometries and structures, which has resulted in the development of numerous variants such as refill friction stir spot welding (RFSSW), stationary shoulder friction stir welding (SSFSW), and bobbin tool friction stir welding (BTFSW). In terms of FSW machines, significant development has occurred in the new design and adaptation of the existing machining equipment through the use of their structures or the new and specially designed FSW heads. In terms of the most used materials in the aerospace industry, there has been development of new high strength-to-weight ratios such as the 3rd generation aluminum-lithium alloys that have become successfully weldable by FSW with fewer welding defects and a significant improvement in the weld quality and geometric accuracy. The purpose of this article is to summarize the state of knowledge regarding the application of the FSW process to join materials used in the aerospace industry and to identify gaps in the state of the art. This work describes the fundamental techniques and tools necessary to make soundly welded joints. Typical applications of FSW processes are surveyed, including friction stir spot welding, RFSSW, SSFSW, BTFSW, and underwater FSW. Conclusions and suggestions for future development are proposed.
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Affiliation(s)
- Mohamed M. Z. Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Mohamed M. El-Sayed Seleman
- Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, Egypt
| | - Dariusz Fydrych
- Institute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
| | - Gürel Çam
- Department of Mechanical Engineering, Iskenderun Technical University, Iskenderun 31200, Hatay, Türkiye
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Rani KU, Kumar R, Mahapatra MM, Mulik RS, Świerczyńska A, Fydrych D, Pandey C. Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses. Materials (Basel) 2022; 15:7094. [PMID: 36295161 PMCID: PMC9604903 DOI: 10.3390/ma15207094] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/18/2022] [Revised: 10/06/2022] [Accepted: 10/08/2022] [Indexed: 06/16/2023]
Abstract
Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on the arc welding process in which wire is melted by an electric arc and deposited layer by layer. Due to the cost and rate benefits over powder-based additive manufacturing technologies and other alternative heat sources such as laser and electron beams, the process is currently receiving much attention in the industrial production sector. The gas metal arc welded (GMAW) based WAAM process provides a higher deposition rate than other methods, making it suitable for additive manufacturing. The fabrication of mild steel (G3Si1), austenitic stainless steel (SS304), and a bimetallic sample of both materials were completed successfully using the GMAW based WAAM process. The microstructure characterization of the developed sample was conducted using optical and scanning electron microscopes. The interface reveals two discrete zones of mild steel and SS304 deposits without any weld defects. The hardness profile indicates a drastic increase in hardness near the interface, which is attributed to chromium migration from the SS304. The toughness of the sample was tested based on the Charpy Impact (ASTM D6110) test. The test reveals isotropy in both directions. The tensile strength of samples deposited by the WAAM technique measured slightly higher than the standard values of weld filament. The deep hole drilling (DHD) method was used to measure the residual stresses, and it was determined that the stresses are compressive in the mild steel portion and tensile in austenitic stainless steel portion, and that they vary throughout the thickness due to variation in the cooling rate at the inner and outer surfaces.
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Affiliation(s)
- Kasireddy Usha Rani
- School of Mechanical Sciences, Indian Institute of Technology, Bhubaneswar 752050, India
| | - Rajiv Kumar
- School of Mechanical Sciences, Indian Institute of Technology, Bhubaneswar 752050, India
| | - Manas M. Mahapatra
- School of Mechanical Sciences, Indian Institute of Technology, Bhubaneswar 752050, India
| | - Rahul S. Mulik
- Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India
| | - Aleksandra Świerczyńska
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
| | - Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
| | - Chandan Pandey
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur N.H. 62, Nagaur Road Karwar, Jodhpur 342037, India
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Fydrych D, Tomków J. Underwater Processing of Materials. Materials 2022; 15:ma15144902. [PMID: 35888369 PMCID: PMC9321041 DOI: 10.3390/ma15144902] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Download PDF] [Subscribe] [Scholar Register] [Received: 07/10/2022] [Accepted: 07/13/2022] [Indexed: 11/20/2022]
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Sirohi S, Kumar A, Soni S, Dak G, Kumar S, Świerczyńska A, Rogalski G, Fydrych D, Pandey C. Influence of PWHT Parameters on the Mechanical Properties and Microstructural Behavior of Multi-Pass GTAW Joints of P92 Steel. Materials (Basel) 2022; 15:ma15124045. [PMID: 35744119 PMCID: PMC9227405 DOI: 10.3390/ma15124045] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/10/2022] [Revised: 05/30/2022] [Accepted: 06/03/2022] [Indexed: 11/16/2022]
