ELK ASIA PACIFIC JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING

ISSN Online: 2394-0425; Volume 1 Issue 2 (2016)

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THE EFFECT OF WELDING ON MECHANICAL AND MICROSTRUCTURAL

PROPERTIES OF MATERIALS- A CRITICAL REVIEW

Md. Anis Raza Sudhir Kumar Kashyap Rakesh

Post Graduate Scholar, Production Sr. Principal Scientist, CSIR- Central Assistant Professor,
Technology and Management, Institute of Mining & Fuel Research, Deptt. Of Production Engg, Birsa
Birsa Institute of Technology, Sindri, Dhanbad, Jharkhand, Institute of Technology, Sindri,
Dhanbad, Jharkhand & Professor, Academy of Scientific & Dhanbad, Jharkhand,
anniiissss786@gmail.com Innovative Research profrakesh.2008@gmail.com
(AcSIR – CIMFR)
sudhirnutan@yahoo.com

ABSTRACT

Welding is extensively used in the finishing stage of steel casting production and in fabricating components for
joining. The ease of welding as well as the effects of welding on mechanical properties is thus very pertinent
considerations in the production of engineering components. The purpose of this review is therefore to summarize
and evaluate the published literature with respect to weld ability and the effects of welding processes on mechanical
properties. In this paper a critical review has been presented on the effect of different welding processes like friction
stir welding, arc welding, laser welding, plasma welding on mechanical properties such as tensile strength,
toughness, hardness and microstructural properties of different grade of steels. The different steels which were taken
for studies are stainless steel, low carbon steel, high strength low alloy steel, aluminum alloy etc. After critical
review of related papers it was concluded that there were microstructural change as more pearlite and ferrite were
present in weld zone and HAZ compared to base metal that resulted in increased hardness and loss of tensile
strength. The welding parameters like welding speed, heat input and welding conditions have also resulted on the
affect the weld joint properties and weld joint strength. The mechanical properties of weld joints have also been
affected by filler material composition and type of welding used. Finally, out of all the welding processes friction
welding and laser welding led to superior quality compared to other fusion welding.

Keywords: steel casting production, tensile strength, HAZ, plasma weldin

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INTRODUCTION resistance welding such as spot welding and

Welding is a permanent joining process in seam welding were developed by E.
which two or more parts are coalesced at their Thompson in between 1885 and 1900 [1].
contacting surface by suitable application of
heat and/or pressure [1]. In modern time LITERATURE REVIEW
welding is widely used in various industries Welding has eminent effect on mechanical
like power generation, oil and gas, marine property of materials due to heat produced
transportation, petrochemical industry etc. It during welding. Some of the properties which
has advantages over other joining process due affect the material due to welding are:
to design flexibility, cost saving, overall
weight reduction and structural performance. 1. Tensile property :
Welded joints have high corrosion resistance Tensile strength is the maximum stress that a
compared to bolted and riveted joints and thus material can sustain in tension. In other words
different variety of joints can be made by we can say the amount of applied load per
welding. Due to such advantage it is widely cross sectional area that a material can
used in boiler, pressure vessels, off structure, withstand before failure. Mathematically it is
naval vessel and mining machinery of calculated as the ratio of maximum tensile
underground and open cast mines [2]. load to the original cross section area.

Welding is considered as an extension of hot As per a research done on AA6061 aluminum

