Superalloy—Steel Joint in Microstructural and Mechanical Characterisation for Manufacturing Rotor Components
Abstract
:1. Introduction
- The lack of appropriate production equipment concerning a crack occurrence during the production process [7];
- The wide range of solidification of these alloy types leads to cracks [8];
- Welding of fully cured material promotes the formation of cracks as an effect of the relative inability of the material to compensate for the differential expansion [9].
- -
- Different Inconel superalloy grades;
- -
- Inconel alloys with various austenitic sheets of steel.
Authors | Method | Materials Used and Superalloy Steel | Rotor Application |
---|---|---|---|
Handa V., et al. [53] | Microwave hybrid heating | Inconel with another Inconel or with austenite steel No | No |
Li Y.-F., et al. [54] | Electrically assisted solid-state joining or electrically assisted pressure joining (EAPJ) | 316L steel and Inconel 718 No | No |
Müller R., et al. [55] | Multilayer electron beam cladding (EBC) | Inconel 718 with austenitic stainless steel No | No |
Kumar N, et al. [53] | Rotary friction welded | Inconel 600 with 316L steel No | The joint is not recommended |
Wen Y., et al. [47] | Laser powder with bed fusion materials | Inconel 718 with 316L steel No | No |
Raj S., et al. [48] | Welded dissimilar butt joints friction stir welding | Inconel 718 and AISI 204Cu steel No | The joint is not recommended |
Anuradha M., et al. [49] | Method TIG | Inconel 718 with high-strength steel No | The joint is not recommended |
JP4206216B2 [10] | New method of welding with the interlayers | Inconel with austenitic steel Yes | No |
[27,36,37,38] | Method requires several preparatory steps | High-alloy, heat-resistant martensitic–ferritic steels and nickel-based superalloys Yes | No |
Tomota Y., et al. [58] | No information | Inconel and Low Alloy Steel Yes | Yes but no details on method |
Zhu M. L., et al. [62] | TIG welding and submerged arc welding (SAW) techniques | 23CrMoNiWV88 steel and 26NiCrMoV145 Yes | Yes, but only for the examined materials |
Nivas R., et al. [61] | GTAW with stress relief annealing or | Inconel 82 or with low alloy steel Yes | No |
SMAW with stress relief annealing | Inconel 182 with low alloy steel Yes | No |
2. Materials, Technology and Methods
Tests Details
3. Results and Discussion
3.1. Weld Inspection, Hardness and Microstructure
- There is an occurrence of small cracks in joints made with G19-9NbSi austenitic wire using the following shielding gases: argon and Ar-10% He;
- No defects and inconsistencies for the B level (according to PN-EN ISO 5817: 2005 standard [74]) appeared in joints made with G19-9NbSi austenitic wire and the shielding compound of Ar-5% He;
- No defects or incompatibilities for the B level (according to PN-EN ISO 5817: 2005 standard) occurred after using NiCr23Mo16 electrode wire and a tested shielding gas mixture (Ar-5% He, Ar-10% He).
- Electrode wire: NiCr23Mo16 wire;
- Gas mixture: Ar-5% He, current and welding speed: I3 = 110, V3 = 230 mm/min, I2 = 120 A, I1 = 130 A, V1,2 = 270 mm/min.
- Electrode wire: NiCr23Mo16 wire,
- Gas mixture: Ar-5% He,
- Current and welding speed: I3 = 110, V3 = 230 mm/min, I2 = 120 A, I1 = 130 A, V1,2 = 270 mm/min.
3.2. The Base Metal and MIG Hybrid Weld under Tensile Force
- (a)
- Reorientation of axial and shear stress components follow the degradation of the Alloy 59 as well as differences in their values as stress state components;
- (b)
- In the case of the weld manufactured by means of Alloy 59 and S355J2W+N steel, the proportion between axial and shear stress can be indicated as a constant because the fracturing is represented by one fundamental region.
4. Novelty and Application
- The MIG process at the determined parameters can be directly used for mixed joint manufacturing;
- The welding process does not require additional devices or systems, i.e., cooling or heating;
- The hourglass specimen with a weld in its middle region of a measurement section is very useful for determining the joint quality;
- For mixed joint quality, the fundamental features of the joint such as stress–strain characteristics, mechanical parameters and hardening curves for analytical and FEA approaches are determined.
