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Solid-state phase transformations and the evolution of thermal and elastic strains in novel low temperature transformation (LTT) weld filler materials in the near surface region are monitored in real time by means of an innovative experimental set-up at the PDIFF (powder diffraction) beamline at the synchrotron light source ANKA (Angströmquelle Karlsruhe) at the KIT (Karlsruhe Institute for Technology). The key components of the diffraction set-up are two fast microstrip line detectors, which enables the strain evolution to be followed as a function of time and temperature for a 0.5?s counting time. During controlled heating and cooling cycles, as well as during near welding cycles, the martensite–austenite–martensite phase transitions are analysed. The transformation kinetics are monitored during resistance heating of small chips of the pure LTT alloys and during gas tungsten arc welding of simplified LTT welds using a specially designed welding rig for in-situ studies on the diffraction instruments. Under the mechanically unconstrained condition allowing free thermal expansion and shrinkage, the LTT alloys are found to exhibit decreasing transformation temperatures Ac and MS and increasing phase fraction of retained austenite for increasing Ni content. The strain evolution during welding reveals increased compressive stresses upon welding, which is attributed to the martensite formation upon cooling, which counteracts the thermal contraction strains. Comparison of the transformation temperatures reveals higher values than in the pure LTT alloys, but no variation between the different alloys. On the one hand, this is attributed to preferred grain orientation affecting the diffraction measurements and the determination of the transformation temperatures. On the other hand, it is possible that with the different chemical compositions of the LTT alloys and the mechanical constraints during welding, the evolution of the residual strain and stress may vary and result in counteracting affects with respect to lowered martensite start temperatures.
Various test methods are available for assessing the susceptibility of materials to solidification cracking during welding. In the widely used Varestraint test, the crack length is selected as a criterion as a function of the applied bending strain.
Unfortunately, the crack length does not characterize the material behavior alone but depends to varying degrees on the individual test parameters used, which makes the interpretation of the results difficult. In addition, the crack length is not comparable under different test conditions. To overcome these disadvantages, we have developed a novel evaluation methodology that decouples the machine influence from the material behavior. The measured crack length is related to the maximum possible value specified by welding speed and deformation time. This relative crack length is calculated numerically, considering the orientation of the cracks. Experiments on two high-alloy martensitic welding consumables show that, in contrast to the conventional evaluation, a comparison of different welding parameters becomes possible. Furthermore, the strain rate proved to be a suitable crack criterion in agreement with Prokhorov's hot cracking model.
For a newly developed 10% Cr and 10% Ni low transformation temperature (LTT) weld filler material, the local phase transformation kinetics and the strain evolution during gas tungsten arc welding (GTAW) under real welding conditions was studied. An experimental set-up and a measuring and evaluation strategy are presented to gain a real time insight into the welding process. The experiments were carried out at the beam line ID15@ESRF using a two detector EDXRD (energy dispersive X-ray diffraction) set-up and high energy synchrotron X-rays. The time-resolved diffraction analysis during welding was carried out locally throughout the weld in longitudinal as well as in transverse direction to the weld line to examine the interdependence of the strain state and the transformation kinetics. This comprehension is crucial for the optimization of the weld process, and thus for the tailoring of the resulting residual stress states, which is one of the main issues for the application of LTT alloys. Using the herein proposed approach EDXRD diffraction pattern can be monitored during real welding with a counting rate of 5 Hz. By means of the time resolved diffraction data the local transformation temperatures and times were determined and the local phasespecific strain evolutions are discussed with respect to the transformation rates and the time-delayed phase transformations.
Modifying the level of mostly detrimental welding residual stresses already during the welding process would be highly attractive as time- and cost-consuming post processing may be prevented. The nature of stress buildup during welding-associated cooling is highly affected by phase transformations. Up to now, it is not clear in which way this is applicable to real component welding exhibiting high shrinkage restraint and complex heat input. In this study, two different low transformation temperature (LTT) alloys have been investigated concerning the stress development in restrained multi-run butt welding in order to evaluate the potential of stress reduction. Pulsed gas metal arc welding (P-GMAW) welding was executed on a testing facility designed to simulate real lifelike restraint conditions of component weldments. The effect of reducedMS-temperatures and the heat control on the globally acting stresses was monitored by in-situ measurement of the reaction forces during welding fabrication. Additional local residual stress measurements allowed analyzing global as well as local loading of the welded construction. Although phase transformation has a significant influence on unloading the joint during each weld pass, the reaction stress upon cooling to room temperature seems to be determined mainly by the heat input. On the surface, low longitudinal residual stresses were observed in case of LTT whereas transverse residual stresses are less affected.
