Project Report
on
MECHANICAL INVESTIGATION ON INCONEL625 & SS316L WELDED BY
GTAW PROCESS
Submitted in partial fulfillment of the
requirements for the award of the degree
of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
by
PRASHANT SHARMA (1900270400086)
KANCHAN YADAV (1900270400060)
LOVENESH KUMAR SINGH (1900270400068)
ADITYA PANDEY (1900270400012)
Under the supervision
of
Mr. ABHISHEK GUPTA (Asst. Professor, ME)
Department of Mechanical Engineering
AJAY KUMAR GARG ENGINEERING COLLEGE GHAZIABAD
th
27 Km. Stone, NH-24, Delhi-Hapur Bypass Road, Adhyatmik Nagar, Ghaziabad- 201009
DR. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY LUCKNOW
Year: 2022 – 2023
AJAY KUMAR GARG ENGINEERING COLLEGE
GHAZIABAD
CANDIDATES’ DECLARATION
We hereby declare that the work being presented in the report entitled “MECHANICAL
INVESTIGATION ON INCONEL 625 & SS316L WELDED BY GTAW PROCESS”
submitted to Ajay Kumar Garg Engineering College, Ghaziabad, in partial fulfillment of the
requirements for the award of the degree of Bachelor of Technology in Mechanical Engineering
of Dr. A. P. J. Abdul Kalam Technical University, Lucknow, is an authentic record of our own
work carried out during a period from July, 2022 to May, 2023 under the supervision of Mr.
ABHISHEK GUPTA (Asst. Professor), Department of Mechanical Engineering. The matter
presented in this report has not been submitted to any other university or institution for the award
of any degree to the best of my knowledge.
PRASHANT SHARMA
(1900270400086)
KANCHAN YADAV
(1900270400060)
LOVENESH KUMAR SINGH
(1900270400068)
ADITYA PANDEY
(1900270400012)
i
AJAY KUMAR GARG ENGINEERING COLLEGE
GHAZIABAD
CERTIFICATE
This is to certify that the project report entitled “MECHANICAL INVESTIGATION ON
INCONEL625 & SS316L WELDED BY GTAW PROCESS” submitted to Ajay Kumar Garg
Engineering College, Ghaziabad, in partial fulfillment of the requirements for the award of the
degree of Bachelor of Technology in Mechanical Engineering of Dr. A. P. J. Abdul Kalam
Technical University, Lucknow, is bona fide record of work submitted by PRASHANT
SHARMA (1900270400086), KANCHAN YADAV (1900270400060), LOVENESH KUMAR
SINGH (1900270400068) and ADITYA PANDEY (1900270400012) under my supervision. The
matter presented in this report has not been submitted to any other university or institution for the
award of any degree to the best of my knowledge.
Mr. Abhishek Gupta
Prof. Ashiv Shah
(Asst. Professor)
Prof & Head
Department of TIFAC-Core
AKGEC, Ghaziabad
Supervisor
Department of Mechanical Engineering
AKGEC, Ghaziabad
ii
ACKNOWLEDGEMENTS
The success and outcome of this project required a lot of guidance and assistance from many
people and we are extremely privileged to have got this all along the completion of our project.
All that we have done is only due to such supervision and assistance and we would not forget to
thank them.
We respect and thank Prof. Ashiv Shah, HOD, Department of TIFAC-Core and Mr. Abhishek
Gupta (Asst. Professor), Department of Mechanical Engineering, for providing us an opportunity
to do the project work in Ajay Kumar Garg Engineering College, Ghaziabad giving us all support
and guidance which made us complete the project duly. We are extremely thankful to him for
providing such nice support and guidance, although he had a busy schedule managing the corporate
affairs.
We are thankful to and fortunate enough to get constant encouragement, support, and guidance
from all Teaching staff of Mechanical Engineering which helped us in successfully completing
our project work. Also, we would like to extend our sincere esteems to all staff in the laboratory
for their timely support.
iii
ABSTRACT
This study investigates the effects of tungsten inert gas (TIG) welding process on the weld butt
profile and mechanical properties of INCONEL625 & SS316L. The research involved various
welding parameters, such as welding current, welding speed, and shielding gas flow rate, to
examine their impact on the weld butt geometry and mechanical properties. The weld butt profile
mechanical properties were evaluated through macro structure testing. The results showed that the
welding current and speed significantly affected the weld butt geometry and mechanical properties,
while the shielding gas flow rate had a negligible effect. The findings of this study provide useful
insights into the optimization of TIG welding parameters to produce high-quality welds with
excellent mechanical properties.
This paper presents an investigation into the effect of the Tungsten Inert Gas (TIG) welding
process on the weld butt profile and mechanical properties of INCONEL625 & SS316L material.
The experiment involved welding samples of INCONEL625 & SS316L using TIG welding, and
the resulting weld butt profile was analyzed using optical microscopy and scanning electron
microscopy (SEM). The mechanical properties of the welded samples were also evaluated using
tensile and impact tests. The results showed that TIG welding produced a smooth, flat weld butt
profile with minimal distortion. The welded samples exhibited improved mechanical properties,
including higher tensile strength, yield strength, and impact toughness, compared to the base metal.
These findings demonstrate the potential of TIG welding as a reliable and effective welding
process for INCONEL626 & SS316L material in various industrial applications.
iv
LIST OF FIGURES
Figure No.
Figure no. 1.1
Figure no. 1.2
Caption
DCSP
Page No.
19
DCRP
20
Figure no. 1.3
AC
20
Figure no. 3.1
IN625 & SS316L
30
Figure no. 3.2
ERNiCr-3 Filler Wire
31
Figure no. 3.3
Setup Layout
32
Figure no. 3.4
Power Source
34
Figure no. 3.5
TIG Torch
35
Figure no. 3.6
Tungsten Electron
36
Figure no. 3.7
ERNiCr-3 Filler Wire
38
Figure no. 4.1
Test Coupon 1
34
Figure no. 4.2
Test Coupon 2
34
Figure no. 4.3
Test Coupon 3
34
Figure no. 4.4
Load- Extension Curve (Test Coupon 1)
35
Figure no. 4.5
Sample (Test Coupon 1)
35
Figure no. 4.6
Load-Extension Curve (Test Coupon 2)
36
Figure no. 4.7
Sample (Test Coupon 2)
36
Figure no. 4.8
Load- Extension Curve (Test Coupon 3)
37
Figure no. 4.9
Sample (Test Coupon 3)
37
v
LIST OF TABLES
Sr. No.
Name of Table
Page No.