- Improvement of welding technology for other mixed metal joints;
- Power plant industry for operational conditions at elevated temperatures and inspections for replacing selected components due to failure;
- Analytical and numerical approaches for superalloy and steel welding using the collected results;
- Forecasting service life using the determined mechanical parameters of the joint.
5. Summary
- It is possible to make a correct mixed joint made of S355J2W + N steel and Alloy 59 using the MIG process without welding defects and incompatibilities.
- The MIG connection technology with one-side bevelling and using NiCr23Mo16 nickel-based electrode wire and Ar-5% He shielding gas is the correct choice.
- The parameters of the welding technology for joining superalloy (Alloy 59) and S355 steel:
- o
- Electrode wire: NiCr23Mo16 wire,
- o
- Gas mixture: Ar-5% He, current and welding speed: I3 = 110, V3 = 230 mm/min, I2 = 120 A, I1 = 130 A, V1,2 = 270 mm/min.
- The mixed weld had excellent mechanical properties: yield stress (248 MPa) and ultimate tensile strength (518 MPa) values, which means the joint can be applied to rotor structural elements.
- In the case of the superalloy and mixed joint, the hardening sections of the tensile curves were very similar in shape, and digital results represented almost the same values of power law coefficients.
- The fracturing of the steel and mixed weld was expressed by the one fundamental decohesion region, which has reflected the constant proportion of values of axial and shear stress components up to the separation.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Parameters of the Lower Stitch Pattern | Parameters of the Upper Stitch Pattern | Shielding Gases | YS, [MPa] | UTS, [MPa] | UTS/YS |
---|---|---|---|---|---|
U = 21 V I3 = 110 V3 = 230 mm/min | U = 21 V I2 = 120 A I1 = 130 A V1,2 = 240 mm/min | Ar-5% He | 365 | 553 | 1.52 |
Ar-10% He | 346 | 547 | 1.58 | ||
U = 21 V I3 = 120 V3 = 210 mm/min | U = 21 V I2 = 140 A I1 = 150 A V1,2 = 220 mm/min | Ar-5% He | 341 | 537 | 1.57 |
Ar-10% He | 333 | 534 | 1.60 |
Parameters of: | Hardness in Point: | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
The Lower Stitch Pattern | The Upper Stitch Pattern | Shielding Gases | ||||||||||
A | B | C | D | E | F | H | I | J | K | |||
U = 21 V I3 = 110 V3 = 230 mm/min | U = 21 V I2 = 120 A I1 = 130 A V1,2 = 270 mm/min | Ar-5% He | 371 | 345 | 333 | 250 | 224 | 376 | 347 | 330 | 286 | 186 |
Ar-10% He | 378 | 352 | 346 | 248 | 231 | 378 | 354 | 345 | 298 | 184 | ||
U = 21 V I3 = 120 V3 = 200 mm/min | U = 21 V I2 = 140 A I1 = 150 A V1,2 = 220 mm/min | Ar-5% He | 372 | 346 | 329 | 246 | 218 | 371 | 353 | 330 | 291 | 188 |
Ar-10% He | 380 | 355 | 341 | 251 | 227 | 375 | 358 | 339 | 296 | 185 |
Structural Materials | ||
Alloy 59 (base metal) | S355J2W+N (base metal) | Alloy 59—S355J2W+N (MIG weld) |
Power law | ||
1205 ε 0.2360 | 944.24 ε 0.1559 | 1120 ε 0.2643 |
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Szczucka-Lasota, B.; Szymczak, T.; Węgrzyn, T.; Tarasiuk, W. Superalloy—Steel Joint in Microstructural and Mechanical Characterisation for Manufacturing Rotor Components. Materials 2023, 16, 2862. https://doi.org/10.3390/ma16072862
Szczucka-Lasota B, Szymczak T, Węgrzyn T, Tarasiuk W. Superalloy—Steel Joint in Microstructural and Mechanical Characterisation for Manufacturing Rotor Components. Materials. 2023; 16(7):2862. https://doi.org/10.3390/ma16072862
Chicago/Turabian StyleSzczucka-Lasota, Bożena, Tadeusz Szymczak, Tomasz Węgrzyn, and Wojciech Tarasiuk. 2023. "Superalloy—Steel Joint in Microstructural and Mechanical Characterisation for Manufacturing Rotor Components" Materials 16, no. 7: 2862. https://doi.org/10.3390/ma16072862