Low Transformation Temperature (LTT) alloys are high alloyed filler materials, which exhibit a martensitic phase transformation at comparatively low temperatures in order to prevent high tensile residual stresses. A number of publications have already shown that even compressive residual stresses can be observed when using LTT filler materials. Up to know it is not clear in which way this it applicable to multi-run welding exhibiting high shrinkage restraint and complex heat input. In this study the potential for stress reduction during welding of LTT alloys was studied by numerical simulation. This allows for evaluation of the stress development in every single weid run. Additionally, the impact of the structural stiffness was incorporated by modelling a special sample geometry exhibiting a high intensity of restraint. The results show that the stress formation in weid longitudinal direction is determined by the phase transformation as high compressive residual stresses were found here independent from the weid run. On the other hand the transformation induced stresses in weid transverse direction are superimposed by tensile stresses originated from shrinkage restraint. With increasing number of runs the tensile residual stress level is raised. The results were confirmed by residual stress measurements using diffraction methods.
Investigations on weldability often deal with hot cracking as one of the most prevalent failure mechanisms during weld fabrication. The modified varestraint transvarestraint hot cracking test (MVT) is well known to assess the hot cracking susceptibility of materials. The shortcoming of this approach is that the information is only from the very near surface region which inhibits access to the characteristic of the hot crack network in the bulk. Here, we report about an alternative approach to monitor the entire 3D hot crack network after welding by means of microfocus X-ray computer tomography (µCT). However, to provide sufficient high spatial resolution small samples must be sectioned from the MVT-welded joint. The sampling is accompanied by local relaxation of the residual stress distributions that are induced by welding, which can have an impact on the crack volumes prior to the sampling. The studies were carried out to investigate the hot cracking susceptibility of low transformation temperature filler materials (LTT). As high compression residual stresses up to -600 MPa in the area of the crack networks were determined by means of the contour method, stress relaxation caused by sectioning for µCT sample extraction can affect the detectability of the cracks later on. X-ray diffraction studies revealed surface residual stress relaxations up to about 400 MPa due to cutting. To investigate this effect, the specimens with hot cracks were subjected to a load test with known stress states. The results clearly show that local stress relaxations will have a strong impact on the volume images reconstructed from tomography analysis. This effect must be considered during hot crack assessment on basis of µCT data.
Investigations on weldability often deal with hot cracking, as one of the most popular failure during weld fabrication. The modified varestraint transvarestraint hot cracking test (MVT) is well known for the assessment of the hot cracking susceptibility of materials. The shortcoming of this approach is that the information is only from the very near surface region, which inhibits access to the characteristic of the hot crack network in the bulk. Here, we report about a new approach, illustrated in the example of low transformation temperature (LTT) weld filler materials, to monitor the entire 3D hot crack network after welding by means of microfocus X-ray computer tomography (μCT).
Two-dimensional residual stress mapping of multilayer LTT weld joints using the contour method
(2018)
Low transformation temperature (LTT) weld filler materials offer an attractive alternative to cost intensive postweld treatments as they can mitigate detrimental welding residual stresses during the welding process. Compared to conventional weld filler materials, LTT alloys are characterized by a delayed martensite transformation at low temperatures, which can result in compressive residual stresses in the weld. The high strength of these filler materials makes them potentially applicable to high-strength steels as well as for a large amount of requested repair works in steel structures. The focus of the study is on the confirmation of the LTT idea with regard to the residual stress state for multipass weld lines processed by metal active gas welding. It is demonstrated that the contour method is a well-suited technique for measuring the residual stress in the weld joint as it gives an entire two-dimensional map of the residual stress state in the weld line, heat affected zone (HAZ), and base material. The technique was applied at different LTT alloys with varying chemical compositions. Additionally, the results are compared to residual stress maps that were determined by Neutron diffraction using the Strain Analyzer for Large Scale Engineering Applications, an
instrument referred to as SALSA, at the Institut Laue-Langevin in Grenoble. For all investigated specimens, compressive residual stress distributions were determined in the area of the weld joint and the HAZ. They are balanced by tensile residual stresses in the surrounding base material. However, it is shown that the size of theregion exhibiting compressive residual stresses and the absolute values of the compressive residual stresses depend on the chemical composition of the weld filler material.