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<p>Imperfections present in a weld joint critically influence the reliability of the welded joints, which correspond to the failure of the component. Therefore, identification of the defects becomes essential to prevent catastrophic failures. The current work focuses on controlling defect formation via optimum heat supplied in continuous mode, and application of the least heat supplied is recommended in compliance with full depth of penetration. Further enhancement in joint features is attained by better control over the average heat supplied using pulse mode. The lowest heat input for pulse current yields the best results in terms of fine equiaxed morphology (~36&#xa0;µm), reduced secondary dendritic arm spacing, and the lowest number of internal pores. The highest joint efficiency (~100%) is achieved using pulse current. Hence, a comprehensive investigation is carried out to establish the micro-plasma arc welding (M-PAW) schedule through microstructural and mechanical characterization of 700-µm-thick cupronickel alloy.</p>

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Optimizing Heat Input in Continuous and Pulse Current Mode to Control Defect Formation and Weld Properties in Cupronickel Alloy

  • 期刊论文

  • 发表日期：

    2025年3月8日

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  • Swagat Dwibedi,
  • Swarup Bag

摘要

Imperfections present in a weld joint critically influence the reliability of the welded joints, which correspond to the failure of the component. Therefore, identification of the defects becomes essential to prevent catastrophic failures. The current work focuses on controlling defect formation via optimum heat supplied in continuous mode, and application of the least heat supplied is recommended in compliance with full depth of penetration. Further enhancement in joint features is attained by better control over the average heat supplied using pulse mode. The lowest heat input for pulse current yields the best results in terms of fine equiaxed morphology (~36 µm), reduced secondary dendritic arm spacing, and the lowest number of internal pores. The highest joint efficiency (~100%) is achieved using pulse current. Hence, a comprehensive investigation is carried out to establish the micro-plasma arc welding (M-PAW) schedule through microstructural and mechanical characterization of 700-µm-thick cupronickel alloy.