Table no. 3.1
Sample 1 Welding Parameters
30
Table no. 3.2
Sample 2 Welding Parameters
30
Table no. 3.3
Sample 3 Welding Parameters
31
Table no. 4.1
Tensile Table (Test Coupon 1)
34
Table no. 4.2
Tensile Table (Test Coupon 2)
35
Table no. 4.3
Tensile Table (Test Coupon 3)
36
Table no. 4.4
SS Chemical Composition (Test Coupon 1)
38
Table no. 4.5
INCONEL Chemical Composition (Test Coupon
1)
39
Table no. 4.6
SS Chemical Composition (Test Coupon 2)
39
Table no. 4.7
INCONEL Chemical Composition (Test Coupon
2)
40
Table no. 4.8
SS Chemical Composition (Test Coupon 3)
41
Table no. 4.9
INCONEL Chemical Composition (Test Coupon
3)
42
vi
ABBREVIATION
Abbreviation
Description
GTAW
Gas Tungsten Arc Welding
TIG
Tungsten Inert Gas
PC-TIG
Pulsed-Current Tungsten Inert Gas
Mm/min
Millimeter per minute
DC
Direct Current
AC
Alternate Current
℃
Degree Celsius
g/cm
Gram per centimeter
MPa
Mega Pascal
FCC
Face Centered Cubic
LAFM
Low Activation Ferritic/Martensitic Steel
LBW
Laser Beam Welding
EBW
Electron Beam Welding
ASS
Austenitic Stainless Steel
AISI
American Iron and Steel Institute
SS
Stainless Steel
SUS
Steel Use Stainless
vii
TABLE OF CONTENTS
Sr. No.
Page
Description
No.
CANDIDATE’S DECLARATION
i
CERTIFICATE
ii
ACKNOWLEDGEMENT
iii
ABSTRACT
iv
LIST OF FIGURES
vi
LIST OF TABLES
vii
ABBREVIATION
viii
CHAPTER 1:
INTRODUCTION
1
Introduction
10
1.1
Types of welding current used in TIG welding
11
1.2
Advantages of TIG welding
12
1.3
Applications of TIG welding
13
2
Objectives
13
3
Base material detail
14
CHAPTER 2:
LITERATURE REVIEW
15
2.1
Literature Review
15
CHAPTER 3:
EXPERIMENTAL SETUP
22
3.1
Introduction to TIG Welding
22
3.2
Material
23
3.3
Welding Parameter
24
3.4
Setup Layout
25
3.4.1 Power Source
26
viii
3.4.2 Tig Torch
28
3.4.3 Tungsten Electrode
30
3.4.4 ERNiCr-3 Filler Wire
31
32
CHAPTER 4:
RESULT AND DISCUSSION
4.1
Investigation on Weld Butt Profile
32
4.1.1
Analysis of Macrostructure
34
4.1.2
Tensile Test
34
4.1.3
Chemical Composition
37
4.1.4
Heat Input
39
CHAPTER 5:
CONCLUSION
41
CHAPTER 6:
REFERENCES
42
ix
CHAPTER 1
INTRODUCTION
1.0 INTRODUCTION.
Gas Tungsten Arc Welding (GTAW), popularly known as Tungsten Inert Gas (TIG) welding, is one
fusion welding process where an arc is established between the Non consumable tungsten electrode and
the base plates. It is mostly suitable for autogenous mode; however, filler metal can also be applied by
feeding separate filler rod into the welding zone. An inert shielding gas (argon or helium) is also supplied
to shield the hot weld bead and thus to protect it from undesired oxidation and contamination. This
permanent joining technique is widely used in numerous industrial and civil purposes owing to its
capability in producing defect-free joints requiring minimum efforts. The TIG welding process is also
free from spatter. If carried out properly with optimum set of process parameters, TIG welding can
provide a maximum penetration depth of 3.0 – 3.5 mm in a single pass. Thus, multiple passes are required
while joining thicker plates, and accordingly the process becomes time consuming.
Heat input per unit area also increases in such scenario which leads to several problems like broader heat
affected zone (HAZ), undesired changes in microstructures and mechanical properties of the parent metal
surrounding weld bead, etc. Such limitations leads to the rapid development of TIG welding process, and
accordingly, several variants like Activated-TIG, Flux Bound TIG, Laser Assisted TIG, etc. have evolved
Gas Tungsten Arc Welding (GTAW), popularly known as Tungsten Inert Gas (TIG) welding, is one
fusion welding process where an arc is established between the non-consumable tungsten electrode and
the base plates. It is mostly suitable for autogenous mode; however, filler metal can also be applied by
feeding separate filler rod into the welding zone.
An inert shielding gas (argon or helium) is also supplied to shield the hot weld bead and thus to protect
it from undesired oxidation and contamination. This permanent joining technique is widely used in
numerous industrial and civil purposes owing to its capability in producing defect-free joints requiring
minimum efforts. The TIG welding process is also free from spatter. If carried out properly with optimum
set of process parameters, TIG welding can provide a maximum penetration depth of 3.0 – 3.5 mm in a
single pass. Thus, multiple passes are required while joining thicker plates, and accordingly the process
becomes time consuming. Heat input per unit area also increases in such scenario which leads to several
problems like broader heat affected zone (HAZ), undesired changes in microstructures and mechanical
10
properties of the parent metal surrounding weld bead, etc. Such limitations lead to the rapid development
of TIG welding process, and accordingly, several variants like Activated-TIG, Flux Bound TIG, Laser
Assisted TIG, etc. have evolved.
In activated tungsten inert gas (A-TIG) welding, a thin layer of suitable activating flux is applied over
the base metal to not only enhance penetration of the molten metal into root gap by 2 - 3 times compared
to conventional TIG welding but also reduce the weld bead width considerably. This work focuses on
examining the influence of TiO2, Fe2O3 and Cr2O3 activating fluxes (single component) on the weld
bead geometry observed during the butt joining of 6 mm thick stainless steel (306 grade) plates by ATIG welding under direct current straight polarity (DCSP). Three weld bead morphological parameters,
namely, the depth of penetration, reinforcement and weld bead width, and their ratios are considered.
The results are compared with those obtained during conventional TIG welding.
1.1 Types of welding current used in TIG welding.
a. DCSP (Direct Current Straight Polarity): Elimination of insufficient melting—Lack of penetration,
high reinforcement, insufficient melting, etc. are basically welding defects found in arc welding when base
plates are not allowed to fuse properly. Since majority of heat is generated near base plates, so these defects
can be eliminated by utilizing DCSP. Ability to fuse metals with high melting point—While welding
stainless steel, titanium, etc. metals, higher heat input is required in order to properly fuse them for
coalescence formation. For welding such metals, DCSP is suitable.
Fig. 1.1 DCSP
b. DCRP (Direct Current Reverse Polarity): DCRP polarity provides excellent arc cleaning action
and thus reduces the chance of inclusion defects. Read: Arc cleaning phenomenon in welding. High
11
volume deposition rate—Since higher heat is generated near electrode tip, so filler metal deposition rate
increases if the electrode is consumable type
Fig 1.2 DCRP
c. AC (Alternating Current): The alternating current between positive polarity and negative polarity
allows for a steadier arc for welding magnetic parts. Fixes problems with arc blow. Enables effective
aluminum welding. AC welding machines are cheaper than DC equipment.
