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Thermal and Weld Bead Characteristics of Bead-on-Plate PGMA Welding of Dissimilar ASS Bead on HSLA Plate

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Abstract

The research work has focused on identifying the influence of pulsed gas metal arc welding (PGMAW) parameters on the austenitic stainless steel (ASS) weld bead on high-strength low-alloy (HSLA) steel plate. The effect of pulse parameters such as dimensionless factor (ϕ), mean current (Im), and heat input (Ω) has been analyzed on the thermal behavior of weld, weld pool geometry, and the weld bead microstructure. The influence of ϕ on the thermal and metal transfer behaviors has been also examined to produce the desired weld bead quality. The optimized pulse parameters such as Im (160–230 A), Ω (6.5–11.2 kJ/cm), ϕ (0.05–0.25), and welding speed (S) (15–25 cm/min) have been considered to perform the experiment. The microstructural evaluation of the weld bead was carried out by an optical microscope. The enhanced Im from 160 A to 230 A considerably increased the amount of temperature received by the weld pool (QT) from 4525 to 6525 J/S. The results also depicted that the increase of ϕ from 0.05 to 0.25 predominantly reduced the width of the weld bead (Wb) from 15 to 13.5 mm, depth of penetration (Pd) from 3.5 to 2.5 mm, and area of fusion (Af) from 40 to 30 mm2, respectively. It is also found that the formation of fine-grain microstructure in the weld deposit primarily happened due to the effect of thermal behaviors such as QT, transfer of heat content from filler to weld pool (Qf), and characteristics of filler metal transfer to the weld deposition.

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Abbreviations

a h, b h, c h :

Ellipsoidal heat source parameters (m)

a h, b h, c hf, c hb :

Double ellipsoidal heat source parameters (m)

A s :

Surface area of the droplets transferred per pulse (m2)

A F :

Area of fusion (mm2)

A R :

Area of reinforcement (mm2)

A W :

Cross-sectional area of the filler wire, m2 or Area of weld deposit (m2)

b :

Thermal diffusivity of HSLA steel 1.172 × 10−5 (m2/sec)

C 1 :

Specific heat of ASS = 0.500 (J g−1 K−1)

C 2 :

Specific heat of HSLA Steel = 0.686 (J g−1 K−1)

C R :

Cooling rate (K/sec)

D :

Diameter of droplets (m)

d :

Thickness of the base plate (m)

D L :

Dilution of weld deposit (%)

f :

Pulse frequency (Hz)

G :

Solidification temperature gradient

HSLA:

High-strength low-alloy steel

I :

Welding current (A)

Nu:

Nusselt number

Ω:

Heat input per unit length of weld (kJ cm−1)

N D :

Number of droplets transfer per pulse

Q AW, ρ 1, ρ 2, c 1, c 2, a, b, T 0 and a h, b h, c hf, c hb :

Weld pool heat exchanged from the arc

Q AW :

Arc heat transferred to the weld pool (J s−1)

Q de :

Heat content per unit mass of the filler wire at the time of deposition (J kg−1)

Q f :

Heat of the filler metal transferred to the weld pool (J s−1)

Q r :

Heat generated due to resistive heating of the filler wire (J s−1)

Q R :

Heat loss during flight of the droplets due to radiation (J kg−1)

Q T :

Total heat transferred per unit time (J s−1)

R G :

Growth rate of dendrite (cm/min)

R LG :

Ripple lag ratio

S :

Welding speed (cm/min)

T :

Temperature (K)

T de :

Temperature at any point in the weld due to arc heating (K)

ρ 1 :

Mass density of the ASS (kg m−3)

ρ 2 :

Mass density of the HSLA steel (kg m−3

ϕ :

Summarized influence of pulse parameters factor

ζ :

Work function of the cathode surface (Mild steel = 4.5 eV)

λ 1 :

Thermal diffusivity of γ-SS × 10−6 (m2/sec)

λ 2 :

Thermal diffusivity of Mild steel 1.172 × 10−6 (m2/sec)

I b :

Base current (A)

I e :

Peak current in excess over the base current (A)

I eff :

Effective current (A)

c hf :

Front side of the heat source

c hb :

Back side of the heat source

I m :

Mean current (A)

m t :

Mass of filler metal transmitted per pulse (kg)

I p :

Peak current (A)

t p :

Peak time in (ms)

t b :

Base time in (ms)

j eff :

Effective current density (J A−2)

k 1 :

Thermal conductivity of γ-SS = 16 (W m−1 K−1)

k 2 :

Thermal conductivity of Mild Steel = 60 (W m−1 K−1)

R and ξ :

Central and x-axis distance of the welding arc (mm)

L d :

Length of dendrite arm (μm)

L rg :

Length of ripple lag (mm)

L w :

Weld length (mm)

R and ξ :

Central and x-axis distance of the welding arc (mm)

T de :

Temperature of the droplet at the time of deposition (K)

T m :

Melting temperature (K)

T WP :

Average weld pool temperature (K)

V :

Arc voltage (V)

V eff :

Effective velocity of plasma (m s−1)

V W :

Wire feed speed (m s−1)

x, y, z :

Rectangular coordinates w.r.t. to a fixed origin

x hw :

Distance between the heat source and the rear of the weld pool (mm)

ASS:

Austenitic stainless steel

ξ:

Distance of the point along the x-axis with respect to the origin of moving heat source (m)

ψ:

Effective melting potential at anode (Mild steel = 5.8 V) or angle between the tangent to the weld pool boundary and the welding direction (deg)

η s :

Process efficiency

t :

Time (sec)

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Acknowledegments

The authors acknowledge the Board of Research in Nuclear Sciences (BRNS) for the material support to carry out this work and record their sincere thanks.

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Authors and Affiliations

  1. School of Mechanical Engineering, Vellore Institute of Technology, Vellore, 632014, Tamilnadu, India

    G. Rajamurugan & Prabu Krishnasamy

  2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Roorkee, 247667, Uttarakhand, India

    P. K. Ghosh

  3. Department of Mechanical Engineering, Bannari Amman Institute of Technology, Sathyamangalam, 638401, Tamilnadu, India

    D. Dinesh & S. M. Vinukumar

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  1. G. Rajamurugan
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Rajamurugan, G., Ghosh, P.K., Krishnasamy, P. et al. Thermal and Weld Bead Characteristics of Bead-on-Plate PGMA Welding of Dissimilar ASS Bead on HSLA Plate. Trans Indian Inst Met 74, 89–106 (2021). https://doi.org/10.1007/s12666-020-02106-4

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