Abstract
The 9% Cr steels were developed for ultra-supercritical (USC) power plants to meet the requirements of high operating temperature and pressure. These steels are produced to operate at high temperatures where impact toughness is not a concern; however, it becomes important for the welded joints to have good impact toughness at room temperature for manufacturing. The present work investigates the effect of the post-weld heat treatment (PWHT) parameters, i.e., temperature and time, on the impact toughness of multi-pass gas tungsten arc welded (GTAW) joints of ferritic/martensitic grade P92 steel. The microstructural evolution in welded joints given varying post-weld temperatures and times was studied. The lath martensitic structure of the weld metal for the as-welded joints resulted in high hardness and low impact toughness. The weld fusion zone toughness was 12 J, which was lower than the minimum specified values of 41 J (ASME standards) and 47 J (EN ISO 3580:2017). The PWHT temperature and time were found to have a significant effect on the impact toughness of the weld metal. A drastic increase in the impact toughness of the weld metal was noticed, which was attributed to lath break-up, reduction in dislocation density and reduction in solid solution hardening. The maximum impact toughness of 124 J was measured for PWHT temperature and time of 760 °C and 120 min, respectively. The effect of PWHT parameters on tensile strength was also investigated, and test results showed that the joint was safe for USC boiler application as it failed from the region of the P92 base metal. The variation in microstructural evolution along the weldments resulted in hardness variation. PWHT led to homogeneity in microstructure and, ultimately, reduction in hardness value. According to the study, the optimum temperature and time for PWHT of a GTAW joint of P92 steel were found to be 760 °C and 120 min, respectively.
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Affiliation(s)
- Sachin Sirohi
- Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, India; (S.S.); (S.K.)
| | - Amit Kumar
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur, N.H. 62, Nagaur Road, Jodhpur 342037, India; (A.K.); (G.D.)
| | - Shiva Soni
- Department of Computer Science Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, India;
| | - Gaurav Dak
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur, N.H. 62, Nagaur Road, Jodhpur 342037, India; (A.K.); (G.D.)
| | - Sanjeev Kumar
- Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, India; (S.S.); (S.K.)
| | - Aleksandra Świerczyńska
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.Ś.); (G.R.)
| | - Grzegorz Rogalski
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.Ś.); (G.R.)
| | - Dariusz Fydrych
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.Ś.); (G.R.)
- Correspondence: (D.F.); (C.P.)
| | - Chandan Pandey
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur, N.H. 62, Nagaur Road, Jodhpur 342037, India; (A.K.); (G.D.)
- Correspondence: (D.F.); (C.P.)
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Bokov DO, Jawad MA, Suksatan W, Abdullah ME, Świerczyńska A, Fydrych D, Derazkola HA. Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation. Materials (Basel) 2021; 14:7883. [PMID: 34947482 PMCID: PMC8708288 DOI: 10.3390/ma14247883] [Citation(s) in RCA: 17] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/21/2021] [Revised: 12/15/2021] [Accepted: 12/16/2021] [Indexed: 11/23/2022]
Abstract
This article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials' flow. Simulation results revealed that the mechanical work on the joint line increased with the pin angle and larger stir zone forms. The simulation results show that in the angled pin tool, more than 26% of the total heat is produced by the pin. Meanwhile, in other cases, the total heat produced by the pin was near 15% of the total generated heat. The thermo-mechanical cycle in the steel zone increased, and consequently, mechanical interlock between base metals increased. The simulation output demonstrated that the frictional heat generation with a tool without a pin angle is higher than an angled pin. The calculation result also shows that the maximum heat was generated on the steel side.
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Affiliation(s)
- Dmitry Olegovich Bokov
- Pharmaceutical Natural Sciences Department Institute of Pharmacy, Sechenov First Moscow State Medical University, 8 Trubetskaya St., Bldg. 2, 119991 Moscow, Russia;
| | - Mohammed Abed Jawad
- Department of Medical Laboratory Technology, Al-Nisour University College, Baghdad 6770, Iraq;
| | - Wanich Suksatan
- Faculty of Nursing, HRH Princess Chulabhorn College of Medical Science, Chulabhorn Royal Academy, Bangkok 10210, Thailand;
| | - Mahmoud E. Abdullah
- Mechanical Department, Faculty of Technology and Education, Beni-Suef University, Beni-Suef 62511, Egypt;
| | - Aleksandra Świerczyńska
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.Ś.); (D.F.)
| | - Dariusz Fydrych
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.Ś.); (D.F.)
