Restricted accessResearch articleFirst published online 2025
Investigation of the microstructure,residual stresses,and mechanical behavior of Inconel 59 and AISI 904L fusion joint using single pulse GMAW with post-weld cryogenic treatment
Inconel 59 and AISI 904L are widely used in chemical processing and systems for flue gas desulfurization due to their superior corrosion resistance and mechanical strength. This study evaluates dissimilar joints formed by Single Pulse Gas Metal Arc Welding (SP-GMAW) using ERNiCrMo-13 filler. Microstructural analysis revealed coarse grains in the heat-affected zone on the 904L side, with the fusion zone showing columnar and cellular grains. The heat-affected zone was larger on the AISI 904L side (280 µm) than on the Inconel 59 side (180 µm). SEM/EDS analysis indicated minimal secondary phases, with molybdenum (Mo) enrichment and nickel/iron depletion in the fusion zone. Mechanical testing showed fracture occurring in the AISI 904L base metal, while deep cryogenic treatment contributed to notable improvements in yield strength, tensile strength, and elongation. The fusion zone hardness was 224 HV, exceeding Inconel 59 by 16% and AISI 904L by 23%, attributed to Mo segregation. Impact toughness in the weld zone averaged 85 J, 26% lower than Inconel 59 but 47.36% higher than AISI 904L. Residual stress analysis revealed compressive stresses in the fusion zone and tensile stresses in the base metals. SP-GMAW, combined with deep cryogenic treatment, achieved a refined microstructure and enhanced mechanical properties.
AgarwalDCKloewerJ.Nickel base alloys: corrosion challenges in the new millennium. In: NACE CORROSION, 2001. NACE; Paper no. 01325.
2.
AgarwalDCHerdaWRKloewerJ. Case histories on solving severe corrosion problems in the CPI by an advanced NiCrMo alloy 59 UNS N06059. In: NACE CORROSION2000, 2000. NACE; Paper no. 00501.
3.
AgarwalDCGrossmannGK. Case histories on the use of nickel alloys in municipal and hazardous waste fueled facilities. In: NACE CORROSION2001, 2001. NACE. Paper no. 01177.
4.
UNSN.Specification sheet: Alloy 904L. United States Nickel, 2023; 1.
5.
ZambonAFerroPBonolloF.Microstructural, compositional and residual stress evaluation of CO2 laser welded superaustenitic AISI 904L stainless steel. Mater Sci Eng A2006; 424(1–2): 117–127.
6.
MauryaAKPandeyCChhibberR.Dissimilar welding of duplex stainless steel with Ni alloys: a review. Int J Press Vessels Pip2021; 192: 104439.
7.
Velázquez de la HozJLChengK.Investigation on the modeling and simulation of hydrodynamics in asymmetric conduction laser micro-welding of austenitic stainless steel and its process optimization. Proc Inst Mech Eng Part B: J Eng Manuf2024; 239(4): 530–543.
8.
MuthukumaranNArulmuruganB.Microstructural analysis and mechanical characterization of dissimilar welds between nickel-based and steel-based superalloys post-cryogenic treatment using hotwire GTAW. J Adhes Sci Technol2024; 38(24): 4439–4466.
9.
SivakumarNGandhiBSKumarKS, et al. Effect of constant current and pulsed current gas tungsten arc welding process on microstructure and mechanical properties of superalloy 59 joints. Mater Res Express2022; 9(4): 046525.
10.
ReddyKVBVenkateshGMishraRR.Effect of SS-316L and nickel-based interface powders on joint characteristics of microwave welded SS-316L plates. Proc Inst Mech Eng Part B: J Eng Manuf2024; 239(6–7): 965–976.
11.
KöseC.Heat treatment and heat input effects on the dissimilar laser beam welded AISI 904L super austenitic stainless steel to AISI 317L austenitic stainless steel: surface, texture, microstructure and mechanical properties. Vacuum2022; 205: 111402.
12.
ChenYYangZPengW, et al. Experimental investigation and optimization on field shaper structure parameters in magnetic pulse welding. Proc Inst Mech Eng Part B: J Eng Manuf2021; 235(13): 2108–2117.
13.
MadićMMladenovićSGostimirovićM, et al. Laser cutting optimization model with constraints: maximization of material removal rate in CO2 laser cutting of mild steel. Proc Inst Mech Eng Part B: J Eng Manuf2020; 234(10): 1323–1332.
14.
PalaniPKMuruganN.Selection of parameters of pulsed current gas metal arc welding. J Mater Process Technol2006; 172(1): 1–10.
15.
SathishkumarMRamkumarKDMohanrajT, et al. Investigation of double-pulsed gas metal arc welding technique to preclude carbide precipitates in aerospace grade Hastelloy X. J Mater Eng Perform2021; 30(1): 661–684.
16.
CaiYLuoZZengY.Influence of deep cryogenic treatment on the microstructure and properties of AISI 304 austenitic stainless steel A-TIG weld. Sci Technol Weld Join2017; 22(3): 236–243.
17.
KumarSDKumarSS.Effect of heat treatment conditions and cryogenic treatment on microhardness and tensile properties of AZ31B alloy. J Mater Eng Perform2023; 32(19): 8786–8794.
18.