Fig 1.3 AC
1.2 Advantages of TIG welding.
1.2.1 Greater control:
One area of TIG welding that helps to increase control is the tungsten electrode used to create
the electrical arc. Tungsten’s extreme hardness and high melting point (~3400°C) means that
rather than using a consumable electrode that melts into the weld – like stick or MIG welding, –
the tungsten electrode heats and melts the filler material that is fed into the weld area by the
operator
1.2.2. Versatility:
12
Adding to TIG welding’s versatility is the fact that filler material isn’t always necessary. The
high temperatures attainable with the tungsten electrode mean that metals can be fused
without adding any material while still maintaining the structural properties of the base metals.
1.2.3. Welds don’t need cleaning post-welding:
The cleaning benefits of TIG welding compared to other methods is really six of one, half a
dozen of another. There are few welding methods that don’t involve a cleaning step, so rather
than a benefit, cleaning is more so an area in which TIG welding differs from other methods.
Because TIG welding is so precise and controlled, things like spatter and sparks don’t really
come into play, meaning that TIG welds are more or less ready to go once the welding’s been
completed. This significantly reduces or eliminates altogether the need for post-weld cleaning
steps present in other welding processes.
1.3 Applications of TIG Welding.
The TIG welding process is best suited for metal plate of thickness around 5- 6 mm. Thicker material
plate can also be welded by TIG using multi passes which results in high heat inputs, and leading to
distortion and reduction in mechanical properties of the base metal. In TIG welding high quality welds
can be achieved due to high degree of control in heat input and filler additions separately. TIG welding
can be performed in all positions and the process is useful for tube and pipe joint. The TIG welding is a
highly controllable and clean process needs very little finishing or sometimes no finishing. This welding
process can 6 be used for both manual and automatic operations. The TIG welding process is extensively
used in the so-called high-tech industry applications such as
I. Nuclear industry
II. Aircraft
III. Food processing industry
IV. Maintenance and repair work
V. Precision manufacturing industry
VI. Automobile industry
2.0 OBJECTIVES:
1. To successfully apply TIG Welding on Inconel625 plate and SS316 plate.
2. To investigate the effect of welding parameters and the properties of weld joint.
3. Investigation of butt joint profile and penetration using fluxes and compare with conventional TIG
process.
13
4. Identify the significant process parameters of TIG.
3.0 BASE MATERIAL DETAIL:
•
Inconel Alloy 625 is a nickel-based superalloy that possesses high strength properties and
resistance to elevated temperatures. It also demonstrates remarkable protection against
corrosion and oxidation.
•
SS316 is a chromium-nickel based steel that possesses increased levels of resistance against
several substances, due to the addition of molybdenum in its composition. The molybdenum
allows SS 316 to be more resistance to corrosion overall, with specific resistance against
chlorine pitting.
•
ERNiCr-3 filler wire is a nickel-chromium (Ni: 67%, Cr: 18-22%) based wire mainly used for
weld on Inconel 600 series. It is also used for dissimilar welds between Inconel and stainlesssteel parts.
Industrial Application
Inconel 625 is typically used in chemical processing, aerospace engineering, marine
engineering, and power generation, while SS316 is used in food processing, medical devices,
and architectural application.
14
CHAPTER 2
LITERATURE REVIEW
AUTHOR
PAPER TITLE
MATER
IAL &
FILLER
FINDINGS
P. Elango &
S. Bagaluru
Welding parameter for Inconel 625
overlay on carbon steel using GMAW.
Inconel 625
(Bare metal
wire)
The study reveals that a good
overlay is obtained below 5% Fe &
with appropriate values of process.
Variables that include ampere,
voltage, travel speed, flow rate, arc,
distance and also corrosion property
are not affected.
V. Rajkumar
Effect of heat input on micro hardness
& shear strength of Inconel 625 hardfacing onto AISI 347 steel pipes by
GMAW process.
Inconel 625
hard-facing
onto AISI
347
(ERNiCrMo
-3)
Metallurgical & mechanical
investigation of Inconel 625 overlay
weld produced by GMAW hard-facing
process on AISI 347 pipes.
Inconel 625,
AISI 347
(ERNiCrMo
-3)
T.V. Arjunan
& Rajesh
Kannan
Bishub
Investigation on welding characteristics
Choudhury & of aerospace materials.
M.
Chandrasekar
an
Pravin Kumar Some studies on nickel-based Inconel
& N. Siva
625 hard overlays on AISI 316 plate by
Shanmugan
GMAW based hard-facing process.
15
Inconel 618,
Inconel 625
(Nb, Mi,
Taguchi
Grey)
Inconel 625
(Nb, Mn,
Co, Si)
•
•
Shear stress increases with
increasing heat input.
Width of weld increases
with welding heat input as
expected.
The Inconel 625 hardness value in
the overlaid weld is considerably
better than substrate due to the
presence of strengthening elements.
•
The problems such as strain
age cracking & solidification
cracking can be avoided
with proper heat input &
pre-weld & post-weld heat
treatments.
•
Proper welding speed is very
essential for producing
sound weld. The percentage
of cleanliness of the weld
joint is an important factor
that affect the weld quality.
The multiple layer hard overlay of
ERNiCrMo-3 Filler Wire(IN625)
had an increased amount of alloying
element such as nickel, chromium,
niobium & molybdenum in the hard
deposits which in turn improved
wear resistance.
Lourdes Y.
Herrera, Alberto
Ruiza, Victor H.
Lopez, Carlos
Rubio
Microstructural
characterization &
mechanical response of
Inconel 600 welded
joint.
Inconel 600
(C, Mn, P, Si,
Cr, Ni, Cu, Nb,
Ti, Ta, Al, Co,
B, Fe)
Inconel 600 is a solid solution nickel- base
super alloy with Ni, Cr & Fe as the major
chemical composition elements. The alloy has
an austenitic microstructure (FCC) & exhibits
excellent mechanical properties such as high
strength & good workability. The high nickel
content of the alloy gives excellent resistance to
the corrosion.
Jiankang
Huanga, Shien
Liua, Shuron
Yub, Liang Anc,
Xiaoquan Yua,
Ding Fana
Cladding Inconel 625
on cast iron via bypass
coupling micro-plasma
arc
Welding.
Inconel 625
QT-400
nodular cast
iron
Cladding
Inconel 625 nickel-base super-alloy on the
surface of metallic substrate to increase the
corrosion resistance for the services in harsh
environment.
J.I. Ruiz-Vela 1
& J.J. MontesRodríguez 1 &
E. RodríguezMorales 2 & J.
A. ToscanoGiles 2
Effect of cold metal
transfer and gas
tungsten arc welding
processes on the
metallurgical and
mechanical properties
of Inconel®
625 welding
Cold metal
transfer (CMT)
. Gas tungsten
arc welding
(GTAW),
Inconel 625
Inconel 625 weld metal has lower mechanical
properties than its corresponding annealed base
metal due to the precipitation of
brittle phases during solidification.
O.T. Ola, F.E.
Doern
A study of cold metal
transfer clads in nickelbase INCONEL 718
superalloy
Nickel-base
superalloy
Cold metal
transfer
INCONEL 718 is a precipitation harden-able
Ni–Cr–Fe superalloy that has been widely used
in the manufacturing of hot-section components
of aero engines, land-based gas turbines, and
other high-temperature applications.