| | - Hamed Aghajani Derazkola
- Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain
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Chupradit S, Bokov DO, Suksatan W, Landowski M, Fydrych D, Abdullah ME, Derazkola HA. Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation. Materials (Basel) 2021; 14:ma14247565. [PMID: 34947176 PMCID: PMC8708232 DOI: 10.3390/ma14247565] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/14/2021] [Revised: 12/06/2021] [Accepted: 12/07/2021] [Indexed: 11/24/2022]
Abstract
The friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic (CFD) model was implemented to analyze the effects of pin angle on the thermo-mechanical action during the FSW process of AA5058 Al-Mg alloy. Experimental test results validate the thermal outcomes of the used model. The obtained results revealed that, when the pin angle is increased, the heat generation decreases while the mechanical action of the tool increases. The internal heat distribution at a higher pin angle is symmetrical. The higher mechanical action of the tool decreases the viscosity of the internal materials and increases stirring action (materials flow) around the pin. Furthermore, plastic flow near the tool increased stirring action and formed a larger stir zone in the joint area.
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Affiliation(s)
- Supat Chupradit
- Department of Occupational Therapy, Faculty of Associated Medical Sciences, Chiang Mai University, Chiang Mai 50200, Thailand;
| | - Dmitry Olegovich Bokov
- Institute of Pharmacy, Sechenov First Moscow State Medical University, 119991 Moscow, Russia;
| | - Wanich Suksatan
- Faculty of Nursing, HRH Princess Chulabhorn College of Medical Science, Chulabhorn Royal Academy, Bangkok 10210, Thailand;
| | - Michał Landowski
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, 80-233 Gdańsk, Poland; (M.L.); (D.F.)
| | - Dariusz Fydrych
- Faculty of Mechanical Engineering and Ship Technology, Institute of Manufacturing and Materials Technology, Gdańsk University of Technology, 80-233 Gdańsk, Poland; (M.L.); (D.F.)
| | - Mahmoud E. Abdullah
- Mechanical Department, Faculty of Technology and Education, Beni-Suef University, Beni-Suef 62511, Egypt;
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Sauraw A, Sharma AK, Fydrych D, Sirohi S, Gupta A, Świerczyńska A, Pandey C, Rogalski G. Study on Microstructural Characterization, Mechanical Properties and Residual Stress of GTAW Dissimilar Joints of P91 and P22 Steels. Materials (Basel) 2021; 14:ma14216591. [PMID: 34772132 PMCID: PMC8585238 DOI: 10.3390/ma14216591] [Citation(s) in RCA: 28] [Impact Index Per Article: 9.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/08/2021] [Revised: 10/22/2021] [Accepted: 10/30/2021] [Indexed: 11/16/2022]
Abstract
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.
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Affiliation(s)
- Anupam Sauraw
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur N.H. 62, Nagaur Road, Karwar, Jodhpur 342037, India; (A.S.); (A.K.S.); (A.G.); (C.P.)
| | - Atul Kumar Sharma
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur N.H. 62, Nagaur Road, Karwar, Jodhpur 342037, India; (A.S.); (A.K.S.); (A.G.); (C.P.)
| | - Dariusz Fydrych
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (D.F.); (G.R.)
| | - Sachin Sirohi
- Mechanical Department, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, India
- Correspondence: (S.S.); (A.Ś.)
| | - Ankur Gupta
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur N.H. 62, Nagaur Road, Karwar, Jodhpur 342037, India; (A.S.); (A.K.S.); (A.G.); (C.P.)
| | - Aleksandra Świerczyńska
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (D.F.); (G.R.)
- Correspondence: (S.S.); (A.Ś.)
| | - Chandan Pandey
- Department of Mechanical Engineering, Indian Institute of Technology Jodhpur N.H. 62, Nagaur Road, Karwar, Jodhpur 342037, India; (A.S.); (A.K.S.); (A.G.); (C.P.)
| | - Grzegorz Rogalski
- Institute of Manufacturing and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (D.F.); (G.R.)
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Memon S, Fydrych D, Fernandez AC, Derazkola HA, Derazkola HA. Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation. Materials (Basel) 2021; 14:ma14164754. [PMID: 34443275 PMCID: PMC8400211 DOI: 10.3390/ma14164754] [Citation(s) in RCA: 20] [Impact Index Per Article: 6.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/03/2021] [Revised: 08/19/2021] [Accepted: 08/20/2021] [Indexed: 11/21/2022]
Abstract
One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.
