Characterization of Fillet Welded Armor Steel Performed by Robotic Gas Metal Arc Welding: Effect of Heat Input on Microstructure and Microhardness
Source abstract
Abstract
In this research, fillet welding was conducted on 8-mm thick Miilux OY Protection 600 (MIL-A-46100) armor steel using AWS A5.9 GeKa ER307 austenitic filler wire. The welding process involved robotic MIG/MAG with five different heat inputs ranging from 0.3 to 1.2 kJ/mm. The study focused on examining the influence of heat input on the microstructure, elemental changes, microhardness, and dimensions of the weld metal and the heat-affected zone (HAZ). These investigations were conducted to determine the welding parameters that they satisfy the quality requirements of the MIL-STD-1185 standard for this steel grade and weld consumable. Through analysis of macrostructure, microstructure, and microhardness, it was observed that increasing the heat input led to a decrease in hardness for both the weld metal and the HAZ, while expanding the HAZ width. The weld metal exhibited a homogenous hardness distribution at lower and higher heat inputs, but hardness increased from the root to the face for both heat inputs of 0.5 and 0.7 kJ/mm welds. Notably, a significant decrease in hardness occurred in the transition of partial transformation region (intercritical HAZ) and tempering region (subcritical HAZ) for heat inputs above 0.7 kJ/mm, indicating softening. Moreover, the width of the subcritical heat-affected zone substantially increased. Evaluation of the distance required to reach base metal hardness from the welding toe revealed that a heat input of 1.2 kJ/mm exceeded the maximum requirement of 15.9 mm according to the MIL-STD-1185 standard. However, the requirements of the military standard were satisfied for other heat input values. These findings were associated with microstructural changes in grain size, martensite, bainite, martensite/austenite morphology and their fractions, as well as delta ferrite morphology. The results successfully demonstrated that robotic GMAW welding can be applied using lower strength (undermatched) filler metal to satisfy the requirements of the respective standard of MIL-STD-1185.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Welding Techniques and Residual Stresses · Metal Alloys Wear and Properties · Metal and Thin Film Mechanics
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (39)
Show source-provided references
1. L. Kuzmikova, An Investigation of the Weldability of High Hardness Armor Steel, PhD Thesis, University of Wollongong, Australia, 2013
2. G. Magudeeswaran, V. Balasubramanian, and G. Madhusudhan Reddy, Effect of Welding Process and Consumables on High Cycle Fatigue Life of High Strength Quenched and Tempered Steel Joints, Mater. Des., 2008, 29, p 1821–1827. https://doi.org/10.1016/j.matdes.2008.03.00610.1016/j.matdes.2008.03.006 ↗
3. G. Magudeeswaran, V. Balasubramanian, and G. Madhusudhan Reddy, Effect of Welding Process Consumables on Fatigue Crack Growth Behavior of Armor Grade Quenched and Tempered Steel Joints, Def. Technol., 2014, 10, p 47–59. https://doi.org/10.1016/j.dt.2014.01.00510.1016/j.dt.2014.01.005 ↗
4. U. Gürol, T. Karahan, S. Erdöl et al., Characterization of Armour Steel Welds using Austenitic and Ferritic Filler Metals, Trans. Indian Inst. Met., 2022, 75, p 757–770. https://doi.org/10.1007/s12666-021-02464-710.1007/s12666-021-02464-7 ↗
5. S. Naveen Kumar, V. Balasubramanian, S. Malarvizhi, A. Rahman, and V. Balaguru, Effect of Welding Consumables on Shielded Metal Arc Welded Ultra High Hard Armour Steel Joints, J. Mech. Behav. Mater., 2022 https://doi.org/10.1515/jmbm-2022-000210.1515/jmbm-2022-0002 ↗
6. S.S. Sabari, S. Malarvizhi, V. Balasubramanian, and M.G. Reddy, Experimental and Numerical Investigation on Under-Water Friction Stir Welding of Armour Grade AA2519-T87 Aluminium Alloy, Def. Technol., 2016, 12(4), p 324–333. https://doi.org/10.1016/j.dt.2016.02.00310.1016/j.dt.2016.02.003 ↗
