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The fusion zone and heat-affected zone (HAZ) microstructures obtained during tungsten inert gas (TIG) welding of a commercial superalloy IN 738LC were examined. The microsegregation observed during solidification in the fusion zone indicated that while Co, Cr, and W segregated to the ␥ dendrites, Nb, Ti, Ta, Mo, Al, and Zr were rejected into the interdendritic liquid. Electron diffraction and energydispersive X-ray microanalyses using a transmission electron microscope (TEM) of secondary phases, extracted from the fusion zone on carbon replicas, and of those in thin foils prepared from the fusion zone showed that the major secondary solidification constituents, formed from the interdendritic liquid, were cubic MC-type carbides and ␥-␥Ј eutectic. The terminal solidification reaction product was found to consist of M 3 B 2 and Ni 7 Zr 2 formed in front of the interdendritic ␥-␥Ј eutectic. Based on the knowledge of the Ni-Ti-C ternary system, a pseudoternary solidification diagram was adapted for IN 738 superalloy, which adequately explained the as-solidified microstructure. The HAZ microfissuring was observed in regions surrounding the fusion zone. Closer and careful microstructural examination by analytical scanning electron microscopy revealed formation of re-solidified constituents along the microfissured HAZ grain boundaries, which suggest that HAZ cracking in this alloy involves liquation cracking. Liquation of various phases present in preweld alloy as well as characteristics of the intergranular liquid film contributing to the alloy's low resistance to HAZ cracking were identified and are discussed.

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The effect of filler alloys C-263, , and FM-92 on heat-affected zone (HAZ) cracking susceptibility of cast IN-738 LC, which is a high-temperature Ni-based superalloy used at temperatures up to 980 °C and is precipitation hardened by the ␥Ј (Ni 3 Al,Ti) phase, by gas-tungsten-arc (GTA) welding was studied. In addition, autogenous welds were also made on the IN-738 parent material. The preweld treatments consisted of the standard solution treatment at 1120 °C for 2 hours followed by air cooling, and a new heat treatment, which was developed to improve the HAZ cracking resistance of IN-738 LC. This heat treatment consisted of solution treating at 1120 °C followed by air cooling then aging at 1025 °C for 16 hours followed by water quenching. Welds were observed to suffer intergranular HAZ cracking, regardless of the filler alloy; however, the autogenous welds were most susceptible to HAZ cracking. In general, the cracking tendency for both heat treatments was maximum for C-263 and RENE-41 fillers and decreased with the use of FM-92 and IN-718 filler alloys. The HAZ cracking was associated mainly with constitutional liquation of ␥Ј and MC carbides. On some cracks, liquated low melting point containing Zr-carbosulfide and Cr-Mo borides were also observed to be present. The cooling portion of the weld thermal cycle induced precipitation hardening via ␥Ј phase in the ␥ matrix of the weld metal. The HAZ cracking increased as the weld metal lattice mismatch between ␥Ј precipitates and ␥ matrix of the weld and its hardness (Ti ϩ Al) increased. However, the weld-metal solidus and solidification temperature range, determined by high-temperature differential scanning calorimetry, did not correlate with the HAZ cracking susceptibility. It is suggested that the use of filler alloys with small ␥Ј-␥ lattice mismatch and slow age-hardening response would reduce the HAZ cracking in IN-738 LC superalloy welds.

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The influence of gap size and brazing parameters (temperature and time), on the microstructure and properties of diffusion-brazed Inconel 738 (IN-738) superalloy, was investigated using two commercial brazing alloys, Amdry ‘DF3’ and Nicrobraz 150. The residual liquid present at brazing temperature was observed to transform on cooling into centreline eutectic constituents in ‘NB 150’ brazement while three different dispersed intermetallic phases were observed in the ‘DF3’ joint. The volume fraction of the second phases increased with gap size in both ‘NB 150’ and ‘DF3’ brazements. In addition to the centreline eutectic constituents, nickel and chromium rich borides were observed at the melt back zone in samples brazed below the Ni3B eutectic temperature of 1093°C, and above this temperature only chromium rich borides were observed. Joints containing the second phase intermetallics in ‘NB 150’ and ‘DF3’ brazed materials were found to exhibit tensile properties inferior to that of the base alloy.

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