Influences of Filler Metals on Microstructure and Mechanical Characteristics of GTA Weld Carbon Steel/ Austenitic Stainless Steel Dissimilar Metal Joint

Abstract:

The structural requirements for power plants service environment characteristically demand for welded joints of multi-materials and hybrid structures. The excellent corrosion resistance of AISI 316 and API 5L X56; the negligible response of AISI 316 to magnetic field and the economic viability of API 5L X56 makes these alloy considerable as hybrid structure in power plants application. Also, the appropriate filler metals that will support the intended properties for the proposed service condition is critical for a quality Dissimilar metal welded joint (DMWJ). This study investigates the effect of filler metals on the microstructural and mechanical properties of DMWJ produced from carbon steel API 5L X56 and stainless steel 316L using Gas Tungsten Arc (GTA) welding techniques. The DMWJs were produced using duplex ER2209, austenitic ER308 and austenitic ER316 grade filler. Microstructural evaluation of the joints revealed macro segregation occurrence and formation of type II boundaries at the interface of API 5L X56 steel. In tension tests, the ER2209 filler metal joints showed the maximum ultimate tensile strength values compared to the welds of other filler metals. The average yield strengths of the three welded joints were higher than those of AISI 316L base metal (BM), which indicates that the yield strength of all the welded joints can satisfy the minimum requirements of engineering application for the API 5L X56/AISI 316L DMWJs. The highest hardness value of about 237.5Hv was obtained in the ER2209 filler metal weld. Keywords: AISI 316; API 5L X56; Dissimilar metal welds; GTAW; Mechanical properties; Microstructural characteristics.

• Periodical: Key Engineering Materials (Volume 1012)
• Pages: 41-56
• DOI: https://doi.org/10.4028/p-5R7pvr
• Online since: May 2025
• Authors: Waidi Saka*, Taiwo F. Lawal, M. O. H. Amuda
• Keywords: AISI 316, API 5L X56, Dissimilar Metal Welds, GTAW, Mechanical Properties, Microstructural Characteristic

References

[1] Yan, T. F., Wang, G. Z., Wang, K., Xuan, F. Z., and Tu, S. T. (2021). Limit loads of dissimilar metal welded joints for joining safe end to pipe-nozzle of nuclear pressure vessel. International Journal of Pressure Vessels and Piping, 194, 104554.

DOI: 10.1016/j.ijpvp.2021.104554

[2] Murthy, A. R., Gandhi, P., Vishnuvardhan, S., and Sudharshan, G. (2020). Crack growth analysis and remaining life prediction of dissimilar metal pipe weld joint with circumferential crack under cyclic loading. Nuclear Engineering and Technology, 52(12), 2949–2957.

DOI: 10.1016/j.net.2020.06.001

[3] Dev, S., Ramkumar, K. D., Arivazhagan, N., and Rajendran, R. (2018). Investigations on the microstructure and mechanical properties of dissimilar welds of inconel 718 and sulphur rich martensitic stainless steel, AISI 416. Journal of Manufacturing Processes, 32, 685–698.

DOI: 10.1016/j.jmapro.2018.03.035

[4] Corleto, C. R., and Argade, G. R. (2017). Failure analysis of dissimilar weld in heat exchanger. Case Studies in Engineering Failure Analysis, 9, 27–34.

DOI: 10.1016/j.csefa.2017.05.003

[5] Sirohi, S., Kumar, A., Pandey, S. M., Purohit, P., Fydrych, D., Kumar, S., and Pandey, C. (2023). Dissimilar autogenous TIG joint of Alloy 617 and AISI 304H steel for AUSC application. Heliyon, 9(9), e19945.

DOI: 10.1016/j.heliyon.2023.e19945

[6] Seo, W. G., Suh, J. Y., Shim, J. H., Lee, H., Yoo, K., and Choi, S. H. (2020). Effect of post-weld heat treat ment on the microstructure and hardness of P92 steel in IN740H/P92 dissimilar weld joints. Materials Characterization, 160:110083.

