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<p>Inconel 738LC superalloys are prone to HAZ liquation cracking during repair welding, making filler selection critical for alleviating cracks. This study investigates how IN-625, H-230, and C-263 fillers with differing Al + Ti contents influence liquation cracking during rotationally repaired welding of Inconel 738LC, following Original Equipment Manufacturer standards. A stepwise cast plate (200 × 60&#xa0;mm) was solution heat-treated at 1120&#xa0;°C for 2 hours, followed by air cooling. Microstructure was analyzed using optical and electron microscopy; crack dimensions were measured by ImageJ; Vickers microhardness and thermal diffusivity were assessed by Shimadzu and JMatPro. All welds exhibited intergranular, zigzag cracks in the HAZ intersecting the fusion boundary. IN-625 filler reduced crack length by 69% compared to H-230 and 22% compared to C-263, and the number of cracks decreased by 45% and 26%, respectively. IN-625 and C-263 welds solidified 84&#xa0;s and 31&#xa0;s faster than the base metal; their higher hardness and thermal diffusivity accelerated premature solidification, fostering HAZ crack formation and propagation toward the weld. Above 1000&#xa0;°C, IN-625’s minimal thermal expansion mismatch with the base metal reduced crack susceptibility. At the same weld cooling rate, H-230’s larger solidification range and higher solidus temperature made its weld most prone to liquation cracking, whereas IN-625 was the least sensitive.</p>

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Filler Effects on Heat-Affected Zone Liquation Cracking in Rotationally Repaired Inconel 738LC Tungsten Inert Gas Welds: An Industrial Perspective

  • 期刊论文

  • 发表日期：

    2025年9月29日

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  • Amirhossein Anisi,
  • Eslam Ranjbarnodeh,
  • Mohammad Cheraghzadeh

摘要

Inconel 738LC superalloys are prone to HAZ liquation cracking during repair welding, making filler selection critical for alleviating cracks. This study investigates how IN-625, H-230, and C-263 fillers with differing Al + Ti contents influence liquation cracking during rotationally repaired welding of Inconel 738LC, following Original Equipment Manufacturer standards. A stepwise cast plate (200 × 60 mm) was solution heat-treated at 1120 °C for 2 hours, followed by air cooling. Microstructure was analyzed using optical and electron microscopy; crack dimensions were measured by ImageJ; Vickers microhardness and thermal diffusivity were assessed by Shimadzu and JMatPro. All welds exhibited intergranular, zigzag cracks in the HAZ intersecting the fusion boundary. IN-625 filler reduced crack length by 69% compared to H-230 and 22% compared to C-263, and the number of cracks decreased by 45% and 26%, respectively. IN-625 and C-263 welds solidified 84 s and 31 s faster than the base metal; their higher hardness and thermal diffusivity accelerated premature solidification, fostering HAZ crack formation and propagation toward the weld. Above 1000 °C, IN-625’s minimal thermal expansion mismatch with the base metal reduced crack susceptibility. At the same weld cooling rate, H-230’s larger solidification range and higher solidus temperature made its weld most prone to liquation cracking, whereas IN-625 was the least sensitive.