forging which Egyptian and other eastern alloy using GMAW (Gas Metal Arc
Mediterranean used for making weapon and Welding) it was observed that in GMAW
tools. Modern welding technology was joints elongation (in length) and reduction in
established in 1800s by an English scientist cross section area were 8.4 % and 5.8 % while
Sir Humhrey Davy. In 1801 Sir Davy of parent material were 18% and 12.24%. It
observed that electric arc could be struck suggests that there is reduction of around 53%
between two carbon electrodes. In mid 1800s in ductility due to GMA welding. The same
Nikolai Benardos, a Russian working on a material when welded using FSW the
laboratory in France was granted a series of reduction were 14.2 % and 9.56 % [3].
patent for carbon arc- welding process. In Another test was carried to study effect of Gas
1892 an American, Charles Coffin developed Tungsten Arch Welding (GTAW) on AA6061
arc welding using filler and electrode. The T6 alloy by machining the alloy to ASTM E8-
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04 standards and welding was done using parent material. The elongation in base metal,
AlMg5 as filler alloy wire for welding and PAW joints, CCGTAW joint and PCGTAW
following result was obtained [4]. joint was 12 %, 7.5 %, 4.5 % and 6.2 %
(Refer table 1) respectively, which means there is reduction in
(Refer figure 1) ductility by 62 % and 48 % in CCGTA and
From Table 1 and figure 1 we can conclude PCGTAW respectively. In SMAW and
that toughness has decreased due to welding GMAW the reduction in ductility were 30 %
and the tensile strength of the specimen has and 39 % respectively [6] [7].
reduced about 54% [4]. The weld joint tensile test was carried on
Tensile test was carried on torr (torsteg) steel stainless steel to see the effect of GTAW and
joined by Shielded Metal Arc Welding SMAW and found that GTA welds exhibits
(SMAW) and the transverse tensile strength greater strength and ductility due to equi-axed
observed was 524 MPa while that of parent fusion zone grain morphology and protective
material was 523 MPa. It is higher than the nature of the shielding gas. By the addition of
minimum specified tensile strength. Similarly oxygen in the shielding gas in GTAW and
transverse strength for Cu-TMT bar was found addition of Ar+O2 backing in SMAW reduced
to be 600 MPa which was above the MSTS the ductility and strength. The addition of
(minimum specified tensile strength) [5]. copper resulted in increase of strength but
A study was done on rolled plate of ferric reduction in ductility. It has also been
stainless to see the effect of CCGTAW observed that initially with increase in
(continuous current gas tungsten arc welding), austenite, strength decreases and with further
PCGTAW (pulsed current gas tungsten arc increase in austenite content results as increase
welding) plasma arc welding (PAW), GTAW, in strength [8].
SMAW, GMAW and concluded that the joints The effect of different welding process on
made by the PAW (tensile strength 990 MPa) naval grade High Strength Low Alloy steel
were higher by 40 % compared to CCGTAW (HSLA) was studied and found that weld
(600MPa) and by 35 % to PCGTAW (650). metal was comparatively stronger than the
But there is reduction in strength by 41 % in base metal. The yield strength of all type of
case of SMAW and 44 % in GTAW. The welding joints on HSLA steel was higher than
tensile strength of base metal was 524 MPa. the base metal and this was associated with
The elongation study of each specimen precipitate hardening. The increase in strength
showed that PAM joints exhibit higher in case of FSW (Friction Stir Welding) was
ductility than other two types, but less than the 8% more than the base metal due to fine grains
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of acicular, upper banite and small martensite material occurred at the fractured surface [13].
region. The comparison between various weld
joints tensile strength can be done from figure In study of GTA and Laser beam welding on
2 [9]. The effect of filler material was duplex stainless steel showed that the failure
observed using E309L and 18Cr-8Ni-6Mn occurred in the HAZ and they showed ductile
(18-8-6) as filler and found that tensile mode of fracture. The UTS of both joints were
strength of both weld joints were 1230 MPa less than the base metal by 1 % and was
and 1260 MPa respectively which are quite associated with ferrite – austenite ratio that
low compared to base metal (1720 MPa). The resulted due to high cooling rate. The laser
failure has ductile mode. The joint efficiency beam welding produces better mechanical
was around 72% compared to base metal when property due to finer grain size [14]. The weld
calculated on UTS (Ultimate Tensile Strength) joint made using low hydrogen ferritic steel
basis [10]. consumables have high tensile strength due to
(Refer figure 2) ferrite presence in the weld metal [15]. A
Another study made on HSLA HY-80 steel comparative study was made on stainless steel
showed that during tensile test all the joints made by TIG, Laser and Laser –Tig
specimens failed at the base metal which hybrid welding and it was observed that TIG
means HAZ (Heat Affected Zone) and weld welded joint showed a cup-cone shaped
metal has higher strength than the base metal. fracture while Laser and Laser-TIG hybrid
The yield stress and strain of welded specimen showed shear fracture. The tensile strength for
were 639 MPa and 6.8% respectively and of TIG Laser and Laser-TIG hybrid were 560,
the base metal was 577 MPa and 20.7 % [11]. 733 and 683 MPa respectively [16].
From the study of FSW (friction stir welding)
on ferric stainless steel we can conclude that 2. Hardness
ultimate tensile strength of base metal and The ability of materials to resists penetration,
welded joint was almost comparable (536MPa abrasion, scratching or cutting is known as
and 574 MPa respectively) when failure occur hardness. It is the property by which material
in base metal. A notched tensile strength test resists permanent deformation. Various
was done to know the tensile strength of hardness tests are available such as Rockwell
friction stir welded joint and was found to be Hardness Test, Vickers Hardness Test, Brinell
1030 MPa which is 57% higher than the base Hardness Test, Knoop Hardness Test,
metal [12]. The Friction welded joints showed Scleroscope Test and Durometer Test. In
ductile mode of fracture and shear failure of Rockwell Hardness test a cone shape indenter
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or a small ball is pressed into the specimen. for Cu-TMT bar it varied from 256 VHN to
Similarly Vickers Hardness test and Knoop 422 VHN (figure 5). The hardness values at
Hardness test use Pyramid shaped indenter. some location in HAZ were found to be
The difference between Vickers and Knoop is significantly higher in one or two locations.
that the later use indenter having length to This shows that weld joints in both of these
width ratio about 7:1. Knoop Hardness Test is show sufficient internal soundness [5].
generally done to measure micro hardness (Refer figure 4)
which means measuring small thin specimens (Refer figure 5)
or hard material which might fracture when From the hardness examination by Zakaria on
heavy load is applied. industrial low carbon steel (0.19 wt. % C) it
can be said that maximum hardness was in the
Using Vickers Micro hardness testing machine weld metal as well as in the heat affected
the hardness value of parent material (AA6061 zone, which was result of residual stresses just
aluminum alloy) was 105 VHN while of after welding and grain size etc [17]. The
GMAW and FSW (Friction Stir Welding) micro-hardness of different zone can be easily
joints was found to be 58 VHN and 85 VHN. seen in figure 6.
This suggests that the hardness across the (Refer figure 6)
welded section has decreased in the GMAW Another microscopic observation was done on
specimen and increased in FSW [3]. HAZ of a weld joint made of 30CrMo5-2 plate
(base metal) using austentic stainless steel
The effect of hardness with distance has been EN160018 8 Mn B22 as filler material and the
checked using Rockwell hardness as per result obtained showed that, although filler
ASTM E18-05 standards on AA6061 T6 alloy material has very low hardness yet when we
and the result obtained can be seen in table 2 move away from the fusion boundary the
and figure 3. Hardness is expressed as HRF hardness value of HAZ increases slightly [18].
which means Rockwell test is carried out at
load of 60 Kgf [4]. The study of friction stir weldment of X80
(Refer table 2) (0.13 C, 1.52 Mn, 0.26 Si, 0.17 Mo, 0.034 Cr,
(Refer figure 3) 0.026 Ni, 0.0002Nb, 0.003 Ti, 0.062 V, 0.041
A hardness examination was carried on torr Al, 0.032 Cu, 0.0003 B) concluded that there
steel using 10 kg load and found that hardness was little softening of HAZ and the overall
vary along the different zones of the specimen hardness of weld area was more compared to
from 146 HV to 236 HV (figure 4). Similarly base metal and the hardest zone was TMAZ
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(Thermo Mechanical Affected Zone) at the (Refer figure 7)