DOI: 10.1016/j.matchar.2019.110083

[7] Wen, J. B., Zhou, C. Y., Li, X., Pan, X. M., Chang, L., Zhang, G. D., Xue, F., and Zhao, Y. F. (2019). Effect of temperature range on thermal-mechanical fatigue properties of P92 steel and fatigue life prediction with a new cyclic softening model. International Journal of Fatigue, 129, 105226.

DOI: 10.1016/j.ijfatigue.2019.105226

[8] Abe, F. (2016). Progress in creep-resistant steels for high efficiency coal-fired power plants. Journal of Pressure Vessel Technology, 138(4), 040804.

DOI: 10.1115/1.4032372

[9] Maziasz, P. J. (2018). Development of creep-resistant and oxidation-resistant austenitic stainless steels for high temperature applications. JOM, 70(1), 66–75.

DOI: 10.1007/s11837-017-2642-x

[10] Dak, G., Singh, V., Kumar, A., Sirohi, S., Bhattacharyya, A., Pandey, C., and Pandey, S. M. (2023). Microstructure and mechanical behavior study of the dissimilar weldment of'IN82 buttered'P92 steel and AISI 304L steel for ultra-super critical power plants. Materials Today Communications, 37, 107552.

DOI: 10.1016/j.mtcomm.2023.107552

[11] Dak, G., Sirohi, S., and Pandey, C. (2022). Study on microstructure and mechanical behavior relationship for laser-welded dissimilar joint of P92 martensitic and 304L austenitic steel. International Journal of Pressure Vessels and Piping, 196, 104629.

DOI: 10.1016/j.ijpvp.2022.104629

[12] Kim, M. Y., Kwak, S. C., Choi, I. S., Lee, Y. K., Suh, J. Y., Fleury, E., Jung, W. S., and Son, T. H. (2014). High-temperature tensile and creep deformation of cross-weld specimens of weld joint between T92 martensitic and Super304H austenitic steels. Materials Characterization, 97, 161–168.

DOI: 10.1016/j.matchar.2014.09.011

[13] Liang, Z., Zhao, Q., Deng, J., and Wang, Y. (2018). Influence of Aging treatment on the microstructure and mechanical properties of T92/Super 304H dissimilar metal welds. Materials at High Temperatures, 35(4), 327–334.

DOI: 10.1080/09603409.2017.1334857

[14] Deng, J., Liang, Z., Hui, S. E., and Zhao, Q. (2015). Aging treatment on the microstructures and mechanical properties of new groove T92/Super 304H dissimilar steel joints. High Temperature Materials and Processes, 34(5), 425–433.

DOI: 10.1515/htmp-2014-0067

[15] Kumar, R., Varma, A., Kumar, Y. R., Neelakantan, S., and Jain, J. (2022). Enhancement of mechanical properties through modified post-weld heat treatment processes of T91 and Super304H dissimilar welded joint. Journal of Manufacturing Processes, 78, 59-70.

DOI: 10.1016/j.jmapro.2022.04.008

[16] Sirohi, S., Pandey, C., and Goyal, A. (2021). Role of the Ni-based filler (IN625) and heat-treatment on the mechanical performance of the GTA welded dissimilar joint of P91 and SS304H steel. Journal of Manufacturing Processes, 65, 174-189.

DOI: 10.1016/j.jmapro.2021.03.029

[17] Thakare, J. G., Pandey, C., Mahapatra, M. M., and Mulik, R. S. (2019). An assessment for mechanical and microstructure behavior of dissimilar material welded joint between nuclear grade martensitic P91 and austenitic SS304 L steel. Journal of Manufacturing Processes, 48, 249-259.

