Mechanical and microstructural characterization of AISI SAE 4130 steel welded joints made by robotic gas metal arc welding process: influence of electrode work angle in 'T' welded joints

Abstract

Microstructural variations within welded metals, specifically in terms of phases and their corresponding volume fractions, play a crucial role in influencing weld strength and other mechanical properties. Welded joints in a ‘T’ configuration pose a unique challenge due to the dynamic heat distribution caused by changes in the electrode work angle (EWA) between perpendicularly aligned plates. This study focuses on characterizing the microstructure and micro-hardness of ‘T’ welded joints in a 6 mm thick plate of AISI SAE 4130, welded using the robotic gas metal arc welding process. The examination covers three distinct zones: the base material (BM), the fusion zone (FZ), and the heat-affected zone (HAZ). The extent of the HAZ is meticulously measured on both the vertical and horizontal plates within the weld zones. The x-ray diffraction (XRD) analysis results indicated that the average crystallite size of the base metal and fusion zone is 25.75 nm and 24.51 nm respectively. As per the scanning electron microscope (SEM) image observations, the higher wire feed rate yields to brittle fracture surface. The torch angles notably influence the dimensions of the HAZ on the vertical and horizontal plates of a ‘T’-Joint. Welding at higher EWA and contact-tip-work-distance, results in a larger HAZ on the vertical plate. Conversely, employing a flattened EWA and an increased contact-tip-work-distance leads to a greater extent of the HAZ on the horizontal plate. Furthermore, the micro-hardness of the fusion zone and heat-affected zone demonstrates an increase at higher settings of wire feed rate and travel speed. This phenomenon is attributed to the elevated heat inputs, which contribute to the formation of a finer microstructure within the weldment.