advancing side. The softening of HAZ was (Refer figure 8)
due to lower peak temperature attained in the (Refer figure 9)
FSW HAZ and the hardness in TMAZ is due A research was done on low carbon steel plate
to formation of acicular phases such as LM (SAE 1020 steel) to see the effect of coarse
and LB. In L80 (steel (0.32 C, 1.20 Mn, 0.35 initial grain size and heat input on
Si, 0.65 Mo, 1.30 Cr, 0.20 Ni, 0.04 Nb, 0.04 microstructure using heat input for welding as
Ti, 0.05 V, 0.04 Al, 0.20 Cu, and 0.0025 B) 0.5, 1 and 2 kJ/mm and concluded that lower
hardness of TMAZ was higher compared to heat input (0.5 KJ/mm) resulted in maximum
HAZ (figure 7). A comparison was made hardness due to formation of martensite.
between hardness of fusion welding and FSW While observing effect on Initial Coarse Grain
on X 80 steel as shown in figure 8 and (ICG) size it was seen that the maximum
concluded that in fusion welding hardest zone hardness was obtained for ICG specimen with
was HAZ while in FSW it was TMAZ [19]. heat inputs of 0.5 and 1 kJ/mm and this was
On ferric stainless steel the hardness varied associated with high carbon, martensite and
from 320 HV to 382 HV which is higher banite. As the heat input increased to 2 kJ/mm
compared to base metal (170 HV) as shown in there was decrease in the hardness of weld
figure 9 [12]. The relation of hardness and metal and HAZ due to ductile phases, pearlite
post welded banitic structure was studied for and ferrite formation. For the same heat input
FSW and concluded that hardness increases the coarse grain has very little effect in
almost linearly with decreasing banite-lath and hardness of weld metal (figure10). The
packet sizes. The maximum hardness was hardness value from the fusion line of base
found in the region of upper banitic structure metal was decreasing almost linearly, while of
and the lowest hardness was in the HAZ. In coarse grained one was fluctuating due to
the stir zone due to frictional heat and plastic existence of martensite and polygonal ferrite
flow; granular banite and recrystallized eqi- [21]. The effect of ICG on hardness of inter-
axed polygonal ferritic structure were formed critical HAZ can be observed by figure 11.
in HAZ. In the hard zone classical lath- like The maximum hardness value was associated
upper banitic structure was formed [20]. with heat input of 0.5 kJ /mm due to the
In ferric stainless steel the hardness value of formation of coarse grain; similarly the
plastic zone (PZ) is higher than partially maximum hardness loss was seen with heat
deformed zone (PDZ) due to formation of input of 2 kJ/mm due to formation of
finer grain size in PZ [13]. polygonal ferrite and fine grain pearlite in
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specimen 1 &2, and fine grain pearlite in HAZ to base metal (as shown in figure no13)
specimen 3. While the hardness of specimens and the increased hardness of weld zone may
with heat input 1 kJ/mm was between the be associated with the martensite formation
above results [22]. The increase in heat input [10]. In HSLA HY-80 steel the weld zone has
is inversely proportional to hardness as higher hardness value (275 HV) than the
experiment showed when heat input increased parent metal (235 HV), and the maximum
from 5 to 8 kJ/cm and hardness decreased to hardness was achieved by SMAW and lowest
148 BHN from 160 BHN [23]. by GMAW when comparison was made
(Refer figure 10) between SMAW, GMAW, and Shielded Arc
(Refer figure 11) welding [11]. Another study was done to see
In the study of hardness of CCGTAW, the effect of Nb (Niobium) microalloyed
PCGTAW, SMAW, GMAW and PAW HSLA steel and found that the parent steel
welded ferric stainless steel specimen it was was harder than the Nb alloyed steel [24].
observed that regardless of the welding (Refer figure 13)
process hardness value of weld region is The study of hardness on laser beam and GTA
greater than HAZ as shown in figure 12 [6] welded joints on Duplex stainless steel
[7]. revealed that there is no significance
(Refer figure 12) difference in hardness of WM, HAZ and base
The hardness study of different weld joints of metal in-spite of variation of ferrite and
HSLA steel showed that there was austenite ratio [14].The welds having acicular
transformation of banite ferrite with carbide ferrite structure have higher hardness [15].
and acicular ferrite at the weld joint that The examination of microhardenss in
resulted into high hardness. The hardness in Titanium Aluminide varied with change in
case of FSW is higher compared with HAZ welding speed and heat input. The fusion zone
and base metal of parent material due to was wider at low speed and high heat input
plastic deformation, continuous dynamic (analyzed from figure 14) [25].
recrystallization and fast cooling rate. Due to (Refer figure 14)
micro-segregation of alloying agent the In the study of ferrite morphology of stainless
hardness increased where prior-austenite grain steel weldment it was concluded that ferrite
size was smaller compared to fusion line. [9] distribution in the austentic matrix affects the
The effect of filler materials E309L and 18-8- stress rupture behavior particularly at elevated
6 showed that the maximum hardness was in temperature. And the ferritic distribution
the HAZ and the hardness decreased in from mainly depends upon heat input [26].
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3. Microstructure as shown in figure15 [27].