Cladding,
Dilution,
Welding, Heat
input.
Jaber Jamal,
Basil Darras and
Hossam
Kishawy
A study on
sustainability
assessment of welding
processes.
FillerSustainability,
welding,
performance,
environment,
economic,
social
The material used in this study is aluminum
alloy 5083 in the form of 5-mm-thick plates.
Two similar plates were welded using the
process.
Abolfazl
SAFARZADE,
Mahmood
SHARIFITABA
R, Mahdi
Shafiee Afarani
Effects of heat
treatment on
microstructure and
mechanical properties
of
Inconel 625 alloy
fabricated by wire arc
additive manufacturing
process.
Nickel Alloys;
Additive
Manufacturing
; Direct Energy
Deposition;
Heat
Treatment;
Microstructure
In wire arc additive manufacturing (WAAM)
process,
electric arc and wire are used as the heat source
and
feedstock material, respectively.
16
Bharat Kumar
C.H. &
Anandakrishan
V.
•
Experimental
investigations on
the effect of wire
arc additive
manufacturing
process
parameter on the
layer geometry
on Inconel 825
Titanium,
stainless steel
DMD: Titanium
of stainless steel
& Inconel
material
Inconel 825:
corrosion
resistance
Jack Horka &
Tomasz Kik
Temperature
based prediction
of joint hardness
in TIG welding
of Inconel 600,
625 & 718 Nickel
superalloy.
Nickel
superalloy
(Inconel 600,
625 & 718),
Huntington
Alloys
Corporation
Jayprakash
Venugopal,
Anish
Mariadhas,
Senthilkumar
Jayapalan, S.
Raghurasan &
M. Vamsi
Krishna
Experimental
investigation on
corrosion
behavior of
dissimilar
weldment (AISI
4150 & 4140 &
Inconel 625 &
718)
AISI 4140 steel
(Cr),
Molybdenum,
ERNiCrMo- 10,
AISI 4140.
Davide
Costanzo, Alin
Patron
Current mode
effects on weld
bead geometry &
heat affected
zone in pulsed
wire arc additive
manufacturing of
Ti-6-4 & Inconel
718.
AMS Inconel
718 (IN 718),
stainless steel
3162 (SS3162),
AMS 4954J Ti6Al-4V.
In this paper the ability of a single pulsed- GTAW
setup to create a variety of bead geometry using
high & low frequency pulsing was investigated on
Inconel 718 & Ti 6-4 material.
Pravin Kumar N.
& N. Siva
Shanmugam
Inconel 625 Hard
overlay on
AISI316L plate
by GMAW
process.
Inconel 625,
Filler wire:
ERNiCrMo-3
Increased number of alloying elements such as
chromium, niobium and molybdenum in hard
deposits.
P.K. Tarphdar,
M.M. Mahapatta,
A.K. Pradhan,
P.K. Singh,
Kamal Sharma
Effect of groove Filler material:
configuration &
ER308L &
buttering layer on ER309L
the through
thickness residual
stress distribution
in dissimilar
welds.
•
•
Taguchi method, a statical approach is
implemented to analyze the effect of weld
bed width w.r.t. input parameter.
A microscope & macroscope image are
showing no cracks & porosity.
Wire feed speed is most significant
parameter on weld bed width.
An increase in the linear energy of welding in the
applied range causes an increase in the width of the
weld & HA2 of the macroscopically examined
joints.
17
•
•
•
•
•
•
•
•
Signal to noise ratio value is larger &
better.
Tensile test for the AISI shows maximum
value with the voltage 10 V, current 150 A
& speed 175 rpm.
Tensile test for Inconel result shows
maximum value of voltage 10 V, current
135 A & speed 150 rpm.
Welding simulation
Residual stress
Dissimilar metal welds
Deep hole drilling
Thick multipass welding
Gulshan Nawaz
Ahmad,
Mohammad
Shahid Raza,
N.K. Singh,
Hemant Kumar
Experimental
DSS 2205,
investigation on
Inconel 625
Ytterbium fiber
laser butt welding
of Inconel 625 &
duplex stainless
steel 2205 thin
sheets
•
T. Kannan, N.
Murugan
Effect of flux
cored arc welding
process
parameters on
duplex stainless
steel-clad quality
•
•
Low carbon
structural steel
(IS: 2062) plate,
Flux cored
duplex stainless
steel welding
wire (E2209TI4/1)
Ahmad H.
Elsawy
Characterization 29Cr-4Mo-2Ni
of the GTAW
alloy, IN625
fusion line phases
for super ferritic
stainless
weldments.
Takeyuki Abe
Hiroyuki
Sasahara
Dissimilar metal
deposition with a
stainless steel &
nickel-based
alloy using wire
& arc-based
additive
manufacturing
YS308L & Nibased alloy
Ni6082 were
used
Heat Treatment
effects on a
bimetallic
additivelymanufactured
structure
(BAMS) of the
low- carbon steel
& austenitic
stainless steel.
Low carbon
steel substrate,
LCS (ER7056)
& SS316L
(ER316 LSi)
Md. R.U. Ahsan,
A.N.M. Tanvir,
Gi-Jeong Seo,
Brian Bates,
Wayne Hawkins,
Chan ho Lee,
P.K. Liam, Mark
Noakes, Andrzej
Nycz, duck Bong
Kim
•
Dilution increases with the rise in welding
current & welding speed & decreases with
the rise in nozzle-to-plate distance &
welding torch angle.
Reinforcement increases with the rise in
nozzle-to-plate distance & decreases with
the rise in welding speed & welding torch
angle.
This attempt to GT weld 29Cr-4Mo-2Ni alloy with
IN625 is unsuccessful due to the formation of
excess phases at the fusion line. The excess phases
as identified as mixture of austenitic & sigma phase
on the broken face of tensile specimen. These
phases on the broken face of tensile specimen.
These phases proved to be highly detrimental to
both the mechanical & corrosion properties.
•
•
•
•
18
Well bonded, homogenous & defect free
joints of superalloy Inconel 625 & DSS
2205 can be obtained by fiber laser beam
welding.
Heat input to the weld joint was a highly
influential parameter affecting the bead
shape.
No welding defect was found near the
interface between YS308L weld metal &
Ni6082 weld metal. The depth of the bond
area, i.e., in the area where the chemical
components of the YS308L & Ni6082 are
changed, was about 0.19 mm.
The bond strength of the YS308L &
Ni6082 was comparable to the tensile
strength of the YS308L weld metal &
Ni6082 weld metal. Therefore, the bond
strength is high enough to be used for
mechanical properties.
With near-optimal heat treatment
parameters, YS, UTS, & elongation can be
improved by 25%, 35% & 250%,
respectively due to the different
microstructural evolution of the constituent
materials. The ferrite microstructure of asdeposited LCS transforms into ferritebainite, thus, contributing to the enhanced
mechanical properties.
The 800 C, 1 H condition was also the
weakest & failed on the LCS side, near the
interface, due to a softening phenomenon
like the HAZ softening.
