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<p>The electron beam welding (EBW) of a <i>γ</i>′ strengthened nickel-based superalloy, Haynes 282 (HY282), with austenitic stainless steel SS321, has applications in aerospace and advanced ultra-supercritical (AUSC) power plants. In this study, a dissimilar combination of materials, HY282 and SS321, were welded using EBW process. The convection in the weld pool and rapid solidification during EBW resulted in the formation of Fe- and Ni-rich bands throughout the weld pool. A standard two-step aging process for HY282 was performed on the weld, and its effects were studied using SEM and TEM analysis. These bands lead to the formation of an inhomogeneous distribution of <i>γ</i>′ within the weld after the two-step aging process. A FIB sample taken at the SS321 fusion boundary (FB) shows the presence of <i>γ</i>′ even with the enrichment of Fe and its size increased to 56nm at the FB. To study the effect of macrosegregation on the mechanical properties, microhardness survey and high-temperature tensile testing at 720&#xa0;°C were performed. The hardness contour plots showed the correlation with the microstructural band. The hardness of HY282 increased from 220 to 320 HV after two-step aging, whereas SS321 exhibited a slight reduction to 140 HV, attributed to abnormal grain growth (AGG) during aging. The weld joint demonstrated superior high-temperature tensile strength at 720&#xa0;°C compared to SS321, despite the presence of microstructural bands in the weld and liquation cracking in the HAZ of HY282. During high-temperature tensile testing, failure occurred in the SS321, with ultimate tensile strengths of 311 MPa in the as-welded condition and 285 MPa after aging.</p> Graphical Abstract <p></p>

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Microstructural Evolution and Mechanical Properties of the Dissimilar Weld of Haynes 282 and AISI 321 Using Electron Beam Welding

  • 期刊论文

  • 发表日期：

    2025年7月21日

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  • Muralidharan Arunkumar,
  • Gandham Phanikumar

摘要

The electron beam welding (EBW) of a γ′ strengthened nickel-based superalloy, Haynes 282 (HY282), with austenitic stainless steel SS321, has applications in aerospace and advanced ultra-supercritical (AUSC) power plants. In this study, a dissimilar combination of materials, HY282 and SS321, were welded using EBW process. The convection in the weld pool and rapid solidification during EBW resulted in the formation of Fe- and Ni-rich bands throughout the weld pool. A standard two-step aging process for HY282 was performed on the weld, and its effects were studied using SEM and TEM analysis. These bands lead to the formation of an inhomogeneous distribution of γ′ within the weld after the two-step aging process. A FIB sample taken at the SS321 fusion boundary (FB) shows the presence of γ′ even with the enrichment of Fe and its size increased to 56nm at the FB. To study the effect of macrosegregation on the mechanical properties, microhardness survey and high-temperature tensile testing at 720 °C were performed. The hardness contour plots showed the correlation with the microstructural band. The hardness of HY282 increased from 220 to 320 HV after two-step aging, whereas SS321 exhibited a slight reduction to 140 HV, attributed to abnormal grain growth (AGG) during aging. The weld joint demonstrated superior high-temperature tensile strength at 720 °C compared to SS321, despite the presence of microstructural bands in the weld and liquation cracking in the HAZ of HY282. During high-temperature tensile testing, failure occurred in the SS321, with ultimate tensile strengths of 311 MPa in the as-welded condition and 285 MPa after aging.

Graphical Abstract