The structural features such as grain and (Refer figure 15)
phase structure which are subjected to The optical microstructure examination of torr
microscopic observation are called steel show that the weld metal has refined
microstructure. Microstructure is very polygonal pearlite structure and the HAZ has a
useful in study and characterization of transition to coarse ferrite structure with large
materials. Various microscopic techniques volume of pearlite. Similarly in case of Cu-
are Optical microscopy, Electron TMT bar the weld metal has ferrite –pearlite
Microscopy, Scanning Electron structure and the HAZ has Widmanstatten
Microscopy etc. ferrite structure with some percentage of
banite [5].
In AA6061 aluminum alloy the base metal From the microscopic examination (figure 16
contains coarse and elongated grain with and 17) of industrial low carbon steel (0.19 wt.
uniformly distributed very fine % C) shows that the microstructure of weld
precipitates, on the other hand in GMAW zone and HAZ are different. HAZ contains
the fusion zone have dendritic structure. In widmanstatten ferrite and some colonies of
FSW the weld region of FSW contains pearlite, while that of base metal has eqiaxed
very fine equiaxed grains. The dendritic ferrite grains [17]. During cooling of the HAZ
structure was due to fast heating of base first transformation occur as δ-Fe to γ-Fe and
metal and fast cooling of molten metal second transformation occur as γ-Fe to α-Fe
(molten by welding heat) and the fine transformation [28].
equiaxed grain formed in FSW may be due (Refer figure 16)
to dynamic recrystallisation occurred (Refer figure 17)
during welding [3].The microstructure of
AA 6061 T6 alloy was studied using
scanning electron microscopy (SEM) and Another microscopic observation was done on
found that grain growth took place at HAZ HAZ of a weld joint made of 30CrMo5-2 plate
[4]. (base metal) using austentic stainless steel
In Low alloy steel 16Mo3 the EN160018 8Mn B22 as filler material and the
metallographic observation was made by result obtained showed that there was
an optical microscope Olympus PMG3 for tempered martensite in the HAZ as well as
MMA and MAG joints and following base metal [18].
structure were obtained for different region
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A research was done on FSW weldments of containing martensite, banite, pearlite and
X-80 and concluded that the grain size of polygonal ferrite changed to pearlite and
HAZ region and the base metal was almost polygonal ferrite (as shown in figure 18). The
same around 5 microns. Grain size increases amount of pearlite has been formed with
up to 30 micron as we advance towards decrease in martensite and banite also the
TMAZ. While in Fusion Welding coarse grain microstructure in the GCHAZ has refined
are present. This shows that the conventional [21]. The study on intercritical HAZ showed
coarse grain structure has moved to the that the microstructure in fine grained
advancing side of TMAZ in FSW that were at specimen transformed from grain boundary
fusion line in Fusion Welding. The base metal ferrite and pearlite to polygonal ferrite, and in
of X-80 steel contains ferrite, granular banite coarse grain it changed from martensite to
and martensite while HAZ contains ferrite, ferrite and fine grain pearlite. The ferrite
granular banite, and lath martensite. TMAZ changed to polygonal in original and coarse
contain large fraction of granular banite, grain specimen and pearlite grains tended to
degenerated upper banite and lath martensite. refine [22]. The microstrucute of the HAZ in
Similar experiment was carried out for L-80 low carbon steel depends on the chemical
and observed that coarsening of carbide and composition, the peak welding temperature
hard martensite were formed at the HAZ and and the welding voltage. The amount of
in TMAZ higher coarse grain of lath pearlite is inversely proportional to heat input
martensite was formed while the base metal [23]. The welded region in high strength steel
contain mainly tempered carbides [19]. In contains acicular ferrite and pro eutectic ferrite
ferric stainless steel joined by FSW, due to on boundary at low heat input while at higher
rapid cooling and high strain due to plastic heat input the ferrite side is the main phase
deformation the microstructure changed to [29].
ferrite and martensite [12]. (Refer figure 18)
In weldability study of Titanium Aluminide it
A research was done on low carbon steel to was found that the microstructural
see the effect of coarse initial grain size on characteristics of weldment were function of
microstructure and as a result of increase in welding speed, heat input and cooling rate. At
heat input the microstructure in weld metal low welding speed (low cooling rate or high
changed from martensite and banite to grain heat input) fine acicular were formed and at
boundary ferrite, Widmanstatten ferrite, high welding speed (high cooling rate or low
acicular ferrite and pearlite. And HAZ heat input) β and ordered β were formed. The
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microstructure in HAZ gradually varies from the temperature range of 250 C. [5].
fusion line to far HAZ [25]. In friction stir welding of ferric steel the
The microstructure of GCHAZ in HSLA steel toughness decreased in weld centre line (28 J)
showed that with decrease in heat input the and HAZ (30 J) compared to base metal (34 J)
fraction of baintite increase and ferrite [12].
decrease by volume. At 30 kJ/cm only fine The research was carried out in low carbon
lathe bainite and at 60kJ/cm only granular steel SAE 1020 steel and SAE 1020 steel with
banite was formed [24]. In comparative study coarse initial grain size (CIG steel) for finding
between TIG, laser and TIG –laser hybrid toughness at different heat input showed that
welding showed that only in TIGW transition maximum toughness at weld metal for both
zone and HAZ were present [16]. steel were achieved with 1 kJ/mm due to
presence of tougher acicular ferrite. On the
4. Toughness other hand due to martensite formation at heat
The ability of materials to absorb input of 0.5 kJ/mm, minimum toughness was
energybefore fracture is called toughness. The obtained and there was small decrement in
area under stress strain curve gives toughness. weld metal at 2 kJ/mm due to coarsened phase
Izod and Charpy test are most common (figure 19 and 20). In the same way for HAZ it
method to find toughness of material. was seen that maximum toughness of base
V notch Charpy impact test on HAZ was material was observed at 1 kJ/mm and for CIG
carried for low alloy 16Mo3 and found that steel at 2 kJ/mm. The maximum toughness is
MMA and MAG welded specimen has value associated with ductile phase’s ferrite and
136 J and 89 J while that of base metal have pearlite. The minimum toughness was
31 J, which means toughness has increased observed with heat input 0.5 kJ/mm. In CIG
after welding [27]. steel compared to base metal the loss of
The charpy test carried on torr steel and Cu- toughness is more due to high carbon
TMT bar suggest that SMAW joints on these martensite formation [21]. The toughness of
materials posses sufficient toughness at room steel can be controlled by varying welding
temperature and 00 C, but as the temperature parameters. Toughness varied from 92.3 to
drops down below 00 C the steels are 40.8 kJ as welding condition varied from
susceptible to brittle fracture. CIT (Charpy 130A/20V to 180 A/30V as in figure 19 [23]
Impact Test) of torr steel for Parent Metal [30].
show drop down from 117 J at 260C to 7.8 J at (Refer figure 19)
00C, it shows high ductile -brittle transition in (Refer figure 20)
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(Refer figure 21) strength when fusion welding (except