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Affiliation(s)
- Shabbir Memon
- Department of Mechanical Engineering, Wichita State University, Wichita, KS 67260-133, USA;
| | - Dariusz Fydrych
- Institute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland;
| | - Aintzane Conde Fernandez
- Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain; (A.C.F.); (H.A.D.)
| | - Hamed Aghajani Derazkola
- Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain; (A.C.F.); (H.A.D.)
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Janeczek A, Tomków J, Fydrych D. The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints. Materials (Basel) 2021; 14:3244. [PMID: 34208418 PMCID: PMC8231140 DOI: 10.3390/ma14123244] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/26/2021] [Revised: 06/07/2021] [Accepted: 06/08/2021] [Indexed: 11/16/2022]
Abstract
The purpose of the following study was to compare the effect of the shape of a tool on the joint and to obtain the values of Friction Stir Welding (FSW) parameters that provide the best possible joint quality. The material used was an aluminium alloy, EN AW-3004 (AlMn1Mg1). To the authors' best knowledge, no investigations of this alloy during FSW have been presented earlier. Five butt joints were made with a self-developed, cylindrical, and tapered threaded tool with a rotational speed of 475 rpm. In order to compare the welding parameters, two more joints with a rotational speed of 475 rpm and seven joints with a welding speed of 300 mm/min with the use of a cylindrical threaded pin were performed. This involved a visual inspection as well as a tensile strength test of the welded joints. It was observed that the value of the material outflow for the joints made with the cylindrical threaded pin was higher than it was for the joints made with the tapered threaded pin. However, welding defects in the form of voids appeared in the joints made with the tapered threaded tool. The use of the cylindrical tool resulted in higher values for about 37% of mechanical properties compared with the highest result for the tapered threaded joint. As far as the parameters were concerned, it was concluded that most of the specimens were properly joined for a rotational speed of 475 rpm. In the joints made with a welding speed of 300 mm/min, the material was not stirred properly. The best joint quality was given for a rotational speed of 475 rpm as well as a variety of welding speed values between 150 and 475 mm/min.
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Affiliation(s)
| | - Jacek Tomków
- Institute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland; (A.J.); (D.F.)
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Tomków J, Fydrych D, Wilk K. Effect of Electrode Waterproof Coating on Quality of Underwater Wet Welded Joints. Materials (Basel) 2020; 13:ma13132947. [PMID: 32630224 PMCID: PMC7372381 DOI: 10.3390/ma13132947] [Citation(s) in RCA: 29] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/17/2020] [Revised: 06/25/2020] [Accepted: 06/29/2020] [Indexed: 11/25/2022]
Abstract
In this paper, the effects of different hydrophobic coatings on the surface of covered electrodes on the quality of wet welded carbon steel joints were discussed. Commonly available hydrophobic substances used in industrial applications were selected for the research. The aim of using waterproof coatings was to check the possibility to decreasing the susceptibility of high-strength low-alloy S460N steel to cold cracking. During experiments diffusible hydrogen content in deposited metal determination by mercury method, metallographic macro- and microscopic testing and hardness measurements were performed. Investigations showed that waterproof coatings laid on covered electrodes can improve the quality of wet welded joints, by decreasing the Vickers HV10 hardness in heat-affected zone and decreasing the diffusible hydrogen content in deposited metal, which minimalize possibility of cold cracking.
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Affiliation(s)
- Jacek Tomków
- Division of Welding Engineering, Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza 11/12, 80-233 Gdańsk, Poland;
- Correspondence: ; Tel.: +48-58-347-1863
| | - Dariusz Fydrych
- Division of Welding Engineering, Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza 11/12, 80-233 Gdańsk, Poland;
| | - Kamil Wilk
- Office of Technical Inspection (UDT), Notified Body No. 1433, Trakt Świętego Wojciecha 215B, 80-017 Gdańsk, Poland;
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Landowski M, Świerczyńska A, Rogalski G, Fydrych D. Autogenous Fiber Laser Welding of 316L Austenitic and 2304 Lean Duplex Stainless Steels. Materials (Basel) 2020; 13:ma13132930. [PMID: 32629895 PMCID: PMC7372375 DOI: 10.3390/ma13132930] [Citation(s) in RCA: 49] [Impact Index Per Article: 12.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/01/2020] [Revised: 06/25/2020] [Accepted: 06/28/2020] [Indexed: 11/16/2022]
Abstract
This study presents results of experimental tests on quality of dissimilar welded joints between 316L austenitic and 2304 lean duplex stainless steels, welded without ceramic backing. Fiber laser welded butt joints at a thickness of 8 mm were subjected to non-destructive testing (visual and penetrant), destructive testing (static tensile test, bending test, and microhardness measurements) and structure observations (macro- and microscopic examinations, SEM, element distribution characteristics, and ferrite content measurements). Non-destructive tests and metallographic examinations showed that the welded joints meet the acceptance criteria for B level in accordance with EN ISO 13919–1 standard. Also the results of the destructive tests confirmed the high quality of the joints: specimens were fractured in base material with lower strength—316L austenitic stainless steel and a 180° bending angle was obtained confirming the high plasticity of the joints. Microscopic examination, SEM and EDS analysis showed the distribution of alloying elements in joints. The microhardness of the autogenous weld metal was higher by about 20 HV0.2 than that of the lean duplex steel. Ferrite content in the root was about 37% higher than in the face of the weld. The Schaeffler phase diagram was used to predict the phase composition of the welded joints and sufficient compliance with the magnetic method was found. The presented procedure can be used for welding of 316L–2304 stainless steels dissimilar welded joints of 8 mm thickness without ceramic backing.
