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<p>In the present study, dissimilar metal joints of Monel K500 and stainless steel AISI 304L were produced by electron beam (EB) welding with varying beam current (12-20&#xa0;mA) and speed (600-1000&#xa0;mm/min) under constant accelerating voltage of 50&#xa0;kV. In order to mitigate the cracking issues during autogenous welding, the addition of filler material (ErNiCr3) during EB welding was attempted. In this combination, Monel K500 is a precipitation (γ’ (Ni<sub>3</sub>(Al, Ti))) strengthened alloy, and AISI 304L is a solid solution strengthened alloy. The produced dissimilar metal joints were metallurgically characterized through optical and scanning electron microscopy coupled with energy dispersive spectroscopy to understand the microstructure and chemistry of weldments. Further, microhardness across the joint interface and tensile properties of joints were evaluated in as-welded (AW) and post-weld aging heat treatment (PWAHT) conditions. Detailed metallurgical analysis indicated that in the case of autogenous welding, inter-granular solidification cracking was noted in the weld region due to the formation of low-melting phases (containing Al and Si). With the usage of Ni-based ErNiCr3 filler material, the cracking issue has been mitigated with the formation of sound joints. In the AW condition, the lowest hardness was noticed in the HAZ region toward the Monel K500 side, which has resulted in failure during tensile testing. The PWAHT revealed strengthening (by the formation of γ’) in the Monel K500 side, including the weld region compared to the AISI 304L side, resulting in a change in failure location toward the base metal of AISI 304L with a joint strength of 657&#xa0;MPa, which is on a par with the AISI 304L strength of 650&#xa0;MPa. Further, improvement in ductility (% El—45 %) was noticed relative to the AW condition (~29%), due to the domination of uniform straining toward AISI 304L having the least strength in the combination. Fractographs of welded joints were further investigated in both AW and PWAHT conditions. </p>

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Microstructural and Mechanical Characteristics of Dissimilar Electron Beam Welded Joints of AISI 304L and Monel K500

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • C. Jithesh,
  • Ravi Ranjan Kumar,
  • P. Athul,
  • Varsha Florist,
  • Jobin Cyriac,
  • S. V. S Narayana Murty

摘要

In the present study, dissimilar metal joints of Monel K500 and stainless steel AISI 304L were produced by electron beam (EB) welding with varying beam current (12-20 mA) and speed (600-1000 mm/min) under constant accelerating voltage of 50 kV. In order to mitigate the cracking issues during autogenous welding, the addition of filler material (ErNiCr3) during EB welding was attempted. In this combination, Monel K500 is a precipitation (γ’ (Ni3(Al, Ti))) strengthened alloy, and AISI 304L is a solid solution strengthened alloy. The produced dissimilar metal joints were metallurgically characterized through optical and scanning electron microscopy coupled with energy dispersive spectroscopy to understand the microstructure and chemistry of weldments. Further, microhardness across the joint interface and tensile properties of joints were evaluated in as-welded (AW) and post-weld aging heat treatment (PWAHT) conditions. Detailed metallurgical analysis indicated that in the case of autogenous welding, inter-granular solidification cracking was noted in the weld region due to the formation of low-melting phases (containing Al and Si). With the usage of Ni-based ErNiCr3 filler material, the cracking issue has been mitigated with the formation of sound joints. In the AW condition, the lowest hardness was noticed in the HAZ region toward the Monel K500 side, which has resulted in failure during tensile testing. The PWAHT revealed strengthening (by the formation of γ’) in the Monel K500 side, including the weld region compared to the AISI 304L side, resulting in a change in failure location toward the base metal of AISI 304L with a joint strength of 657 MPa, which is on a par with the AISI 304L strength of 650 MPa. Further, improvement in ductility (% El—45 %) was noticed relative to the AW condition (~29%), due to the domination of uniform straining toward AISI 304L having the least strength in the combination. Fractographs of welded joints were further investigated in both AW and PWAHT conditions.