The toughness of PAW joints were 20 J PAW) is employed.
comparable to base metal (22 J) while of  FSW increases the tensile strength to
PCGTAW and CCGTAW were less than base some extent.
metal and PAW joints. There was decrease in  Higher the ferrite content higher is the
SMAW by 18% and in GMAW by 27% [6] Tensile strength.
[7].  The decrease in tensile strength
Due to presence of martensite –austenite and depends on the electrode material,
ferrite lath in banitic mixture in the GMA filler material, welding speed, heat
weld zone of HSLA steel the toughness has input.
enhanced. But in FSW joints the presence of  The parent material and the welding
martensite lowers the toughness [9]. The process decide whether failure will
charpy V notch test showed that toughness of occur in base material or weld zone.
HAZ region matched with base material when Almost all experiment showed ductile
309L and 18-8-6 filler materials were used, mode of failure.
however toughness of joint made E309L filler  In all the research the hardness of the
material was greater by factor of 3/2 [10]. weld zone was greater, followed by
The presence of nickel and austenite phase in HAZ and base metal due to martensite
the weld metal leads to more toughness [15]. and banite formation.
Due to auto tempering low carbon martensite  Hardness increases with decrease in
has higher toughness than upper banite [31]. heat input, also the hardness depend on
The toughness of HSLA depend on the composition of filler material.
temperature and it increases almost linearly  The weld zone is wider for low speed
with the heat increase in temperature as the welding.
experiment showed variation from 55 J to 125  Martensite and banite is mainly present
J when temperature changed from -50C to 00C in weld area and HAZ. The
[32]. microstructure transformation depends
on heat input. The amount of peralite is
CONCLUSION inversely proportional to heat input.
From the above study following conclusions  The toughness of material is associated
were drawn: with pearlite and ductile ferrite phases.
 For ferrous as well as non ferrous The filler material constituents also
material there is decrease in tensile decide the toughness of the welded
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joints. SMAW Process, Journal of Material