AgrawalBPKumarR.Challenges in application of pulse current gas metal arc welding process for preparation of weld joint with superior quality. Int J Eng Res Technol2016; 5(1): 319–327.
19.
JadhavPSMohantyCP.Performance assessment of energy efficient and eco-friendly turning of Nimonic C-263: a comparative study on MQL and cryogenic machining. Proc Inst Mech Eng Part B: J Eng Manuf2021; 236(8): 1125–1140.
20.
ArulmuruganBManikandanM.Improvement of metallurgical and mechanical properties of gas tungsten arc weldments of Alloy 686 by current pulsing. Trans Indian Inst Met2018; 71(12): 2953–2970.
21.
ArulmuruganBManikandanM.Investigations on microstructure and corrosion behavior of superalloy 686 weldments by electrochemical corrosion technique. IOP Conf Ser Mater Sci Eng2018; 310: 012071.
22.
ASTM E8. ASTM E8/E8M standard test methods for tension testing of metallic materials 1. Annu B ASTM Stand2010; 4: 1–27.
23.
BaldisseraPDelpreteC.Deep cryogenic treatment: a bibliographic review. Open Mech Eng J2008; 2(1): 9.
24.
TaraphdarPKThakareJGPandeyC, et al. Novel residual stress measurement technique to evaluate through thickness residual stress fields. Mater Lett2020; 2 77: 128347.
25.
Sánchez-CruzTdelNJCuriel-LópezFF, et al. Optimization of macro and microstructural characteristics of 316L/2205 dissimilar welds obtained by the GMAW-pulsed process. Mater Today Commun2023; 34: 105401.
26.
MuthukumaranNArulmuruganBManikandanM.Analyzing microstructural, residual stress, and mechanical characteristics in dissimilar welds of Inconel 59 and AISI 904L through double-pulsed gas metal arc welding. Proc IMechE Part L: J Mater Des Appl2024; 238(8): 1467–1487.
27.
PalKPalSK.Effect of pulse parameters on weld quality in pulsed gas metal arc welding: a review. J Mater Eng Perform2011; 20(6): 918–931.
28.
MathivananASenthilkumarADevakumaranK.Pulsed current and dual pulse gas metal arc welding of grade AISI 310S austenitic stainless steel. Def Technol2015; 11(3): 269–274.
29.
ArulmuruganBSathishkumarMBalajiD, et al. Development of arc welding technique to preclude microsegregation in the dissimilar joint of Alloy C-2000 and C-276. Proc IMechE Part E: J Process Mech Eng2021; 235(5): 1408–1419.
30.
KumarSPandeyCGoyalA.Role of dissimilar IN617 nickel alloy consumable on microstructural and mechanical behavior of P91 welds joint. Arch Civ Mech Eng2020; 20: 1–27.
31.
AdinMŞ. A parametric study on the mechanical properties of MIG and TIG welded dissimilar steel joints. J Adhes Sci Technol2024; 38(1): 115–138.
32.
FigueiredoRBKawasakiMLangdonTG.Seventy years of Hall-Petch, ninety years of superplasticity and a generalized approach to the effect of grain size on flow stress. Prog Mater Sci2023; 137: 101131.
33.
WangBBXieGMWuLH, et al. Grain size effect on tensile deformation behaviors of pure aluminum. Mater Sci Eng A2021; 820: 141504.
34.
CuiCWengZGuK, et al. The strengthening role of post-welded cryogenic treatment on the performance and microstructure of 304 austenitic stainless steel weldments. J Mater Res Technol2024; 29: 5576–5584.
35.
Jovičević-KlugPPodgornikB.Review on the effect of deep cryogenic treatment of metallic materials in automotive applications. Metals2020; 10(4): 434.
36.
GuptaASinghJChhibberR.Dissimilar welding of austenitic and ferritic steels using nickel and stainless-steel filler: associated issues. Proc IMechE Part E: J Process Mech Eng2023; 237(6): 1–13.
37.
YeRRLiHYDingRG, et al. Microstructure and microhardness of dissimilar weldment of Ni-based superalloys IN718-IN713LC. Mater Sci Eng A2020; 774: 138894.
38.
SerindağHTÇamG.Characterizations of microstructure and properties of dissimilar AISI 316L/9Ni low-alloy cryogenic steel joints fabricated by gas tungsten arc welding. J Mater Eng Perform2023; 32(15): 7039–7049.
39.
DakGPandeyC.Experimental investigation on microstructure, mechanical properties, and residual stresses of dissimilar welded joint of martensitic P92 and AISI 304L austenitic stainless steel. Int J Press Vessels Pip2021; 194: 104536.
40.
TaraphdarPKKumarRPandeyC, et al. Significance of finite element models and solid-state phase transformation on the evaluation of weld induced residual stresses. Met Mater Int2021; 27: 3478–92.
41.
KumarRMahapatraMMPradhanAK, et al. Experimental and numerical study on the distribution of temperature field and residual stress in a multi-pass welded tube joint of Inconel 617 alloy. Int J Press Vessels Pip2023; 206: 105034.
42.
KumarRMahapatraMMPradhanAK.A comparative analysis of the impact of fillet weld geometry on residual stress distribution in nickel-based superalloy. Int J Interact Des Manuf Epub ahead of print 9October2024. DOI:10.1007/s12008-024-02127-z
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