DOI: 10.1016/j.jmapro.2019.10.002

[18] Rogalski, G., Świerczyńska, A., Landowski, M., and Fydrych, D. (2020). Mechanical and Microstructural Characterization of TIG Welded Dissimilar Joints between 304L Austenitic Stainless Steel and Incoloy 800HT Nickel Alloy. Metals, 10, 559.

DOI: 10.3390/met10050559

[19] Adomako, N. K., Park, H. J., Cha, S. C., Lee, M., & Kim, J. H. (2021). Microstructure evolution and mechanical properties of the dissimilar joint between IN718 and STS304. Materials Science and Engineering: A, 799, 140262.

DOI: 10.1016/j.msea.2020.140262

[20] Shim, J. H., Povoden-Karadeniz, E., Kozeschnik, E., and Wirth, B. D. (2015). Modeling precipitation thermodynamics and kinetics in type 316 austenitic stainless steels with varying composition as an initial step toward predicting phase stability during irradiation. Journal of Nuclear Materials, 462, 250–257.

DOI: 10.1016/j.jnucmat.2015.04.013

[21] Was, G. S., and Ukai, S. (2019). Austenitic stainless steels. In Structural alloys for nuclear energy applications (p.293–347). Elsevier.

DOI: 10.1016/b978-0-12-397046-6.00008-3

[22] Gope, D. K., and Chattopadhyaya, S. (2022). Dissimilar welding of nickel-based superalloy with stainless steel: Influence of post weld heat treatment. Materials and Manufacturing Processes, 37(2), 136–142.

DOI: 10.1080/10426914.2021.1945095

[23] Kulkarni, A., Dwivedi, D. K., and Vasudevan, M. (2020). Microstructure and mechanical properties of A-TIG welded AISI 316L SS-Alloy 800 dissimilar metal joint. Materials Science and Engineering, 790, 139685.

DOI: 10.1016/j.msea.2020.139685

[24] Kulkarni, A., Dwivedi, D. K., and Vasudevan, M. (2019). Dissimilar metal welding of P91 steel-AISI 316L SS with Incoloy 800 and Inconel 600 interlayers by using activated TIG welding process and its effect on the microstructure and mechanical properties. Journal of Materials Processing Technology, 274, 116280.

DOI: 10.1016/j.jmatprotec.2019.116280

[25] Kourdani, A., and Derakhshandeh-Haghighi, R. (2018). Evaluating the properties of dissimilar metal welding between Inconel 625 and 316L stainless steel by applying different welding methods and consumables. Metallurgical and Materials Transactions A, 49(4), 1231–1243.

DOI: 10.1007/s11661-018-4469-7

[26] Ramkumar, T., Selvakumar, M., Narayanasamy, P., Begam, A. A., Mathavan, P., and Raj, A. A. (2017). Studies on the structural property mechanical relationships and corrosion behaviour of Inconel 718 and SS 316L dissimilar joints by TIG welding without using activated flux. Journal of Manufacturing Processes, 30, 290–298.

DOI: 10.1016/j.jmapro.2017.09.028

[27] Vidyarthy, R. S., Kulkarni, A., and Dwivedi, D. K. (2017). Study of microstructure and mechanical property relationships of A-TIG welded P91–316L dissimilar steel joint. Materials Science and Engineering: A, 695, 249-257. Petroleum Institute.

DOI: 10.1016/j.msea.2017.04.038

[28] Gao, X., Shao, Y., Xie, L., and Yang, D. (2020). Behavior of API 5-L X56 submarine pipes under transverse impact. Ocean Engineering, 206, 107337.

DOI: 10.1016/j.oceaneng.2020.107337

[29] Sharma, S. K., and Maheshwari, S. (2017). A review on welding of high strength oil and gas pipeline steels. Journal of Natural Gas Science and Engineering, 38, 203–217.

DOI: 10.1016/j.jngse.2016.12.039

[30] Ramesh, A. P., Subramaniyan, M., and Eswaran, P. (2019). Review on friction welding of similar/dissimilar metals. Journal of Physics: Conference Series, 1362(012032), 1–16.