7. S.J. Alkemade, The Weld Cracking Susceptibility of High Hardness Armour Steel, Def. Sci. Technol. Organ., Australia, 1996, pp. 1–17
8. S. Naveen Kumar, V. Balasubramanian, S. Malarvizhi, A. Hafeezur Rahman, and V. Balaguru, Influence of Microstructural Characteristics on Ballistic Performance and its Mode of Failure in Shielded Metal Arc Welded Ultra-High Hard Armor Steel Joints, Trans. Indian Inst. Met., 2021, 74, p 909–921.10.1007/s12666-021-02197-7 ↗
9. A.K. Pramanick, H. Das, S. Nandy et al., Characterization of Microstructure and Nonmetallic Inclusions of Double V Grooved Armour Steel Weld Metal through Developed Coated Electrode, Trans. Indian Inst. Met., 2017, 70, p 1621–1633. https://doi.org/10.1007/s12666-016-0961-110.1007/s12666-016-0961-1 ↗
10. Z. Balalan, F. Sarsilmaz, and O. Ekinci, Mechanical Properties and Fatigue Behavior of CO2 Laser Beam Welded Armor Steel Joints, Mater. Test., 2020, 62(7), p 689–697. https://doi.org/10.3139/120.11153410.3139/120.111534 ↗
11. C. Evci, H. Işık, and E. Değirmenci, Influence of Welding Wire Selection on the Strength and Toughness of Welded Armor Steel Joints, Mater. Test., 2014, 56(10), p 812–817. https://doi.org/10.3139/120.11063410.3139/120.110634 ↗
12. A. Saxena, A. Kumaraswamy, G.M. Reddy, and V. Madhu, Influence of Welding Consumables on Tensile and Impact Properties of Multi-Pass SMAW Armox 500T Steel Joints Vis-a-Vis Base Metal, Def. Technol., 2018, 14, p 188–195. https://doi.org/10.1016/j.dt.2018.01.00510.1016/j.dt.2018.01.005 ↗
13. S. Naveen Kumar, V. Balasubramanian, S. Malarvizhi et al., Influence of Welding Consumables on Ballistic Performance of Gas Metal Arc Welded Ultra-High Hard Armor Steel Joints, Mater. Perform. Charact., 2021, 10(1), p 443–462. https://doi.org/10.1520/MPC2020015010.1520/MPC20200150 ↗
14. S. Naveen Kumar, V. Balasubramanian, S. Malarvizhi et al., Influence of Microstructural Characteristics on Ballistic Performance and Its Mode of Failure in Shielded Metal Arc Welded Ultra-High Hard Armor Steel Joints, Trans. Indian Inst. Met., 2021, 74, p 909–921. https://doi.org/10.1007/s12666-021-02197-710.1007/s12666-021-02197-7 ↗
15. E. Souza, R. Weber, S. Monteiro, and S. Oliveira, Microstructure Effect of Heat Input on Ballistic Performance of Welded High Strength Armor Steel, Materials, 2021 https://doi.org/10.3390/ma1419578910.3390/ma14195789 ↗
16. United States Department of the Army. Test Operations Procedure 2-2-710. Ballistic Tests of Armor Materials. 1984, https://www.document-center.com/standards/show/TOP-2-2-710. Accessed 7 Sept 2021
17. US Army. MIL-STD-662F Department of Defense. 1997, http://everyspec.com/MIL-STD/MIL-STD-0500-069 9/MIL-STD-662F_6718/. Accessed 7 Sept 2021
18. B. Savic and A. Cabrilo, Effect of Heat Input on the Ballistic Performance of Armor Steel Weldments, Materials, 2021, 14, p 3617.10.3390/ma14133617 ↗
19. A. Netto, F.M.N. Bayock, and P. Kah, Optimization of GMAW Process Parameters in Ultra-High-Strength Steel based on Prediction, Metals, 2023, 13(8), p 1447. https://doi.org/10.3390/met1308144710.3390/met13081447 ↗
20. V. Tandon, M.A. Thombre, A.P. Patil, R.V. Taiwade, and H. Vashishtha, Effect of Heat Input on the Microstructural, Mechanical, and Corrosion Properties of Dissimilar Weldment of Conventional Austenitic Stainless Steel and Low-Nickel Stainless Steel, Metallogr, Microstruct Anal, 2020, 9, p 668–677. https://doi.org/10.1007/s13632-020-00681-y10.1007/s13632-020-00681-y ↗
21. BS EN 1708-2:2018 Welding. Basic Weld Joint Details in Steel Non Internal Pressurized Components, 2018
22. S.A. David, J.M. Vitek, and T.L. Hebble, Effect of Rapid Solidification on Stainless Steel Weld Metal Microstructures and Its Implications on the Schaeffler Diagram, Weld. J., 1987, 66(10), p 289s–300s.