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Tomków J, Fydrych D, Rogalski G. Role of Bead Sequence in Underwater Welding. Materials (Basel) 2019; 12:ma12203372. [PMID: 31623063 PMCID: PMC6829353 DOI: 10.3390/ma12203372] [Citation(s) in RCA: 33] [Impact Index Per Article: 6.6] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/19/2019] [Revised: 10/10/2019] [Accepted: 10/14/2019] [Indexed: 11/16/2022]
Abstract
This paper presents examinations of the role of the bead sequence in underwater welding. Two specimens of wet welded layers made by covered electrodes with the use of normalized S355G10+N steel were welded by a reasonable bead sequence. For each specimen, metallographic macro- and micro-scopic tests were done. Then, Vickers HV10 hardness measurements were conducted for each pad weld in the welded layer. The results show that welding in the water environment carries many problems in the stability of the welding arc, which influences the properties of the welds. The effects of refining and tempering the structure in heat-affected zones of earlier laid beads was observed, which provides a reduction of hardness. The possibility of applying two techniques while welding the layer by the wet method is described. It is stated that a reasonable bead sequence can decrease the hardness in heat-affected zones up to 40 HV10. Tempering by heat from next beads can also change the microstructure in this area by tempering martensite and can decrease susceptibility to cold cracking.
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Affiliation(s)
- Jacek Tomków
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza Street 11/12, 80-233 Gdańsk, Poland.
| | - Dariusz Fydrych
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza Street 11/12, 80-233 Gdańsk, Poland.
| | - Grzegorz Rogalski
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza Street 11/12, 80-233 Gdańsk, Poland.
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Tomków J, Rogalski G, Fydrych D, Łabanowski J. Advantages of the Application of the Temper Bead Welding Technique During Wet Welding. Materials (Basel) 2019; 12:ma12060915. [PMID: 30893901 PMCID: PMC6471556 DOI: 10.3390/ma12060915] [Citation(s) in RCA: 34] [Impact Index Per Article: 6.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/07/2019] [Revised: 03/12/2019] [Accepted: 03/13/2019] [Indexed: 11/25/2022]
Abstract
Thermo-mechanically rolled S460ML steel was chosen for welding in underwater wet welding conditions by covered electrodes. The main aim of this study was to check the weldability for fillet welds in a water environment by controlled thermal severity (CTS) tests and to check the influence of temper bead welding (TBW) on the weldability of the investigated steel. Non-destructive and destructive tests showed that S460ML steel has a high susceptibility to cold cracking. In all joints, hardness in the heat-affected zone (HAZ) was extended to the 400 HV10 values. Microscopic testing showed the presence of microcracks in the HAZ of all welded joints. TBW was chosen as the method to improve the weldability of the investigated steel. This technique allows for the reduction of the maximum hardness in the HAZ below the critical value of 380 HV10, as stated by the EN-ISO 15614-1:2017. It was determined that for S460ML steel, from the point of view of weldability, the pitch between two beads should be in the range 75%–100%. Also, if the pitch between two beads increases, the hardness, grain size, and number of cracks decreases. In all specimens where the hardness of the HAZ was below 380 HV10, there were no microcracks.
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Affiliation(s)
- Jacek Tomków
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza street 11/12, 80-233 Gdańsk, Poland.
| | - Grzegorz Rogalski
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza street 11/12, 80-233 Gdańsk, Poland.
| | - Dariusz Fydrych
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza street 11/12, 80-233 Gdańsk, Poland.
| | - Jerzy Łabanowski
- Faculty of Mechanical Engineering, Gdańsk University of Technology, G. Narutowicza street 11/12, 80-233 Gdańsk, Poland.
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