DOI: 10.1088/1742-6596/1362/1/012032

[31] Shi, H., Chen, K., Liang, Z., Dong, F., Yu, T., Dong, X., Zhang, L., and Shan, A. (2017). Intermetallic compounds in the banded structure and their effect on mechanical properties of Al/Mg dissimilar friction stir welding joints. Journal of Materials Science and Technology, 33(4), 359–366.

DOI: 10.1016/j.jmst.2016.05.006

[32] Kicukov, E., and Gursel, A. (2015). Ultrasonic welding of dissimilar materials: A review. Periodicals of Engineering and Natural Sciences, 3(1), 28–36.

DOI: 10.21533/pen.v3i1.44

[33] Maliutina, I. N., Mali, V. I., Bataev, I. A., Bataev, A. A., Esikov, M. A., Smirnov, A. I., and Skorokhod, K. A. (2014). Structure and microhardness of Cu-Ta joints produced by explosive welding. Rivista Italiana Della Saldatura, 66(5), 839–848

DOI: 10.1155/2013/256758

[34] Afriansyah, A.A. (2020). Dissimilar metal welding using shielded metal arc welding: A review. Technology Reports of Kansai University, 62(4), 1935–1948.

[35] Abioye, T. E., Olugbade, T. O., and Ogedengbe, T. I. (2017). Welding of dissimilar metals using gas metal arc and laser welding techniques: A review. Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS), 8(6), 225–228.

[36] Munteanu, A. (2016). The electron beam welding of dissimilar materials-case study. IOP Conference Series: Materials Science and Engineering, 161.

DOI: 10.1088/1757-899x/161/1/012058

[37] Wang, P., Chen, X., Pan, Q., Madigan, B., and Long, J. (2016). Laser welding dissimilar materials of aluminum to steel: An overview. International Journal of Advanced Manufacturing Technology, 87(9–12), 3081–3090.

DOI: 10.1007/s00170-016-8725-y

[38] Rudrapati, R., Kumar, R., Pal, P.K., and Nandi, G. (2016). Parametric optimization of submerged arc welding of dissimilar mild steel and ferritic stainless steels using Taguchi method. International Journal of Advances in Production and Mechanical Engineering,2,1-31.

DOI: 10.1016/j.matpr.2017.02.068

[39] Antonini, J. M. (2014). Health effects associated with welding. In Comprehensive Materials Processing. Reference Module in Material Science and Materials. Engineering, 8, 49–70.

DOI: 10.1016/b978-0-08-096532-1.00807-4

[40] Nivas, R., Singh, P. K., Das, G., Das, S. K., Kumar, S., Mahato, B., Sivaprasad, K., and Ghosh, M. (2017). A comparative study on microstructure and mechanical properties near interface for dissimilar materials during conventional V-groove and narrow gap welding. Journal of Manufacturing Processes, 25, 274–283.

DOI: 10.1016/j.jmapro.2016.12.004

[41] Mittal, R., and Sidhu, B. S. (2015). Microstructures and mechanical properties of dissimilar T91/347H steel weldments. Journal of Materials Processing Technology, 220, 76–86.

DOI: 10.1016/j.jmatprotec.2015.01.008

[42] Khan, W. N., and Chhibber, R. (2021). Effect of filler metal on solidification, microstructure and mechanical properties of dissimilar super duplex/pipeline steel GTA weld. Materials Science and Engineering, 803, 140476.

DOI: 10.1016/j.msea.2020.140476

[43] Khan, M., Dewan, M. W., and Sarkar, M. Z. (2021). Effects of welding technique, filler metal and post-weld heat treatment on stainless steel and mild steel dissimilar welding joint. Journal of Manufacturing Processes, 64, 1307–1321.

DOI: 10.1016/j.jmapro.2021.02.058

[44] ASME. (2012). B31.3, Process piping pp.10016-5990. American Society of Mechanical Engineers.

