By:-

Mr. K M Varun

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 B A

A+B A+B
A A A B

(1) C (2)

A+B+C
A B

(3)
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 Demand for materials to fit in heterogeneous working condition

 Dissimilar weld Welding 2 different alloy system

Chemically different Metallurgically different

 Weldability difference- Different physical, chemical, mechanical properties and

metallurgical characteristics

 Compromise often required

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 Integration of efficient quality weld technology – key to successful dissimilar weld
.
Processes to join DM

Fusion weld- SMAW, GTAW, GMAW, FCAW,

SAW

Low-dilution- Electron beam, laser etc.

Non fusion weld- Solid state, brazing and soldering

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a • Weld Metal

b • Dilution and alloying

c • Melting temperature ranges

d • Coefficient of thermal expansion

e • Thermal conductivity

f • Heat treatments

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 Weld metal composition & its properties

 WM composition – BM & FM composition and relative dilutions

 Composition gradient exists

 Solidification characteristics- Example high δ ferrite content in SS

 Phase diagram investigation necessary

 Study of intermetallic compounds – crack sensitivity, ductility, susceptibility to

corrosion etc..

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Welding of similar metals/alloys Welding of dissimilar metals/alloys

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 Weld metal- single or mixture of 2 or more phases
 WM – stronger than weakest BM
 WM – sufficient Tensile strength and ductility – withstand failure
 Weld bead composition differ in multipass welding
 Ductile matrix phase with good toughness
 Dilution = Wt. of BM melted/Total wt. of WM
 Calculation of avg. comp. of whole WM:-
(a) Ratio of vol. of BM melted.
[Xw = DaXa + DbXb + Xf(1-Dt)]
(b) Comp. of BM & FM.

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SNO. METHODS ADVANTAGES LIMITATIONS

1 Chemical Analysis of the weld Most accurate determination Time consuming,

expensive
2 Approximation of base metal dilution Less expensive and less time Estimating the % often
by weld cross section and consuming than chemical difficult in weld
composition calculated analysis particularly multipass
weld
3 Approximate dilution for common Very fast way of estimating Welding technique can
welding processes and composition “rough” composition, no have a strong influence
calculated laboratory work involved of dilution in some
processes like GMAW,
GTAW.
[Ref- Guidelines for welding dissimilar
metals, NiDi, Richard E. Avery]
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 Fusion welding involves melting of metals
 Relationship of Physical Properties of Various Base Metals to Those of Carbon Steel

[Ref- AWS handbook vol4]

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 Wide difference in melting temperature range- fusion welding difficult

 Result- liquation cracking of the metal with lower melting temp.

 Example

 Solidification and contraction induces stresses.

 Remedy :- Buttering by filler metal with intermediate melting temp. – reduce

melting temp. differential.

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 Heat flow = f (Temp., K)

 Significant difference in K- rapid heat conduction

 Affect the energy input required to locally melt the base metal

 Remedy:- (a) Directing heat source to BM with higher K

(b) Preheating BM with Higher K

 Example- Welding pure Cu with steel or stainless steel

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 Differences in α generates stresses during changes in temp.

 BM subjected to Tensile stress – Hot crack or cold crack.

 Example- Joining Austenitic SS to Cr Mo LAS pipe butt joints

 Remedy- Ideally the α of WM should be of intermediate value b/w BMs.

 Dilution can alter expansion coefficient

 Linear CTE defined as [α = Δε/ ΔT], Stress in HAZ of one of the metal [σ = EΔ α ΔT]

 Solid state welding best for high CTE differential

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Mean Coefficients of Thermal Expansion as a function of Temperature for Alloys Used in
Transition Joints

[Ref- ASM handbook vol6, fig43, Pg no.825]

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 Heat treatment for one metal may be detrimental to another

 May affect the service condition

 Example- Welding of age hardenable nickel chromium alloy to nonstabalized

austenitic SS

 Solution- (a) Use a stabalized ASS – but high fabrication cost

(b) Buttering Ni-Cr alloy with non age hardenable similar alloy

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[Ref- Edison welding institute website]
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 Parameters required to be taken care of :-
(a) Welding Process
(b) Selection of suitable FM
(c) Joint Design
(d) Buttering
(e) Preheat & PWHT.

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 Fusion weld, low dilution and non fusion weld process available

 Depth of fusion, resulting dilution rates vary for different processes

 Dilution % for Arc welding process- SMAW – 10 to 25%, GMAW – 10 to 50%,

GTAW – 10 to 40%, SAW – 20 to 50%

 Electrode manipulation controls dilution rate

 For low dilution and non fusion weld process- filler metal as an interlayer of
appropriate thickness can be used

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 Necessary criteria to be met:-
(a) Compatible with both BMs
(b) Sound weld within a range of acceptable dilution rates
(c) Meet four requirements – metallurgical compatibility, mechanical, physical and
corrosion properties

 Use of overalloyed filler metal

 Production of transition joints

 Constitution diagram – FM selection (SS)

Like Schaeffler diagram, WRC-1992 etc..

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 ASME Section IX, QW/QB492 : The addition of material, by welding, on one or
both faces of a joint, prior to the preparation of the joint for final welding.

 Advantages of buttering:-
(a) Reduce differential material properties
(b) Barrier layer – slow migration of undesirable elements from BM to WM.