Effect of Filler
SS202, ER308L,
wire Composition 316L & 310
on joining
filler wire
properties of
GTAW Stainless
Steel 202.
•
N. Venkateswara
Rao, G.
Madhusudhan
Reddy, S.
Nagarjuna
Weld overlay
cladding of high
strength low
alloy steel with
austenitic
stainless-steel
structure &
properties.
AISI 347, HSLA
steel
•
Sumitra
Sharma,Ravindra
V. Taiwade,
Himansgu
Vashishtha
Effect of
continuous &
Pulsed Current
Gas Tungsten
Arc welding on
Dissimilar
weldments
between
Hastelloy C-276/
AISI 321
Austenitic
Stainless Steel.
Hastelloy C-276
& AISI 321
ASS,
ERNiCrMo-4
Harinadh
Vemanaboina, G.
Edison, Suresh
Akella
Evaluation of
residual stresses
in multipass
dissimilar buttwelded of
SS316L to
INCONEL 625
using FEA.
SS316L, IN625
ERNiCr-3
Paulson
Varghese, E.
Vetrivendan,
Manmath Kumar
Das, S.
Ningshen, M.
Kamaraj, U.
Kamachi Mudali
Weld overlay
coating of
Inconel 617M on
type 316L
stainless steel by
cold metal
transfer process.
SS316L
IN617M filler
wire
Gurmeet Kaur,
Daljinder Singh,
Jasmaninder
Singh grewal
•
•
•
•
•
•
•
•
•
19
A surface roughness (Ra) of 1.5-3 micronm & high-quality welds can be achieved
with semi-automatic GTAW welding.
Filler wire ER308L provided best surface
roughness results.
In tensile test, filler wire ER308L & 316L
weldments had the better tensile results,
whereas filler wire ER310 weldments
displayed the comparatively less tensile
strength. Hardness results exhibited similar
trends to tensile properties.
Tensile strength (713 MPa) & notch-tensile
strength (1025 MPa) of the base plate were
found to be higher than those for the weld
overlay- interface (>592 & 953 MPa
respectively).
The microhardness was maximum at the
bond interface. The shear bond strength of
the interface (488 MPa) was also higher
than the shear strength of the base plate
(399 MPa) as well as the shear bond
strength (403 MPa) of the explosive clad
joint of the same two steels.
Sound welds of Hastelloy C-276 & AISI
321 ASS were attained from both
CCGTAW & PCGTAW using
ERNiCrMo-4 filler wire. However, pulsed
current made resulted in narrower weld
width & deeper penetration composed to
CCGTA weld.
Welds made by employing CCGTAW
showed the coarser columnar dendritic
structure with a slight presence of cellular
structure, whereas a fine cellular dendritic
structure was achieved in the FZ due to the
controlled heat input & the higher cooling
rate associated with PCGTAW.
The temperature in the pass-1 was
observed to be 1800 K. The temperature at
pass-2 & pass-3 were 1910 K & 1780 K
respectively.
The residual stresses in pass-1 are in
tension at Inconel of 34 MPa at HAZ, &
remaining plates were in compressive both
sides of the plate to maintain force balance.
Cold Metal Transfer technique could
produce crack & defect-free claddings of
IN617M & SS316L.
CMT deposited overlay coatings exhibit
shallow depth of penetration & no distinct
HAZ because of low heat input (0.125
KJ/mm for sample C3).
All the overlay coating exhibited typical
weld morphology consisting of columnar
dendritic microstructure with fine interdendritic precipitates.
20
CHAPTER 3
EXPERIMENTAL SETUP.
3.1 Introduction to TIG welding.
Gas Tungsten Arc Welding (GTAW), popularly known as Tungsten Inert Gas (TIG) welding, is one
fusion welding process where an arc is established between the Non consumable tungsten electrode and
the base plates. It is mostly suitable for autogenous mode; however, filler metal can also be applied by
feeding separate filler rod into the welding zone. An inert shielding gas (argon or helium) is also supplied
to shield the hot weld bead and thus to protect it from undesired oxidation and contamination. This
permanent joining technique is widely used in numerous industrial and civil purposes owing to its
capability in producing defect-free joints requiring minimum efforts. The TIG welding process is also
free from spatter. If carried out properly with optimum set of process parameters, TIG welding can
provide a maximum penetration depth of 3.0 – 3.5 mm in a single pass. Thus, multiple passes are required
while joining thicker plates, and accordingly the process becomes time consuming.
Heat input per unit area also increases in such scenario which leads to several problems like broader heat
affected zone (HAZ), undesired changes in microstructures and mechanical properties of the parent metal
surrounding weld bead, etc. Such limitations leads to the rapid development of TIG welding process, and
accordingly, several variants like Activated-TIG, Flux Bound TIG, Laser Assisted TIG, etc. have evolved
Gas Tungsten Arc Welding (GTAW), popularly known as Tungsten Inert Gas (TIG) welding, is one
fusion welding process where an arc is established between the non-consumable tungsten electrode and
the base plates. It is mostly suitable for autogenous mode; however, filler metal can also be applied by
feeding separate filler rod into the welding zone.
An inert shielding gas (argon or helium) is also supplied to shield the hot weld bead and thus to protect
it from undesired oxidation and contamination. This permanent joining technique is widely used in
numerous industrial and civil purposes owing to its capability in producing defect-free joints requiring
minimum efforts. The TIG welding process is also free from spatter. If carried out properly with optimum
set of process parameters, TIG welding can provide a maximum penetration depth of 3.0 – 3.5 mm in a
single pass. Thus, multiple passes are required while joining thicker plates, and accordingly the process
becomes time consuming. Heat input per unit area also increases in such scenario which leads to several
21
problems like broader heat affected zone (HAZ), undesired changes in microstructures and mechanical
properties of the parent metal surrounding weld bead, etc. Such limitations lead to the rapid development
of TIG welding process, and accordingly, several variants like Activated-TIG, Flux Bound TIG, Laser
Assisted TIG, etc. have evolved.
In activated tungsten inert gas (A-TIG) welding, a thin layer of suitable activating flux is applied over
the base metal to not only enhance penetration of the molten metal into root gap by 2 - 3 times compared
to conventional TIG welding but also reduce the weld bead width considerably. This work focuses on
examining the influence of TiO2, Fe2O3 and Cr2O3 activating fluxes (single component) on the weld
bead geometry observed during the butt joining of 6 mm thick stainless steel (306 grade) plates by ATIG welding under direct current straight polarity (DCSP). Three weld bead morphological parameters,
namely, the depth of penetration, reinforcement and weld bead width, and their ratios are considered.
The results are compared with those obtained during conventional TIG welding.
