Effect of residual stress relaxation by means of local rapid induction heating on stress corrosion cracking behavior and electrochemical characterization of welded Ti-6Al-4V alloy under slow strain rate test
“…temperature, has been widely applied to welds; PWHT reduces tensile residual stress by tempering the HAZ and weld metal [8][9][10], improves microstructural homogeneity and toughness, and decreases the corrosion rate [11]. For this reason, standards and codes related to manufacturing or construction by welding generally require or recommend PWHT after welding.…”
This study analyzes the effects of post-weld heat treatment (PWHT) on the mechanical properties and microstructures of SA-508 Gr.1a welds and proposes a new PWHT exemption criterion based on nonductile fracture evaluation considering welding residual stress. The welding coupons were prepared with submerged-arc welding, gas-tungsten arc welding, and shielded-metal arc welding, using ferritic steel, SA-508 Gr.1a. The microstructure of the heat-affected zone (HAZ) was analyzed using optical microscopy, electron-back-scatter diffraction and Vickers hardness testing. The mechanical properties of the welds were evaluated by uniaxial tensile test, transverse side bend test, Charpy V-notch impact test and side bend test. Bainite and ferrite structures formed mainly in the HAZ, and the grain size became coarser with proximity to the surface and fusion line. The mechanical properties did not depend strongly on PWHT, weldment thickness or welding techniques, and they satisfied the welding procedure qualification test specified in the ASME Boiler & Pressure Vessel code. Welding residual stresses were considered in assessing structural integrity using nonductile fracture evaluation. A margin of safety against nonductile fracture with residual stress was calculated for Korean Standard Nuclear Power Plant steam-generator welds, using its design parameters and operating conditions, and this safety margin is suggested as an acceptance criterion for residual stress for exemption from PWHT.
Graphic abstract
“…temperature, has been widely applied to welds; PWHT reduces tensile residual stress by tempering the HAZ and weld metal [8][9][10], improves microstructural homogeneity and toughness, and decreases the corrosion rate [11]. For this reason, standards and codes related to manufacturing or construction by welding generally require or recommend PWHT after welding.…”
This study analyzes the effects of post-weld heat treatment (PWHT) on the mechanical properties and microstructures of SA-508 Gr.1a welds and proposes a new PWHT exemption criterion based on nonductile fracture evaluation considering welding residual stress. The welding coupons were prepared with submerged-arc welding, gas-tungsten arc welding, and shielded-metal arc welding, using ferritic steel, SA-508 Gr.1a. The microstructure of the heat-affected zone (HAZ) was analyzed using optical microscopy, electron-back-scatter diffraction and Vickers hardness testing. The mechanical properties of the welds were evaluated by uniaxial tensile test, transverse side bend test, Charpy V-notch impact test and side bend test. Bainite and ferrite structures formed mainly in the HAZ, and the grain size became coarser with proximity to the surface and fusion line. The mechanical properties did not depend strongly on PWHT, weldment thickness or welding techniques, and they satisfied the welding procedure qualification test specified in the ASME Boiler & Pressure Vessel code. Welding residual stresses were considered in assessing structural integrity using nonductile fracture evaluation. A margin of safety against nonductile fracture with residual stress was calculated for Korean Standard Nuclear Power Plant steam-generator welds, using its design parameters and operating conditions, and this safety margin is suggested as an acceptance criterion for residual stress for exemption from PWHT.
Graphic abstract
“…As an important factor in influencing the corrosion behavior of welded structures, residual stress has obvious impacts on the corroded damaging rate of welded structures [32][33][34][35]. However, most reports focus on the impact of residual stress on the corrosion behavior in the research of corroded welded structures, but mutual effects between residual stress and corrosion damages are ignored.…”
The nucleation mechanism of corrosion cracks in welded structures in natural seawater has been revealed through investigation on the corrosion behavior of X65-welded structures in natural seawater. The evolution laws of surface corrosion morphology, residual stress, and areas of welded structures with the most serious corrosion damage were analyzed by microstructure observation, corrosion morphology observation, residual stress detection, and magnetic field detection. The results show that the main factors of determining surface corrosion morphology evolution law of welded structures are microstructures of the weld joint, heat-affected zone (HAZ), and the fusion line. Due to the difference of corrosion rates between the weld joint, HAZ, and the coarse Widmänstatten structure in fusion line, the fusion line of welded structures receives the most serious damage while being corroded. Meanwhile, mutual reinforcement of residual stress and corrosion damage on the surface of welded structures further accelerate the nucleation of corrosion cracks. Under the influences of microstructure, residual stress, and corrosion, corrosion cracks that are parallel to weld joints generate first in the fusion line of welded structures. Therefore, it makes welded structures the source of marine steel structures’ corrosion failure.
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