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<p>Present study deals with the effect of different filler wires (AISI 309L austenitic, AISI 410 martensitic, and 2594 super duplex) on the microstructure and mechanical properties of single-pass, semi-automatic metal inert gas (MIG)-welded AISI 410 martensitic stainless steel weldments at a constant heat input of 1478&#xa0;J/mm (V = 20&#xa0;V, I = 150&#xa0;A, welding speed = 7&#xa0;mm/min). Cr<sub>eq</sub>/Ni<sub>eq</sub> values indicate phase behavior: AISI 410 (2.78) and ER410 (2.94) martensitic, ER309L (1.65) austenitic, and ER 2594 (2.27) ferrite–austenite balanced. The hardest of the deposited weld metal (over 320&#xa0;HV) was deposited using the 410 filler, a result mainly because of the formation of untempered lath martensite. The 309L filler, in contrast, formed the softest (~ 200&#xa0;HV), which is the typical feature of a γ-austenitic structure. Of all the conditions, the 2594 super duplex filler exhibited better Charpy impact toughness (greater than 250&#xa0;J in the fusion area), which is due to the joint effect of ferrite and austenite phases which create crack resistance by bridging. On the other hand, 309L filler exhibited the lowest impact toughness in the fusion zone and heat-affected zone (HAZ) which can be explained by the incompatibility between the austenitic weld metal and the martensitic base material in thermal expansion. The fractographic analysis showed that in the 2594 welds, fracture was ductile with dimpled morphology, mixed brittle–ductile fracture in the 410 welds, and mixed-mode fracture behavior at the HAZ of 309L joints. Depending on the final performance, 410 filler can be used in applications that demand high wear rates, 2594 filler can be used in applications that demand high impact loading and in the case where corrosion resistance and crack free filler deposition are paramount, the 309L filler will be used.</p>

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Comparative Analysis of Microstructural Evolution and Mechanical Properties of AISI Grade 410 Stainless Steel Welds Fabricated by Metal Inert Gas Welding Using Austenitic 309 L, Martensitic 410, and Super Duplex 2594 Filler Metals

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Amman Jakhar,
  • Lochan Sharma,
  • Narinder Singh,
  • Vijay Singh,
  • Rahul Chhibber

摘要

Present study deals with the effect of different filler wires (AISI 309L austenitic, AISI 410 martensitic, and 2594 super duplex) on the microstructure and mechanical properties of single-pass, semi-automatic metal inert gas (MIG)-welded AISI 410 martensitic stainless steel weldments at a constant heat input of 1478 J/mm (V = 20 V, I = 150 A, welding speed = 7 mm/min). Creq/Nieq values indicate phase behavior: AISI 410 (2.78) and ER410 (2.94) martensitic, ER309L (1.65) austenitic, and ER 2594 (2.27) ferrite–austenite balanced. The hardest of the deposited weld metal (over 320 HV) was deposited using the 410 filler, a result mainly because of the formation of untempered lath martensite. The 309L filler, in contrast, formed the softest (~ 200 HV), which is the typical feature of a γ-austenitic structure. Of all the conditions, the 2594 super duplex filler exhibited better Charpy impact toughness (greater than 250 J in the fusion area), which is due to the joint effect of ferrite and austenite phases which create crack resistance by bridging. On the other hand, 309L filler exhibited the lowest impact toughness in the fusion zone and heat-affected zone (HAZ) which can be explained by the incompatibility between the austenitic weld metal and the martensitic base material in thermal expansion. The fractographic analysis showed that in the 2594 welds, fracture was ductile with dimpled morphology, mixed brittle–ductile fracture in the 410 welds, and mixed-mode fracture behavior at the HAZ of 309L joints. Depending on the final performance, 410 filler can be used in applications that demand high wear rates, 2594 filler can be used in applications that demand high impact loading and in the case where corrosion resistance and crack free filler deposition are paramount, the 309L filler will be used.