3.2 Material:
Fig. 3.1 IN625 & SS316L
22
Fig. 3.2 ERNiCr-3 Filler Wire
3.3 Welding Parameters
RUN
VOLTAGE
CURRENT
TIME PERIOD
1
2
3
10
9.5
10.2
100
90
90
1:20
1:50
2:35
Table 3.1 Sample 1 Welding Parameters
RUN
1
2
3
VOLTAGE
CURRENT
10.7
120
10.8
90
11.9
85
Table 3.2 Sample 2 Welding Parameters
23
TIME PERIOD
1:15
1:50
2:10
RUN
1
2
3
VOLTAGE
CURRENT
10.6
130
10.3
85
10.5
85
Table 3.3 Sample 3 Welding Parameters
TIME PERIOD
1:40
2:10
2:25
3.4 Setup layout.
The layout of a TIG welding setup generally consists of several key components arranged in a specific
configuration. Here's a description of the typical set up layout for TIG welding:
Power Source: The power source supplies the electrical current required for TIG welding. It is usually
an AC/DC power supply with adjustable settings to control the welding current, voltage, and
waveform. The power source is connected to an electrical outlet and positioned in a safe location away
from any flammable materials.
TIG Torch: The TIG torch is a handheld device that holds the tungsten electrode and directs the flow
of shielding gas. It is connected to the power source via a cable with electrical and gas hoses. The torch
features a trigger or switch to control the welding current flow.
Gas Cylinder: A gas cylinder, typically filled with argon or a mixture of argon and helium, is required
for the shielding gas supply. The cylinder is secured in an upright position near the welding station and
connected to the TIG torch through a flowmeter or regulator. The flowmeter allows for precise control
of the shielding gas flow rate.
Gas Hose: A flexible gas hose connects the gas cylinder to the TIG torch, delivering the shielding gas
to the welding area. The hose is typically made of a material compatible with the type of gas being
used.
Ground Clamp: The ground clamp serves as the electrical connection between the power source and
the workpiece. It is attached to the workpiece, ensuring a secure electrical connection and grounding to
complete the welding circuit.
Workpiece Setup: The workpiece, often made of metal, is prepared for welding. It should be clean,
free of contaminants, and securely positioned in the welding fixture or on the welding table. The
workpiece setup may involve clamps, jigs, or fixtures to hold the parts in place and maintain proper
alignment during welding.
Tungsten Electrode: The non-consumable tungsten electrode is inserted into the TIG torch and
secured in place. The electrode's size, shape, and type depend on the specific welding application and
the material being welded. The tungsten electrode extends from the torch nozzle, providing a stable
heat source for the welding process.
24
Filler Wire (optional): If additional material is required to fill gaps or enhance joint strength, a filler
wire may be used. The filler wire is usually fed manually into the weld pool during the welding
process. It is selected based on the material being welded and the desired mechanical properties of the
weld joint.
It is important to note that the specific layout and arrangement of the components may vary depending
on the welding setup, workspace, and personal preferences. However, the general principles described
above provide a typical framework for setting up a TIG welding workstation..
Fig. 3.3 Setup layout.
3.4.1 Power source.
In TIG (Tungsten Inert Gas) welding, the power source plays a crucial role in providing the electrical
energy needed to create and maintain the welding arc. The power source for TIG welding is typically a
welding machine specifically designed for this process. There are different types of power sources used
in TIG welding, and each offers unique features and capabilities. Here are the common types of power
sources used in TIG welding:
Constant Current (CC) Power Source: This type of power source is the most commonly used in TIG
welding. It delivers a stable current output regardless of changes in the arc length. CC power sources
are suitable for welding applications that require precise control over the welding current. They are
often used for welding thin materials and achieving high-quality welds.
Constant Voltage (CV) Power Source: CV power sources maintain a stable voltage output during the
welding process. They are more commonly used in other welding processes, such as MIG (Metal Inert
Gas) welding, but they can also be used for TIG welding when a specific application requires it. CV
power sources are generally not as common in TIG welding as CC power sources.
AC/DC Power Source: An AC/DC power source is versatile and allows for both AC (Alternating
Current) and DC (Direct Current) outputs. It provides the option to switch between AC and DC modes,
making it suitable for welding various materials. AC mode is typically used for welding aluminum and
25
magnesium, while DC mode is used for welding stainless steel, carbon steel, and other metals. AC/DC
power sources offer flexibility and adaptability for a wide range of TIG welding applications.
Inverter Power Source: Inverter-based power sources are gaining popularity in TIG welding due to
their compact size, lightweight, and improved energy efficiency. These power sources use inverter
technology to convert input power into a high-frequency AC current. Inverter power sources offer
enhanced control over the welding parameters, such as arc stability, arc starting, and overall
performance.
Pulse Power Source: Pulse power sources provide the ability to control the peak current and pulse
duration during the welding process. They deliver current in pulse patterns, allowing for better control
over heat input, reducing distortion, and improving weld quality. Pulse power sources are often used in
applications where precise control and fine-tuning of the welding parameters are required, such as
welding thin materials and intricate joints.
When selecting a power source for TIG welding, factors such as the material being welded, the
thickness of the material, desired weld quality, and specific welding requirements should be
considered. The chosen power source should be compatible with the welding application and provide
the necessary control and performance to achieve the desired results.
Fig. 3.4 Power Source
26
3.4.2 Tig torch.
The TIG torch, also known as a GTAW torch (Gas Tungsten Arc Welding torch), is a handheld device
used in TIG welding to hold and manipulate the tungsten electrode and direct the flow of shielding gas.
It plays a crucial role in the welding process by facilitating the creation and control of the arc.
Here are the key components and features of a typical TIG torch:
Handle: The handle of the TIG torch is ergonomically designed to provide a comfortable grip for the
welder. It is insulated to protect the welder from electrical shocks and heat. The handle often
incorporates a trigger or switch to control the flow of welding current.
Torch Head: The torch head houses several important components of the TIG torch, including the
collet, collet body, gas nozzle, and electrode holder.
Collet: The collet is a small metal sleeve that securely holds the tungsten electrode in place. It is
typically made of copper or another conductive material and is threaded to screw into the collet body.
Collet Body: The collet body surrounds the collet and provides a connection between the torch head
and the power cable. It helps hold the collet firmly in place and assists in the flow of shielding gas.
Gas Nozzle: The gas nozzle is attached to the front end of the torch head and serves as a conduit for
the flow of shielding gas. It directs the flow of gas around the tungsten electrode and the weld pool to
protect them from atmospheric contamination. The gas nozzle is often made of ceramic or other nonconductive materials to withstand the heat generated during welding.
Electrode Holder: The electrode holder is a part of the torch head that grips and positions the tungsten
electrode. It provides stability and control over the electrode's position and alignment during welding.
Cable Assembly: The TIG torch is connected to the welding machine's power source through a cable
assembly. The cable carries the electrical current from the power source to the tungsten electrode,
allowing the formation of the welding arc. The cable assembly also includes gas hoses to deliver the
shielding gas from the gas source to the torch head.
Gas Valve: Some TIG torches feature a gas valve integrated into the handle. This valve allows the
welder to control the flow of shielding gas manually, providing additional flexibility during welding.
TIG torches come in various sizes and designs to accommodate different welding applications and
personal preferences. Some torches are water-cooled, meaning they have a water circulating system
built into them to dissipate heat generated during prolonged welding sessions. Water-cooled torches are
often used in high-amperage or continuous welding applications.