Engineering and Performance, 11(2009), pp:
ACKNOWLEDGEMENT 369-375
Authors are thankful to Director, CSIR-
CIMFR, Dhanbad for his kind permission to [6] A. K. Lakshiminarayanan, K Shanmugam,
do the experimentation with reference to our V Balasubramanian. Effect of Autogenous Arc
post-graduation research work and Welding Processes on Tensile and Impact
publication thereof. Properties of Ferritic Stainless Steel Joints,
Journal of Iron and Steel Research, 16(1)
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[1]M. P. Groover, Fundamentals of Modern
Manufacturing, Wiley India Publication, 2010, [7]A. K. Lakshiminarayanan, K Shanmugam,
pp: 689-691 V Balasubramanian. Effect of Welding
Processes on Tensile and Impact Properties,
[2] R. K. Jain, Production Technology, Hardness and Microstructure of AISI 409M
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pp:273 Duplex Stainless Steel Filler Metal, Journal of
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[3] A. K. Lakshminarayanan, V. 72
Balasubramanian, K.Elangovan. Effect of
welding process on tensile properties of [8] T. Mohandas, G. Madhusudhan Reddy,
AA6061 aluminium alloy joint, Int J Adv Mohammad Naveed. A Comparative
Manuf Tech, 40 (2009), pp: 286-296 evaluation of gas tungsten and shielded metal
arc welds of a “ferritic” stainless steel, Journal
[4] Elsadig. Eltai, E. Mahdi, Akram Alfantazi. of Material Processing Technology, 94(1999),
The Effect of Gas Tungsten Arch Welding on pp: 133-140
the Corrosion and Mechanical Properties of
AA6061 T6, Int. J. Electrochem. Sci., 8(2003), [9] S. RaguNathan, V. Balasubramanian, S.
pp: 7004-7015 Malarvizhi, A.G. Rao, Effect of Welding on
Mechanical and Microstructural Characteristic
[5] Rameen Datta, R.Veeraraghavan, K. L. of High Strength Low Alloy Naval grade Steel
Rohiraa. Weldability Characteristic of Torr Joints, Defence Technology,11(2015) , pp:
and Corrosion- Resistant TMT Bar Using 308-317
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G madhusudhan Reddy, T S Balasubramanian.