[45] ASME, and Section, IX. (2011). Rules for construction of power boilers pp.10016-5990. American Society of Mechanical Engineers.

[46] Amuda, M. O. H., Osoba, L. O., Etuk, N. N., Lawal, T. F., and Adetayo, A. O. (2020). Tracking local brittle zone in the heat affected zone of girth-welded API 5L X46 pipe. Nigerian Journal of Technology, 39(2), 403–416.

DOI: 10.4314/njt.v39i2.10

[47] ASTM International. (2016). Standard test methods for tension testing of metallic materials. Committee E-28 on mechanical testing. Journal of ASTM International.

[48] API, S. T. D. 1104. (2013). Welding of pipelines and related facilities (21st ed). American

[49] Shao, Y., Liu, C., Yan, Z., Li, H., and Liu, Y. (2018). Formation mechanism and control methods of acicular ferrite in HSLA steels: A review. Journal of Materials Science & Technology, 34(5), 737-744.

DOI: 10.1016/j.jmst.2017.11.020

[50] Tasalloti, H., Kah, P., and Martikainen, J. (2017). Effect of heat input on dissimilar welds of ultrahigh strength steel and duplex stainless steel: Microstructural and compositional analysis. Materials Characterization, 123, 29–41.

DOI: 10.1016/j.matchar.2016.11.014

[51] Wang, J., Lu, M. X., Zhang, L., Chang, W., Xu, L. N., and Hu, L. H. (2012). Effect of welding process on the microstructure and properties of dissimilar weld joints between low alloy steel and duplex stainless steel. International Journal of Minerals, Metallurgy, and Materials, 19(6), 518–524.

DOI: 10.1007/s12613-012-0589-z

[52] Shojaati, M., and Beidokhti, B. (2017). Characterization of AISI 304/AISI 409 stainless steel joints using different filler materials. Construction and Building Materials, 147, 608–615.

DOI: 10.1016/j.conbuildmat.2017.04.185

[53] Verma, J., Taiwade, R.V., Khatirkar, R.K., and Kumar, A. (2016). A comparative study on the effect of electrode on microstructure and mechanical properties of dissimilar welds of 2205 austeno-ferritic and 316L austenitic stainless steel. Materials Transactions, 57(4), 494-500.

DOI: 10.2320/matertrans.m2015321

[54] Anaele, J. U., Onyemaobi, O. O., Nwobodo, C. S., and Ugwuegbu, C. C. (2015). Effect of electrode types on the solidification cracking susceptibility of austenitic stainless steel weld metal. International Journal of Metals, 1–7.

DOI: 10.1155/2015/213258

[55] Pouraliakbar, H., Hamedi, M., Kokabi, A. H., and Nazari, A. (2014). Designing of CK45 carbon steel and AISI 304 stainless steel dissimilar welds. Materials Research, 17(1), 106–114.

DOI: 10.1590/s1516-14392013005000170

[56] Nelson, T.W., Lippold, J.C. and Mills, M.J. (2000). Nature and evolution of the fusion boundary in ferritic-austenitic dissimilar metal welds. Part 2: On-cooling transformations. Welding Journal, 79(55): 267s-277s

[57] Sadeghian, M., Shamanian, M. and Shafyei, A. (2014) Effect of heat input microstructure and mechanical properties of dissimilar joints between super duplex stainless steel and high strength low alloy steel. Materials and Design, 60, 678-684.

DOI: 10.1016/j.matdes.2014.03.057

[58] Saedi, A. H., Hajjari, E., and Sadrossadat, S. M. (2018). Microstructural characterization and mechanical properties of TIG-Welded API 5L X60 HSLA steel and AISI 310S stainless steel dissimilar joints. Metallurgical and Materials Transactions A, 49(11), 5497–5508.

DOI: 10.1007/s11661-018-4890-y

[59] Weman, K. (2011). Welding processes handbook. Elsevier.