23. D.J. Kotecki, Metals Handbook, 8th Ed., American Society for Metals, Vol 6 Welding, Brazing And Soldering, Welding Of Stainless Steels, 1972, pp. 1689-1712
24. S. Sirohi, C. Pandey, and A. Goyal, Characterization of Structure-Property Relationship of Martensitic P91 and High Alloy Ferritic Austenitic F69 Steel, Int. J. Press. Vessels Pip., 2020, 188, p 104179. https://doi.org/10.1016/j.ijpvp.2020.10417910.1016/j.ijpvp.2020.104179 ↗
25. S. Kumar, C. Pandey, and A. Goyal, A microstructural and mechanical behavior study of heterogeneous P91 welded joint, Int. J. Press. Vessels Pip., 2020, 185, p 104128.10.1016/j.ijpvp.2020.104128 ↗
26. A.K. Maurya, C. Pandey, and R. Chhibber, Dissimilar Welding of Duplex Stainless Steel with Ni Alloys: A Review, Int. J. Press. Vessels Pip., 2021, 192, p 104439. https://doi.org/10.1016/j.ijpvp.2021.10443910.1016/j.ijpvp.2021.104439 ↗
27. J.N. DuPont, Microstructural Evolution and High Temperature Failure of Ferritic to Austenitic Dissimilar Welds, Int. Mater. Rev., 2012, 57(4), p 208–234. https://doi.org/10.1179/1743280412Y.000000000610.1179/1743280412Y.0000000006 ↗
28. M.L. Huang and L. Wang, Carbon Migration in 5Cr-0.5Mo/21Cr-12Ni Dissimilar Metal Welds, Metall. Mater. Trans. A, 1998, 29, p 3037–3046. https://doi.org/10.1007/s11661-998-0211-110.1007/s11661-998-0211-1 ↗
29. A. Saxena, A. Kumaraswamy, G.M. Reddy, and V. Madhu, Influence of Welding Consumables on Tensile and Impact Properties of Multi-Pass SMAW Armox 500T Steel Joints Vis-a-Vis Base Metal, Def. Technol., 2018, 14(3), p 188–195. https://doi.org/10.1016/j.dt.2018.01.00510.1016/j.dt.2018.01.005 ↗
30. Y. Horii, K. Ichikawa, S. Ohkita, S. Funaki, and N. Yurioka, Chemical Composition and Crystal Structure of Oxide Inclusions Promoting Acicular Ferrite Transformation in Low Alloy Submerged Arc Weld Metal, Q. J. Jpn. Weld. Soc., 1995, 13(4), p 500–507.10.2207/qjjws.13.500 ↗
31. F.J. Barbaro, P. Krauklis, and K.E. Easterling, Formation of Acicular Ferrite at Oxide Particles in Steels, Mater. Sci. Technol., 1989, 5(11), p 1057–1068. https://doi.org/10.1179/02670838979034088810.1179/026708389790340888 ↗
32. D.J. Abson, Acicular Ferrite and Bainite in C-Mn and Low Alloy Steel Arc Weld Metals, Sci. Technol. Weld. Join., 2018, 23(8), p 635–648. https://doi.org/10.1080/13621718.2018.146199210.1080/13621718.2018.1461992 ↗
33. Dileep Chandran Ramachandran, Sung-Dae. Kim, Joonoh Moon, Chang-Hoon. Lee, Jun-Ho. Chung, Elliot Biro, and Yeong-Do. Park, Classification of Martensite-Austenite Constituents According to its Internal Morphology in High-Strength Low Alloy Steel, Mater. Lett., 2020, 278, p 128422. https://doi.org/10.1016/j.matlet.2020.12842210.1016/j.matlet.2020.128422 ↗
34. V.E. Danilchenko, V.F. Mazanko, and V.E. Iakovlev, The Effect of Multiple Martensitic Transformations on Diffusion of Fe and Ni Atoms in Fe-31.7%Ni-0.06%C Alloy, Nanoscale Res. Lett., 2014, 9, p 322. https://doi.org/10.1186/1556-276X-9-32210.1186/1556-276X-9-322 ↗
35. O. Coban, U. Gurol, S. Erdol, and M. Kocak, Effect of Plate Thickness on the Microstructure and Hardness of Robotic Fillet Welded Armour Steels, 6th International Conference onWelding Technologies and Exhibition (ICWET'21), 13-15 October 2021, Hatay-Turkey, Paper ID-46
36. C. Celik, R.M. Kurt, O. Coban, H. Baykal, K. Akben, and U. Gurol, The Effect of Process Parameters on Bead Geometry, Hardness and Microstructural Properties of Armour Steel Welds Performed by Robotic Gas Metal Arc Welding, 21th International Metallurgy and Materials Congress-IMMC2022, 06-08 October 2022, Istanbul-Turkey
37. J. Xu, Y. Peng, S. Guo et al., Softening Behavior of Electron Beam Welded 22SiMn2TiB Steel, J. Mater. Eng. Perform., 2019, 28, p 6669–6681. https://doi.org/10.1007/s11665-019-04366-810.1007/s11665-019-04366-8 ↗
38. MIL-STD-1185, Department of Defense Manufacturing Process Standard: Welding, High Hardness Armor (31 Dec 1979) [Supersedes Mil-W-62162]
39. C. Pandey, Mechanical and Metallurgical Characterization of Dissimilar P92/SS304 L Welded Joints under Varying Heat Treatment Regimes, Metall. Mater. Trans. A, 2020, 51, p 2126–2142. https://doi.org/10.1007/s11661-020-05660-010.1007/s11661-020-05660-0 ↗