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Solidification Behavior and Weldability of Dissimilar Welds Between a Cr-Free, Ni-Cu Welding Consumable and Type 304L Austenitic Stainless Steel

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Abstract

The solidification behavior of a Cr-free welding consumable based on the Ni-Cu system was evaluated in conjunction with Type 304L stainless steel. The weld metal microstructure evolution was evaluated with optical and secondary electron microscopy, energy dispersive spectroscopy, X-ray diffraction, button melting, and thermodynamic (CALPHAD-based) modeling. Solidification partitioning patterns showed that higher dilutions of the filler metal by Type 304L increased segregation of Ti, Cu, and Si to interdendritic regions. Button melting experiments showed a widening of the solidification temperature range with increasing dilution because of the expansion of the austenite solidification range and formation of Ti(C,N) via a eutectic reaction. The model predictions showed good correlation with button melting experiments and were used to evaluate the nature of the Ti(C,N) precipitation reaction. Solidification cracking susceptibility of the weld metal was shown to increase with dilution of 304L stainless steel based on testing conducted with the cast pin tear test. The increase in cracking susceptibility is associated with expansion of the solidification temperature range and the presence of eutectic liquid at the end of solidification that wets solidification grain boundaries.

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Notes

  1. MONEL® is a registered trademark of the Special Metals Corporation, Huntington, WV.

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Acknowledgments

The authors thank Mr. Adam Hope for the laboratory work he performed during the course of this project. Consumable production efforts of Euroweld Ltd. and Haynes International are greatly appreciated. The authors wish to acknowledge the financial support of this project by the Strategic Environmental Research and Development Program (SERDP) Project #1415.

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Author notes

  1. Jeffrey W. Sowards (Graduate Research Assistant, Metallurgist) & Dong Liang (Graduate Research Assistant, Project Engineer)

    Present address: NIST, Boulder, CO, 80305, USA

Authors and Affiliations

  1. Welding & Joining Metallurgy Group, The Ohio State University, Columbus, OH, 43210, USA

    Jeffrey W. Sowards (Graduate Research Assistant, Metallurgist), Boian T. Alexandrov (Research Scientist) & John C. Lippold (Professor)

  2. Fontana Corrosion Center, The Ohio State University, Columbus, USA

    Dong Liang (Graduate Research Assistant, Project Engineer) & Gerald S. Frankel (Professor)

  3. DNV, Columbus, OH, USA

    Dong Liang (Graduate Research Assistant, Project Engineer)

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  1. Jeffrey W. Sowards
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  2. Dong Liang
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  5. John C. Lippold
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Corresponding author

Correspondence to Jeffrey W. Sowards.

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Manuscript submitted March 9, 2010

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Sowards, J.W., Liang, D., Alexandrov, B.T. et al. Solidification Behavior and Weldability of Dissimilar Welds Between a Cr-Free, Ni-Cu Welding Consumable and Type 304L Austenitic Stainless Steel. Metall Mater Trans A 43, 1209–1222 (2012). https://doi.org/10.1007/s11661-011-0961-z

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