[10] G. Madhusudhan Reddy, T.Mohandas, G. Effect of Welding Processes and Consumables
R. N. Tagore. Weldability studies of high- on Tensile and Impact Properties of High
strength low –alloy steel using austenitic Strength Quenched and Tempered Steel Joints,
fillers,Journal of Material Processing Journal of Iron and Steel Research, 15(6)
Technology, 49(1995), pp: 213-228 (2008), pp: 87-94

[11] P.Yayla, E. Kaluc, K.Ural. Effects of [16] Jun Yan, Ming Gao, Xiaoyan Zeng.
welding processes on the mechanical Study on microstructure and mechanical
properties of HY 80 steel weldments. properties of 304 stainless steel joints by TIG,
Materials and Design, 28(2007), pp: 1898- laser and laser- TIG hybrid welding, Optics
1906 and Laser in Engineering, 48(2010), pp: 512-
517
[12] A. K. Lakshminarayanan,V.
Balasubramanian. An asseseement of [17] Zakaria Boumerzoung, Chemseddine
microstructure, hardness, tensile and impact Defouf, Thierry Baudin. Effect of Welding on
strength of friction stir welded ferritic stainless Microstructure and Mechanical Properties of
steel joints, Material and Design, 31(2010), an Industrial Low Carbon Steel. Engineering
pp: 4592-4600 (science research ), 2(2010), pp502-506

[13] P. Sathiya, S. Aravindan, A. Noorul Haq. [18] C. Rodriguez, J. Garcia Cabeza, E.