It's worth noting that specific torch designs and features may vary among manufacturers and models,
but the fundamental components and functionality remain consistent. The choice of TIG torch depends
on the welding requirements, material thickness, and the level of control and precision desired by the
welder.
27
Fig. 3.5 TIG TORCH
3.4.3 Tungsten electrode.
The tungsten electrode is a key component in TIG (Tungsten Inert Gas) welding. It is a nonconsumable electrode that generates and maintains the welding arc, providing the heat source for
melting the base metal and forming the weld. Here are some important aspects of tungsten electrodes in
TIG welding:
Material Composition: Tungsten is the primary material used for TIG electrodes due to its high
melting point and excellent electrical conductivity. Pure tungsten electrodes are suitable for welding
aluminum and magnesium alloys. However, for welding steel, stainless steel, and other alloys, tungsten
electrodes are alloyed with small amounts of other elements to enhance their performance.
Electrode Size and Shape: Tungsten electrodes come in various diameters and lengths to
accommodate different welding applications and materials. Common sizes range from 1.6 mm (1/16
inch) to 4.8 mm (3/16 inch) or larger. The choice of electrode diameter depends on the welding current,
joint configuration, and base metal thickness.
Tungsten electrodes can have different tip geometries, such as pointed, truncated, or balled. The
selection of electrode shape depends on the desired welding characteristics, such as arc control,
penetration, and electrode life.
Proper Preparation and Grinding: Tungsten electrodes should be properly prepared and ground to
ensure a clean and sharp tip. The tip should be ground to a specific angle, typically between 15 and 30
degrees, depending on the application and welding parameters. Proper grinding helps maintain a stable
arc, improves arc starting, and minimizes the risk of tungsten inclusions or contamination in the weld.
28
Proper selection and preparation of tungsten electrodes are essential for achieving high-quality welds in
TIG welding, including A-TIG welding. It is important to consult the welding procedure specifications
and follow the manufacturer's recommendations for selecting the appropriate tungsten electrode type,
size, and grinding techniques based on the specific welding application and materials being welded.
Fig. 3.6 Tungsten electron.
3.4.4 ERNiCr-3 Filler Wire:
ErNiCr-3 is a type of filler wire that is commonly used in Tungsten Inert Gas (TIG) welding and Gas
Metal Arc Welding (GMAW) processes. It is classified as an AWS A5.14 filler metal and is composed
of nickel, chromium, and molybdenum. ErNiCr-3 is designed specifically for joining and overlaying
nickel-chromium alloys such as Inconel 600, Inconel 601, and Inconel 800.
Here are some applications of ErNiCr-3 filler wire:
Aerospace Industry: ErNiCr-3 is frequently used in the aerospace industry for welding and repairing
components that require high-temperature resistance, such as gas turbine parts, exhaust systems, and
combustion chambers. The filler wire helps maintain the mechanical properties and corrosion
resistance of the nickel-chromium alloys used in these applications.
Petrochemical Industry: ErNiCr-3 is utilized in the petrochemical industry for welding or overlaying
equipment and pipelines that come into contact with corrosive substances and high temperatures. It is
suitable for joining or repairing components in oil refineries, chemical plants, and offshore platforms
where resistance to corrosion and high-temperature environments is crucial.
Power Generation: ErNiCr-3 is employed in the power generation sector for welding and repairing
components in gas and steam turbines, heat exchangers, and boiler systems. These applications often
involve high-temperature and corrosive environments, and ErNiCr-3 filler wire helps maintain the
integrity and performance of the welded joints.
Heat Treatment Furnaces: ErNiCr-3 can be used in the construction and maintenance of heat
treatment furnaces, which require materials with excellent resistance to thermal cycling and hightemperature oxidation. The filler wire helps create reliable welds on the furnace components and
ensures their durability under extreme heat conditions.
29
Chemical Processing: ErNiCr-3 filler wire finds applications in the chemical processing industry for
welding or overlaying components used in the production and handling of corrosive chemicals. It helps
create welds that are resistant to various corrosive environments, including acids, alkalis, and salts.
Nuclear Industry: ErNiCr-3 is used in the nuclear industry for welding and repairing components in
nuclear reactors, including pressure vessels, heat exchangers, and piping systems. The filler wire's
excellent resistance to corrosion and high temperatures makes it suitable for these critical applications.
In summary, ErNiCr-3 filler wire is commonly applied in industries such as aerospace, petrochemicals,
power generation, heat treatment, chemical processing, and nuclear power. It is specifically designed
for joining and overlaying nickel-chromium alloys, providing high-temperature resistance, corrosion
resistance, and mechanical integrity in demanding environments.
Fig. 3.7 ERNiCr-3 filler wire
30
CHAPTER 4
RESULT AND DISCUSSION
4.1 Investigation on weld butt profile:
The weld butt profile in TIG (Tungsten Inert Gas) welding refers to the shape and characteristics of the
welded joint when viewed from the cross-section or side view. The investigation of weld butt profiles in
TIG welding involves analyzing and understanding the different types of profiles that can be achieved
and their impact on the weld quality and strength. Here are some aspects to consider in such an
investigation:
Flat Butt Profile: A flat butt profile is achieved when the two pieces being welded are aligned in a flat
or flush position. This type of profile is often used in applications where aesthetics and a smooth surface
finish are important. The flat butt profile results in a uniform and even weld bead with good fusion
between the base metal and the filler material.
Convex Butt Profile: A convex butt profile is characterized by a slightly raised or rounded shape at the
center of the weld bead. This profile can occur due to various factors, such as excessive heat input, high
welding current, or improper torch manipulation. A convex butt profile may lead to reduced penetration
and incomplete fusion, potentially compromising the weld strength.
Concave Butt Profile: A concave butt profile exhibits a slight indentation or groove at the center of the
weld bead. It is typically caused by insufficient heat input or excessive travel speed during welding. A
concave profile can result in inadequate fusion and penetration, reducing the overall strength of the weld
joint.
Penetration Depth: Investigating the weld butt profile also involves examining the depth of penetration
into the base metal. The desired penetration depth depends on the welding application, material thickness,
and joint design. Proper penetration ensures a strong and reliable weld, while inadequate penetration can
result in weak joints susceptible to failure.
Bead Shape and Width: The investigation of weld butt profiles includes analyzing the shape and width
of the weld bead. The ideal bead shape is typically uniform and evenly spaced, indicating consistent heat
31
distribution and proper filler metal deposition. The width of the bead should match the requirements
specified by the welding standards or project specifications.
To conduct a comprehensive investigation on weld butt profiles in TIG welding, various parameters and
variables should be considered, including welding current, welding speed, torch angle, shielding gas flow
rate, and electrode size. Controlling these parameters and ensuring proper technique and equipment setup
can help achieve the desired butt profile, ensuring weld quality, strength, and integrity.
It's important to note that the investigation of weld butt profiles should be carried out in accordance
with industry standards and guidelines, and the specific requirements of the welding application and
materials being welded.