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 Melting characteristics of base and filler metal is affected

 Wide groove angle- less dilution, better control of viscous weld metal, better arc
manipulation

 Back gouging for double sided weld- better dilution control

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Wide Final Layer in a Joint Design
for Dissimilar Metals

Relative Life of Weld Joints Between Ferritic Steels and

Austenitic Stainless Steels Made with Various Filler Metals

[Ref- AWS handbook vol4, Pg no.358]

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 Magnetic Effects

 Interact with DC arc or electron beam- deflection

 Arc blow, beam deflection, metal transfer affected, excessive dilution at

ferromagnetic base metal side

 Remedy- AC arc, short circuit mode of GMAW

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 Mechanical &
Physical Properties

Service
life

Microstructure Corrosion &

stability oxidation resistance

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 Weld metal and 2 HAZs
 DMW intended for elevated temperature
 Design component- DMW is located in areas of known low service stress-
because of addition of thermal stress
 Select filler metal like Ni alloy- are notch tough and resistance to thermal fatigue
 Coarse dendritic cast weld structure- less thermal fatigue than wrought base metal
of same composition
 Remedy- Filler metal overmatching the base metal

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 Composition gradient- Weld metal and HAZ’s
 Microstructural changes- interdiffusion at elevated temperature b/w base and weld
metal
 Reduces the service life of DMW
 Example- C migration (diffusion phenomenon) form LAS to ASS during heat
treatment or elevated service temp.- weakens HAZ of LAS and increases hardness
of weld metal
 Remedy- Use of Ni alloy as filler wire, buttering

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 Galvanic cells formation – Corrosion of anodic metal

 Several microstructural phases – galvanic corrosion

 Compositional variation at interfaces – selective oxidation at high temp – notches

 Corrosion types- galvanic, pitting

 Remedies:-
(a) Join materials with similar corrosion potential
(b) Cathodic protection providing electrode
(c) Coating
(d) Reduce residual stress- to avoid SCC

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[Ref- AWS handbook vol4, Pg no.347] 6/1/2018 28
 Differences in Formation of
M.P., K, α, σ oxide layer

Formation of
brittle Poor solubility in
intermetallic Joining each other
phases techniques
for
Dissimilar
Joints

Proper Welding
Procedure

Hybrid structure

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 Application- DMW joint b/w SA213 (T12) and SA213 (TP 347H) for superheater
tubes in steam generation boiler plant
 Process- Machine GTAW, Joint- V groove
 Filler metal used TGS-70NCb ( Equivalent to AWS A5.14 ERNiCr-3)
 Preheat temp.- 121°C, PWHT- 540°C
 Service temperature- above 540°C
 Failure- After 8 years circumferential cracking at HAZ of LAS side with no plastic
deformation

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Microstructure of
SS sample

(a) Near the weld

junction
(b) Away from the
weld junction

Microstructure of
AS side

(c) HAZ 1

(d) HAZ 2

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 Hardness measurements of AS and SS super heater tube parts.

AS superheater tube part SS superheater tube part

HRB Equivalent BHN Location HRB Equivalent BHN Location

75.4 138.2 Away from weld 83.8 161.9 Away from weld
80.1 150 Near the HAZ 85.6 167 Near the HAZ
92 195 At the welding 90.3 186.3 At the welding

 SEM result- micro cracks along grain boundaries in weld area. Possible reason
◦ Residual internal stresses due to improper PWHT
◦ High hardness due to formation of carbides combined with thermal fatigue

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 Possible causes of failure:-
◦ Expansion differences b/w the 2 steels
◦ Carbon migration
◦ Formation of oxide wedge on OD of LAS tube due to corrosion resistance
differences to flue gases
◦ Bending stresses- Horizontal positioning of the tubes

 Based on microstructure- Carbon migrated from LAS to SS

 Precipitation of carbides- increased hardness
 Decrease in creep strength of AS at weld interface
 Thermal fatigue mechanism can be excluded

[Ref:- Premature failure of dissimilar metal weld joint at intermediate temperature superheater tube. By-
Mohammed Al Hajri, Anees U. Malik & Abdelkader Meroufel. April 2015]

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 Material used- 1060 Al alloy+C10100 pure Cu
 Application- Chemical, aerospace, transportation & electronics industry
 Fusion welding, brazing techniques difficult
 Experimental setup:-
(a) Plates dimension- 300x100x3mm
(b) Tool rpm- 1050, Welding speed- 30mm/min
(c) Stir pin dia.- 4.5mm, Length- 2.8mm
(d) Soaked in 3.5% NaCl for 24hr- Corrosion test H13
steel
 Tool offsetting, tool rpm and traverse speed influence
weld properties

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 Microstructure

Cross section morphology

(macrostructure)

WN Microstructure (Magnified image of A, B, C & D)

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 Microstructure of interface

TEM micrographs of nugget zone

Corrosion morphology of the interface

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 [Ref- “Microstructure & Mechanical properties of Al-Cu
joints by FSW” by Qiu-zheng, Wen-biao Gong, Wei Liu,
 Results & Discussion Nov 2014]

Surface Morphology of Al-Cu FSW joint

Surface Morphology of Al-Cu FSW joint

Transverse cross section hardness

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Material selection based on application

Study the compatibility

Select proper welding process

Optimize welding procedure

Check the results

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 “Guidelines for welding dissimilar metals” By Richard E. Avery, Nickel
Development Institute
 “Premature failure of dissimilar metal weld joint at intermediate temperature
superheater tube”. By- Mohammed Al Hajri, Anees U. Malik & Abdelkader
Meroufel. April 2015
 “Microstructure & Mechanical properties of Al-Cu joints by FSW” by Qiu-zheng,
Wen-biao Gong, Wei Liu, Nov 2014
 Friction Welding to join dissimilar metals by Shubhavardhan RN & Surendran S,
Dept. of ocean engg. & IIT Madras
 “Creep behavior of dissimilar metal weld joints between P91 and AISI 304”by
Javed Akrama, Prasad Rao Kalvalaa, Mano Misraa & Indrajit Charit Dept. of
Metallurgical Engineering, University of Utah, USA
 AWS welding handbook Vol 4 “Materials and Applications”, Part 2

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 Thank You !

Any Questions ?

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