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<p>This study investigated the impact of cold metal transfer and ultrasonic vibration cold metal transfer welding processes on AISI 409L ferritic stainless-steel joints using ER 308L filler metal. The use of ultrasonic vibrations significantly refined the primary ferrite grains, reducing the ferrite content in the weld metal by approximately 45% and achieving a more uniform distribution of alloying elements. The maximum microhardness value of 305.67 HV was observed at the weld center at 9&#xa0;mm/sec, while ultrasonic vibrations increased peak hardness to 325.32 HV at a 25&#xa0;µm amplitude. The softened coarse heat-affected zone exhibited a microhardness of 210-235 HV, which was nearly equivalent to the base metal microhardness. The ultimate tensile strength, % strain, and hardness of the base metal AISI 409L were 565.85&#xa0;MPa, 23.57%, and 197 HV, respectively, after welding with ultrasonic vibration, the maximum tensile strength of 574.6&#xa0;MPa and a joint efficiency of 101.54% were observed compared to cold metal transfer-welded joint. This improvement is attributed to the refined grain structure, which enhances strain distribution and delays fracture onset. Despite the benefits of increased welding speed up to 9&#xa0;mm/sec in the welded joints, these still exhibited lower tensile properties due to larger dendrites and increased interdendritic spacing. It led to a reduced strain of 21.19% and a higher likelihood of premature failure. The novelty of ultrasonic vibration-assisted cold metal transfer welding to ferritic stainless-steel AISI 409L, particularly for use in aerospace, pressure vessels, and automotive exhaust systems.</p>

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Consequence of Ultrasonic Vibration-Assisted Cold Metal Transfer Welding Parameters on Metallurgical and Mechanical Properties of Ferritic Stainless-Steel-Welded Joints

  • 期刊论文

  • 发表日期：

    2025年5月9日

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  • Alka Sharma,
  • Reeta Wattal,
  • M. S. Niranjan

摘要

This study investigated the impact of cold metal transfer and ultrasonic vibration cold metal transfer welding processes on AISI 409L ferritic stainless-steel joints using ER 308L filler metal. The use of ultrasonic vibrations significantly refined the primary ferrite grains, reducing the ferrite content in the weld metal by approximately 45% and achieving a more uniform distribution of alloying elements. The maximum microhardness value of 305.67 HV was observed at the weld center at 9 mm/sec, while ultrasonic vibrations increased peak hardness to 325.32 HV at a 25 µm amplitude. The softened coarse heat-affected zone exhibited a microhardness of 210-235 HV, which was nearly equivalent to the base metal microhardness. The ultimate tensile strength, % strain, and hardness of the base metal AISI 409L were 565.85 MPa, 23.57%, and 197 HV, respectively, after welding with ultrasonic vibration, the maximum tensile strength of 574.6 MPa and a joint efficiency of 101.54% were observed compared to cold metal transfer-welded joint. This improvement is attributed to the refined grain structure, which enhances strain distribution and delays fracture onset. Despite the benefits of increased welding speed up to 9 mm/sec in the welded joints, these still exhibited lower tensile properties due to larger dendrites and increased interdendritic spacing. It led to a reduced strain of 21.19% and a higher likelihood of premature failure. The novelty of ultrasonic vibration-assisted cold metal transfer welding to ferritic stainless-steel AISI 409L, particularly for use in aerospace, pressure vessels, and automotive exhaust systems.