Effect of friction welding parameters on Cardenas, F. J. Belzunce, C. Betengeon.
mechanical and metallurgical properties of Mechanical Properties Characterization of
ferritic stainless steel, Int J Adv Manuf Heat- Affected Zone Using Small Punch Test,
Technol, 31(2007), pp: 1076-1082 Welding Journal, 88(sep 2009), pp: 188-s –
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[14] A-H. I. Mourad, A. Khourshid, T.Sharef.
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process effects on duplex stainless steel 2205 Bangaru, R.Ayer, G. Vaughn, R. Steel,
properties, Material Science and Engineering, S.Packer. A Microstructural Study of Friction
A 549 (2012), pp 105-113 Stir Welded Joints Of Carbon Steels,
Fourteenth International Offshore and Polar
[15] G Magudeeswaran, V Balasubramanian, Engineering Conference Toulon , France
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2004, pp: 61-66

[25] S. A. David, J.A. Horton, G. M.
[20] Hakan Aydin. Relationship Between a Goodwin, D. H. Phillips, R. W. Reed.
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HAZ of a low carbon steel, Material Science 425-s – 429-s
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toughness of intercritical Heat- affected zone Alloy Steel 16Mo3 in the Heat Affected Zone
of a low carbon steel, Material Science and in Welding Processes MMA and MAG,15th
Engineering, A286(2000), pp: 289-297 International Research/ Expert Conference
“Trends in Development of Machinery and
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steel using inert gas welding, Materials and Palmer,6th International conference on Trends
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LI Jin-fu, LIU Wei- ming. Effect of Heat Input [29] Wang Juan, LI Yajiang. Microstructure
on Microstructure and Toughness of Course characterization in the weld metal of HQ130 +
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Research, 16(5) (2009), pp: 73-80
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[30] Millian Karl, Datta Ratan, Zimmermann Carbon Microalloyed Steels, Welding
Horst. Effects off heat input on the Research Supplement, September 1987, pp:
microstructure and toughness of 8MnMoNi 5 266-s – 279-s
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The Heat Affected Zone Toughness of Low
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LIST OF TABLES

Table 1: Tensile property for welded and un-welded specimen of AA6061 T6 [4].

Table 2: Hardness value for welded specimen[4].

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LIST OF FIGURES

Figure 1: Stress – Strain relationship for welded and un-welded specimen of AA6061 T6alloy [4].

Figure 2: Load vs. displacement curves of Parent Metal and welded joints [9].
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Figure 3: Hardness profile for welded area and away from the weld [4].

Fig 4: Hardness profile of torr steel [5]. Fig 5: Hardness profile of Cu TMT steel
[5].

Figure 6: Hardness measurement on surface across the weld metal of industrial low carbon steel [17].
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Figure 9: Hardness profile of friction stir welded 409M ferritic stainless steel [12].
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Figure10: Hardness measurement result with heat input a) 0.5, b) 1 c) 2 kJ/mm [21].

Specimen 1 SAE 1020 steel (base metal)

Specimen 2 SAE 1020 steel with coarse initial grain size

Figure11: Relationship between hardness value of intercritical HAZ and heat input [22].
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Figure 12: Hardness value across weld in ferric stainless steel due to different welding process [6][7].

Figure 13: Hardness profile of HSLA using a) 309L filler b) 18-8-6 filler [10].
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Figure 14: Microhardness variation of Titanium aluminide Electron Beam weldments made at three
welding speeds and heat inputs [25].

Figure 15: Microstructure of different zone for a) MMA joints b) MAG joints [27].
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Figure 16: Microstructure of HAZ after welding of an industrial low carbon steel [17].

Figure 17: Center of weld metal “in the weld fusion zone”[17].

Figure 18: The formation of microstructure in GCHAZ in SAE 1020 steel with coarse initial grain
size for a heat input 0.5 kJ/mm [21].
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Figure 19: Variation of temperature with current and voltage [23].

Figure 20: Relationship of weld metal toughness vs heat input (B, base metal) [21].

Figure: 21Relationship between toughness of HAZ and heat input (B,base metals) [21].
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