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<p>This study examined the effects of straight tube butt welding (STBW) with hot and cold wire conditions on T92 steels. The tube specifications are 4.5-mm thick and 44.5-mm outer diameter, utilizing a V-groove with a 70° angle for both welding processes. ER90SB-9 filler wire, with a diameter of 1.2&#xa0;mm, was used. The weldment was characterized using radiographic analysis to confirm weld quality alongside optical microscopy (OM), x-ray diffraction (XRD), and scanning electron microscopy (SEM). Vickers microhardness measurements, toughness, and tensile tests were conducted to evaluate the mechanical properties of both welded samples and base metals. The tensile strength of the straight tube butt-welded T92 steel was 726&#xa0;MPa under the hot wire condition and 552&#xa0;MPa under the cold wire condition. The toughness of the straight tube butt-welded T92 steel was measured to be 41&#xa0;J under hot wire welding conditions and 45&#xa0;J under cold wire welding conditions. The average hardness values in the weld zone were 483.48&#xa0;HV1 and 456.85&#xa0;HV1 for hot and cold wire conditions, respectively. Radiographic analysis revealed seamless weld regions with no voids or pores, confirming high-quality joints. When compared to the hot wire condition, the hot wire method exhibited an improvement of 174&#xa0;MPa (31.5%) in tensile strength and 26.63 HV1 (5.8%) in average hardness. Failure in tensile tests occurred in the T92 heat-affected zone rather than in the weld zone, indicating sound weld integrity. The results demonstrate that hot wire welding provided superior mechanical performance compared to cold wire welding. </p>

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Effect of Filler Wire Conditions on the Microstructure and Mechanical Properties of Straight Tube Butt-Welded T92 Steel Tubes

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • S. Santhosh Kumar,
  • S. Ramesh Kumar

摘要

This study examined the effects of straight tube butt welding (STBW) with hot and cold wire conditions on T92 steels. The tube specifications are 4.5-mm thick and 44.5-mm outer diameter, utilizing a V-groove with a 70° angle for both welding processes. ER90SB-9 filler wire, with a diameter of 1.2 mm, was used. The weldment was characterized using radiographic analysis to confirm weld quality alongside optical microscopy (OM), x-ray diffraction (XRD), and scanning electron microscopy (SEM). Vickers microhardness measurements, toughness, and tensile tests were conducted to evaluate the mechanical properties of both welded samples and base metals. The tensile strength of the straight tube butt-welded T92 steel was 726 MPa under the hot wire condition and 552 MPa under the cold wire condition. The toughness of the straight tube butt-welded T92 steel was measured to be 41 J under hot wire welding conditions and 45 J under cold wire welding conditions. The average hardness values in the weld zone were 483.48 HV1 and 456.85 HV1 for hot and cold wire conditions, respectively. Radiographic analysis revealed seamless weld regions with no voids or pores, confirming high-quality joints. When compared to the hot wire condition, the hot wire method exhibited an improvement of 174 MPa (31.5%) in tensile strength and 26.63 HV1 (5.8%) in average hardness. Failure in tensile tests occurred in the T92 heat-affected zone rather than in the weld zone, indicating sound weld integrity. The results demonstrate that hot wire welding provided superior mechanical performance compared to cold wire welding.