Metallurgical Characterization of a Weld Bead Coating Applied by the PTA Process on the D2 Tool Steel

Abstract

Abstract:In this investigation, a nickel-base powder mixed with tungsten carbide particles was applied by Plasma Transferred Arc welding (PTA) on the surface of the D2 cold work tool steel to improve surface quality and to extend its lifetime during applications. The Design of Experiment (DoE) method was applied to obtain the appropriate combination of hardfacing parameters and to run the minimum number of tests. Current, travel speed and preheat were considered as variable parameters. These parameters are important to reach a final layer with an appropriate bead geometry accompanied with good metallurgical properties. All samples were prepared for metallurgical investigations and the effect of process parameters on the weld bead geometry was considered. For each experiment run, weld bead geometry parameters were measured including dilution, penetration and reinforcement. Microstructures and the distribution of tungsten carbide particles after welding were analyzed by Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) equipped with an EDS microprobe. In addition, hardness tests were performed to evaluate the mechanical properties of the weld bead layers. Finally, among all the experiments, the best sample with appropriate bead geometry and microstructure was selected.

Experimental investigation and process parameter optimization in cold metal transfer welding for SS304L using response surface method

“…Bead geometry of the deposition of the welded zone is going to be varied based on process parameters: viz welding current, voltage, contact-to-workpiece distance, and travel speed [26]. Among those process parameters current, nozzle to tip distance and travel speed are considered for the experimentation purpose.…”

Comprehensive Investigation of Hastelloy C-22 Powder Weld Overlay on SA 240 Type 316L Using Laser Beam Welding for Enhanced Performance

“…Hardness testing on Hastelloy C-22 weld overlays provides important insights into material quality, weld integrity, heat-affected zone characterization, compliance with acceptance criteria, and quality control. It helps assess the mechanical properties and ensures that the weld overlay meets the required specifications for the intended application [45]. Hardness measurements were performed on transverse cross-sections of the welded specimens using a Vickers hardness tester (Leco, M-400A).…”

Assessment of Plasma Deposition Parameters for DED Additive Manufacturing of AA2319

“…Therefore, arc-DED (directed energy deposition) using wire as feedstock has emerged for printing large structures [4,5]. Amongst the available heat sources [6,7], plasma metal deposition offers higher deposition rates and a better temperature control as well as higher depth-to-width ratios compared to other arc-DED processes [8,9]. These are especially relevant for Al alloys, which are notoriously difficult to deposit [10][11][12].…”