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<p>A comprehensive investigation was conducted on dissimilar weld joints between P92 ferritic-martensitic steel and AISI 316 austenitic stainless steel, fabricated using the Gas Tungsten Arc Welding (GTAW) process with Inconel 82, Inconel 625, and Inconel 617 filler metals. Inconel 82 and Inconel 617 filler welds primarily exhibited dendritic microstructures, whereas Inconel 625 welds showed a combination of dendritic and cellular morphologies. Notable variations in dendrite structure and elemental segregation were observed across the weld thickness and width. Energy-dispersive spectroscopy (EDS) analysis and area elemental map identified Ti(C, N) and NbC in the Inconel 82 filler weld, NbC and Laves phase in the Inconel 625 filler weld, and Cr and Mo-rich phases (M<sub>23</sub>C<sub>6</sub> and Mo<sub>6</sub>C) in the Inconel 617 filler weld. The weld interfaces showed complex morphological features such as unmixed zones, peninsulas, islands, and Type I/II grain boundaries, particularly prominent in Inconel 82 welds. Mechanical characterization indicated that tensile failures consistently occurred in the AISI 316 base metal, with ultimate tensile strength values ranging between 601 and 610&#xa0;MPa, close to that of the AISI 316 base material. Charpy impact testing confirmed adequate toughness across all joints, with Inconel 82 welds exhibiting the highest impact energy due to minimal segregation and absence of brittle phases, while Inconel 625 and 617 welds showed reduced toughness due to hard, crack-prone precipitates. Among all the filler welds, the maximum hardness of 270 ± 11 HV was measured for Inconel 625 filler weld. Residual stress analysis showed tensile stresses across all weldments, with Inconel 82 welds exhibiting the highest, and Inconel 617 welds the lowest residual stress levels. Considering microstructural integrity, mechanical performance, and residual stress behavior, Inconel 617 filler demonstrated superior suitability for high-temperature dissimilar joints involving P92 and AISI 316, making it a promising candidate for advanced thermal power applications.</p>

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Influence of Ni-Based Filler Metals on Weld Integrity in Dissimilar GTAW Joints of P92 Steel and AISI 316 Stainless Steel

  • 期刊论文

  • 发表日期：

    2025年10月15日

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  • Maneesh Kumar Yadav,
  • Shailesh M. Pandey

摘要

A comprehensive investigation was conducted on dissimilar weld joints between P92 ferritic-martensitic steel and AISI 316 austenitic stainless steel, fabricated using the Gas Tungsten Arc Welding (GTAW) process with Inconel 82, Inconel 625, and Inconel 617 filler metals. Inconel 82 and Inconel 617 filler welds primarily exhibited dendritic microstructures, whereas Inconel 625 welds showed a combination of dendritic and cellular morphologies. Notable variations in dendrite structure and elemental segregation were observed across the weld thickness and width. Energy-dispersive spectroscopy (EDS) analysis and area elemental map identified Ti(C, N) and NbC in the Inconel 82 filler weld, NbC and Laves phase in the Inconel 625 filler weld, and Cr and Mo-rich phases (M23C6 and Mo6C) in the Inconel 617 filler weld. The weld interfaces showed complex morphological features such as unmixed zones, peninsulas, islands, and Type I/II grain boundaries, particularly prominent in Inconel 82 welds. Mechanical characterization indicated that tensile failures consistently occurred in the AISI 316 base metal, with ultimate tensile strength values ranging between 601 and 610 MPa, close to that of the AISI 316 base material. Charpy impact testing confirmed adequate toughness across all joints, with Inconel 82 welds exhibiting the highest impact energy due to minimal segregation and absence of brittle phases, while Inconel 625 and 617 welds showed reduced toughness due to hard, crack-prone precipitates. Among all the filler welds, the maximum hardness of 270 ± 11 HV was measured for Inconel 625 filler weld. Residual stress analysis showed tensile stresses across all weldments, with Inconel 82 welds exhibiting the highest, and Inconel 617 welds the lowest residual stress levels. Considering microstructural integrity, mechanical performance, and residual stress behavior, Inconel 617 filler demonstrated superior suitability for high-temperature dissimilar joints involving P92 and AISI 316, making it a promising candidate for advanced thermal power applications.