Investigation on joining P91 steel and Incoloy 800HT through gas tungsten arc welding for Advanced Ultra Super Critical (AUSC) power plants

Bhanu, Vishwa; Gupta, Ankur; Pandey, Chandan

doi:10.1016/j.jmapro.2022.06.029

Cited by 20 publications

(7 citation statements)

References 39 publications

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“…This method estimates the locked-in stresses from the deformation of a reference hole following material removal [ 37 , 38 , 39 ]. The DHD process mainly involves four steps: (1) drilling of a reference hole; (2) measuring the hole diameter by an air probe; (3) trepanning the reference hole using EDM; and (4) re-measuring the hole diameter by an air probe [ 40 , 41 ]. Figure 22 shows the residual stress distribution throughout the thickness at three positions along the height of deposition, one on mild steel, one at the interface and one on the stainless steel portion, as shown in Figure 4 in Section 2 .…”

Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on the arc welding process in which wire is melted by an electric arc and deposited layer by layer. Due to the cost and rate benefits over powder-based additive manufacturing technologies and other alternative heat sources such as laser and electron beams, the process is currently receiving much attention in the industrial production sector. The gas metal arc welded (GMAW) based WAAM process provides a higher deposition rate than other methods, making it suitable for additive manufacturing. The fabrication of mild steel (G3Si1), austenitic stainless steel (SS304), and a bimetallic sample of both materials were completed successfully using the GMAW based WAAM process. The microstructure characterization of the developed sample was conducted using optical and scanning electron microscopes. The interface reveals two discrete zones of mild steel and SS304 deposits without any weld defects. The hardness profile indicates a drastic increase in hardness near the interface, which is attributed to chromium migration from the SS304. The toughness of the sample was tested based on the Charpy Impact (ASTM D6110) test. The test reveals isotropy in both directions. The tensile strength of samples deposited by the WAAM technique measured slightly higher than the standard values of weld filament. The deep hole drilling (DHD) method was used to measure the residual stresses, and it was determined that the stresses are compressive in the mild steel portion and tensile in austenitic stainless steel portion, and that they vary throughout the thickness due to variation in the cooling rate at the inner and outer surfaces.

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Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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“…Naffakh et al [ 40 ] identified NbC particles in the inter-dendritic regions of the IN657/AISI 310 joint. The segregation of Nb, Mo, and Cr elements was also observed in GTAW joints of dissimilar metals, namely Incoloy 800 and P91 [ 41 , 42 ]. Moreover, the secondary phases identified in the weld metal exhibited comparable morphology and composition to those found in the IN617 BM.…”

Section: Resultsmentioning

confidence: 99%

Dissimilar autogenous TIG joint of Alloy 617 and AISI 304H steel for AUSC application

Sirohi,

Kumar,

Pandey

et al. 2023

Heliyon

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“…Using GTAW with ERNiCrCoMo-1 filler, the dissimilar metal weld between P91 and IN 800HT gave optimum weld strength with impact toughness of 117 J in the AW state and 102 J in a postweld heat treatment (PWHT) state (Ref. 8). The mismatch-related failures involving mechanical properties mismatched between base metal and filler and mismatched in coefficient of thermal expansion are detrimental.…”

Section: Introductionmentioning

confidence: 99%

Microstructure-Linked Mechanical Properties of P91-Incoloy 800HT Dissimilar Metal Welds

BHANU,

GUPTA,

PANDEY

2024

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Dissimilar metal welds (DMWs) between P91 steel and Incoloy 800HT® using shielded metal arc welding (SMAW) with ENiCrCoMo-1 filler electrode were characterized in detail. The impact of multiple weld passes on microstructure in the heat-affected zone (HAZ) and weld fusion zone (WFZ) was thoroughly investigated. Postweld heat treatment (PWHT) impacts on mechanical characteristics and microstructure were also observed. The DMW was observed with heavy C, Cr, and Mo microsegregation in the WFZ, which deteriorated mechanical strength. The microstructural changes directly affected the mechanical behavior of the DMW. The ultimate tensile strength of the weld fusion zone was low at 576 MPa compared to the base metals’ strength. The tensile specimens failed in the IN 800HT base metal and WFZ. The WFZ had significant microsegregation near the solidified grain boundaries (SGBs). The metallurgical heterogeneity in the WFZ caused the formation of localized stress zones, which directly affected the mechanical behavior of the WFZ. The carbide particles influenced the microhardness in the WFZ and P91 HAZ regions. The PWHT successfully homogenized the microhardness in the WFZ and P91 HAZ regions. The impact toughness decreased to 64 J from 82 J after PWHT due to precipitation at SGBs and its coarsening. The SMAW process involves multiple thermal cycles during welding. The deposition of filler metal in multiple welding passes created uncontrolled variations in the solidification behavior of the WFZ. Microsegregation had a detrimental impact on the microstructure and mechanical properties of the P91 and IN 800HT dissimilar metal welds.

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Investigation on joining P91 steel and Incoloy 800HT through gas tungsten arc welding for Advanced Ultra Super Critical (AUSC) power plants

Cited by 20 publications

References 39 publications

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Dissimilar autogenous TIG joint of Alloy 617 and AISI 304H steel for AUSC application

Microstructure-Linked Mechanical Properties of P91-Incoloy 800HT Dissimilar Metal Welds

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