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<p>Dissimilar metal joining of different classes of superalloys such as nickel-based superalloy XH60BT and cobalt-based superalloy KC20WN has unique potential in high-performance aerospace applications, such as aero-engine transition liners and rocket engine nozzles. In this study, dissimilar weld joints XH60BT and KC20WN were created using gas tungsten arc (GTA) and electron beam welding (EBW) methods. Two grades of filler metals, Haynes 230 and KC20WN, were used during GTA welding to determine the optimal filler metal for the dissimilar combination. The weld joints underwent extensive nondestructive examinations, metallurgical analyses using techniques such as SEM, XRD, and EBSD, and mechanical characterizations, assessing hardness and tensile properties at room and elevated temperatures of 900-1200&#xa0;°C. In GTA welding, the KC20WN filler wire achieves tensile strength comparable to XH60BT alloy with 33% elongation, while the Haynes 230 filler wire shows a 5% reduction in tensile strength and ductility dropping to 24%. Fractographic analysis reveals that specimens with KC20WN exhibit predominantly ductile dimples, contrasting with the mixture of ductile dimples and brittle cleavage facets in those welded with Haynes 230, leading to reduced ductility. During GTA welding, M<sub>23</sub>C<sub>6</sub> carbides were seen along the heat-affected zone’s grain boundary toward the XH60BT side. EB welding enhances joint strength to match base metal levels and shifts the failure from weld to base metal in XH60BT alloy. Joints demonstrate superior high-temperature strength (900–1200&#xa0;°C), establishing KC20WN as the preferable filler metal for welding XH60BT and KC20WN alloys through GTA welding, with EB welding yielding better overall properties.</p>

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Dissimilar Welding of Nickel- and Cobalt-Based Superalloys: Effect of Welding Processes and Filler Metals on Metallurgical and Mechanical Characteristics of Joints

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Shashi Ranjan,
  • Ravi Ranjan Kumar,
  • Varsha Florist,
  • V. R. Rajeev,
  • S. V. S. Narayana Murty,
  • Rohit Kumar Gupta,
  • M. Arumugam

摘要

Dissimilar metal joining of different classes of superalloys such as nickel-based superalloy XH60BT and cobalt-based superalloy KC20WN has unique potential in high-performance aerospace applications, such as aero-engine transition liners and rocket engine nozzles. In this study, dissimilar weld joints XH60BT and KC20WN were created using gas tungsten arc (GTA) and electron beam welding (EBW) methods. Two grades of filler metals, Haynes 230 and KC20WN, were used during GTA welding to determine the optimal filler metal for the dissimilar combination. The weld joints underwent extensive nondestructive examinations, metallurgical analyses using techniques such as SEM, XRD, and EBSD, and mechanical characterizations, assessing hardness and tensile properties at room and elevated temperatures of 900-1200 °C. In GTA welding, the KC20WN filler wire achieves tensile strength comparable to XH60BT alloy with 33% elongation, while the Haynes 230 filler wire shows a 5% reduction in tensile strength and ductility dropping to 24%. Fractographic analysis reveals that specimens with KC20WN exhibit predominantly ductile dimples, contrasting with the mixture of ductile dimples and brittle cleavage facets in those welded with Haynes 230, leading to reduced ductility. During GTA welding, M23C6 carbides were seen along the heat-affected zone’s grain boundary toward the XH60BT side. EB welding enhances joint strength to match base metal levels and shifts the failure from weld to base metal in XH60BT alloy. Joints demonstrate superior high-temperature strength (900–1200 °C), establishing KC20WN as the preferable filler metal for welding XH60BT and KC20WN alloys through GTA welding, with EB welding yielding better overall properties.