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Development and Evaluation of Dissimilar Gas Tungsten Arc-Welded Joint of P92 Steel/Inconel 617 Alloy for Advanced Ultra-Supercritical Boiler Applications

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Abstract

In the present research work, an effort has been made to examine the effect of the ERNiCrCoMo-1 filler on solidification mechanism, microstructural characterization, welded joint integrity, and residual stresses of the dissimilar welded joint (DWJ) of martensitic grade P92 steel and Ni-based superalloy Inconel 617 for advanced ultra-supercritical (A-USC) power plant application. Weld joints have been fabricated for V groove geometry by using the multipass gas tungsten arc welding (GTAW) process. The multiple aspects of the welded joint structural integrity have been tested by performing the tensile test, microhardness tests and Charpy impact test. The ERNiCrCoMo-1 weld solidified in austenitic mode with columnar and cellular dendrites in the interior region, while columnar dendrites were observed near the interface region. The unmixed zone (UZ) formation was noticed at the ERNiCrCoMo-1 filler weld and P92 steel interface, while the UZ gets eliminated at Inconel 617 interface. The microstructural observation near the interface showed that migrated grain boundaries were observed frequently near the lower region of the weld metal (WM), while at the interface of the P92 steel and ERNiCrCoMo-1 filler welds, higher density of soft δ ferrite patches for the capping and backing passes were observed. The energy-dispersive spectroscopy (EDS) and X-ray diffraction (XRD) results confirmed the presence of the Cr- and Mo-enriched M23C6 precipitates, Mo-enriched M6C and Ti-enriched Ti(C, N) precipitates in the WM. Acceptable mechanical properties were obtained at room temperature. The Charpy impact toughness (CIT) was observed 98 ± 5 J and 108 ± 3 J for WM with V notch at the top and root region, respectively. The dramatic reduction in CIT was after the postweld heat treatment (PWHT) was attributed to the evolution of the carbide particles in interdendritic areas. Tensile strength results of the cross-weld specimen showed the tensile strength value marginally lower than the P92 steel but significantly lower than the Inconel 617 base metal in both as-welded (AW) and PWHT condition along with fracture in the week region of P92 steel. The failure from the region of P92 steel instead of the ERNiCrCoMo-1 filler WM confirmed that the welded joint was safe for A-USC power plants boiler application. A significant heterogeneity in microhardness was seen along the weldments with a peak hardness of 445 ± 8 in P92 CGHAZ and a lower hardness of 181 HV in the peninsula. The increase in microhardness of the WM as a result of PWHT was attributed to the evolution of the carbide particles in the WM. Through thickness residual stresses variation was also measured for both WM and HAZ region and the effect of the PWHT on the magnitude and nature of the residual stresses were also performed. Hence the work provides insight into welding procedure development, microstructural evolution in the WM and HAZ, variation in mechanical properties, and residual stresses variation for the welded joint of P92 steel and Inconel 617 alloy.

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  1. Department of Mechanical Engineering, Indian Institute of Technology (IIT), Jodhpur, Karwar, Rajasthan, 342037, India

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Kumar, A., Pandey, C. Development and Evaluation of Dissimilar Gas Tungsten Arc-Welded Joint of P92 Steel/Inconel 617 Alloy for Advanced Ultra-Supercritical Boiler Applications. Metall Mater Trans A 53, 3245–3273 (2022). https://doi.org/10.1007/s11661-022-06723-0

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