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Effect of Post Weld Heat Treatment and Filler Metal on the Microstructure, Mechanical Properties, and Corrosion Resistance of Dissimilar Welds between Carbon Steel and Stainless Steel

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Abstract:

Food-grade piping and water transportation systems extensively use dissimilar welding between stainless steel and carbon steel, where cost-effectiveness and corrosion resistance are essential consideration. However, the fusion zone of dissimilar welds often observed microstructural inhomogeneities and hardness changes, thus compromising mechanical qualities and corrosion resistance. This study was seperated in two phases to investigate and optimize dissimilar welding between carbon steel and stainless steel in both plate and pipe applications. Phase 1 studied welding A36 carbon steel plate and A304 stainless steel using gas tungsten arc welding (GTAW) with ER308L filler metal, the effect of post-weld heat treatment (PWHT) holding time on the mechanical and microstructural propertie. PWHT was performed at 650 °C for 20 and 60 minutes. The 20-minute condition yielded an optimal combination of mechanical strength and microstructural refinement, while the 60-minute condition led to grain coarsening and reduced strength. Phase 2 extended the findings to pipe welding applications, adopting the 20-minute PWHT condition. Welding was performed on dissimilar joints between A106-B carbon steel pipe and A312 TP304L stainless steel pipe (2-inch OD) using ER308L and ER309L filler metals under 99.99% argon shielding. Tensile and hardness testing indicated that welds with ER309L offered superior mechanical performance. Microstructural analysis revealed delta-ferrite and stabilized austenite in the fusion zone, with enhanced Cr and Ni concentrations contributing to improved corrosion resistance, as confirmed by electrochemical testing.

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Periodical:

Key Engineering Materials (Volume 1041)

Pages:

35-42

DOI:

https://doi.org/10.4028/p-5uxWEl

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Online since:

February 2026

Authors:

Junjira Junpattanasit, Jednupong Palomas, Attaphon Kaewvilai, Chayanee Tippayasam*

Keywords:

Carbon Steel, Corrosion Resistance, Dissimilar Welding, Gas Tungsten Arc Welding (GTAW), Mechanical Properties, Microstructure, Post Weld Heat Treatment (PWHT), Stainless Steel

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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