32
4.1.1Analysis of Macrostructure
Fig. 4.1 Test Coupon 1
Fig.4.2 Test Coupon 2
Fig.4.3 Test Coupon 3
4.1.2 Tensile Test:
•
Test Coupon 1:
S.N
Size (W
X T)
Area
(mm^2)
T1
12.46*4.
92
61.30
Elongati
on (%)
at 4d
36
Ultimat
e Load
(KN)
39.06
U.T.S
(MPa)
637
Y/S
Load
(KN)
23.86
Table 4.1 Tensile Table (Test Coupon 1)
33
Y/S
Load
(MPa)
389
Location
of
Fracture
Parent
Metal
Fig. 4.4 Load- Extension Curve (Test Coupon 1)
Fig. 4.5 Sample (Test Coupon 1)
NOTE:
Load= 39.06 KN when the avg. heat input is 0.60 kJ/mm.
•
Test Coupon 2:
S.N
Size (W
X T)
Area
(mm^2)
T1
12.40*4.
92
61.01
Elongati
on (%)
at 4d
38
Ultimat
e Load
(KN)
39.54
U.T.S
(MPa)
648
Y/S
Load
(KN)
24.08
Table 4.2 Tensile Table (Test Coupon 2)
34
Y/S
Load
(MPa)
395
Location
of
Fracture
Parent
Metal
Fig. 4.6 Load- Extension Curve (Test Coupon 2)
Fig. 4.7 Sample (Test Coupon 2)
NOTE:
Load= 39.54 KN when the avg. heat input is 0.74 kJ/mm.
•
Test Coupon 3:
S.N
Size (W
X T)
Area
(mm^2)
T1
12.50*4.
88
61
Elongati
on (%)
at 4d
41
Ultimat
e Load
(KN)
38.90
U.T.S
(MPa)
638
Y/S
Load
(KN)
23.92
Table 4.3 Tensile Table (Test Coupon 3)
35
Y/S
Load
(MPa)
392
Location
of
Fracture
Parent
Metal
Fig. 4.8 Load- Extension Curve (Test Coupon 3)
Fig. 4.9 Sample (Test Coupon 3)
NOTE:
Load= 38.90 when the avg. heat input is 0.85 kJ/mm.
4.1.3 Chemical Composition:
Test Coupon 1:
Chemical Composition: Stainless Steel
Test Method: JIS:G1253:2013
36
Element
Observation (%)
(Base-1)
C
0.0153
Si
0.465
Mn
1.40
P
0.0299
S
<0.0030
Cr
16.91
Mo
2.06
Ni
10.25
Cu
0.0545
N
0.0342
Table 4.4 SS Chemical Composition (Test Coupon 1)
Chemical Composition: INCONEL
Test Method: ASTM-E-3047-2016
Element
C
Si
S
P
Mn
Cr
Mo
Cu
Co
V
Al
B
Ti
Fe
Nb
Ni
Observation (%)
(Base-2)
Observation (%)
(Weld)
0.0474
0.0376
0.260
0.120
0.0021
<0.0010
0.0095
0.0063
0.191
2.54
21.39
19.72
8.72
0.735
0.0374
0.0111
0.0594
0.0575
0.0773
<0.00050
0.234
0.124
0.00091
0.0032
0.226
0.393
4.40
6.08
3.64
2.38
60.5
67.6
Table 4.5 INCONEL Chemical Composition (Test Coupon 1)
Test Coupon 2:
Chemical Composition: (Stainless Steel)
Test Method:
J:G1253:2013
37
Element
Observation (%)
(Base-1)
C
0.0161
Si
0.482
Mn
1.42
P
0.0313
S
<0.0030
Cr
16.90
Mo
2.05
Ni
10.19
Cu
0.0544
N
0.0375
Table 4.6 SS Chemical Composition (Test Coupon 2)
Chemical Composition: INCONEL
Test Method: ASTM-E-3047-2016
Element
C
Si
S
P
Mn
Cr
Mo
Cu
Co
V
Al
B
Ti
Fe
Nb
Ni
Observation (%)
(Base-2)
Observation (%)
(Weld)
0.0518
0.0255
0.278
0.203
0.0024
<0.0010
0.0104
0.0090
0.192
2.08
21.29
19.57
8.65
1.42
0.0386
0.0202
0.0640
0.0877
0.0769
<0.00050
0.239
0.128
0.00086
0.0030
0.223
0.324
4.41
13.46
3.51
2.21
60.7
60.2
Table 4.7 INCONEL Chemical Composition (Test Coupon 1)
Test Coupon 3:
Chemical Composition: (Stainless Steel)
Test Method: JIS:G1253:2013
38
Element
Observation (%)
(Base-1)
C
0.0149
Si
0.474
Mn
1.40
P
0.0320
S
<0.0030
Cr
16.91
Mo
2.07
Ni
10.2
Cu
0.0559
N
0.0345
Table 4.8 SS Chemical Composition (Test Coupon 3)
Chemical Composition: INCONEL
Test Method: ASTM-E-3047-2016
Element
C
Si
S
P
Mn
Cr
Mo
Cu
Co
V
Al
B
Ti
Fe
Nb
Ni
Observation (%)
(Base-2)
Observation (%)
(Weld)
0.0464
0.0340
0.275
0.175
0.0028
<0.0010
0.0104
0.0089
0.194
2.39
21.36
19.44
8.67
0.894
0.0628
0.0162
0.0628
0.0840
0.0768
<0.00050
0.237
0.116
0.0012
0.0031
0.223
0.356
4.40
11.29
3.50
2.18
60.7
62.8
Table 4.9 INCONEL Chemical Composition (Test Coupon 1)
4.1.4 Heat Input:
Speed= Distance/Time
Heat Input= Voltage*Current*60/ Speed*1000
Test Coupon 1:
39
S.N
1.
2.
3.
Speed (mm/min)
110
80
90
Average H.I
H.I. (Heat Input)(kJ/mm)
0.545
0.641
0.612
0.60
Table 4.10 Heat Input (Test Coupon 1)
Test Coupon 2:
S.N
1.
2.
3.
Speed (mm/min)
120
80
70
Average H.I
H.I. (Heat Input)(kJ/mm)
0.64
0.729
0.86
0.74
Table 4.11 Heat Input (Test Coupon 2)
Test Coupon 3:
S.N
1.
2.
3.
Speed (mm/min)
90
70
60
Average H.I
40
H.I. (Heat Input)(kJ/mm)
0.91
0.75
0.89
0.85
CHAPTER 5
CONCLUSIONS
→ Our materials IN625 & SS316L were perfectly welded
together.
→ All the samples had full penetration.
→ In Test Coupon 2, where the heat input was average= 0.74
kJ/mm, the butt welding of Inconel to SS shows maximum
tensile strength.
→ Test Coupon 3, which has the highest heat input of average
0.85 kJ/mm, had the highest weld width.
→ And Test coupon 3 has the highest Heat Affected Zone
(HAZ).
→ Inconel material melted faster when the current was higher.
→ Coupon 3 has the lowest welding speed & highest Heat Input.
41
CHAPTER 6
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