Dramatic improvement of the strength of laser welded joints of Nb521 to GH3128 by adding pure copper as an interlayer

Weld cracks and low weld strength of Nb521 to GH3128 dissimilar metal welded joint are key factors influencing their weldability. To obtain favorable crack-free laser welded joints, this research adopted copper as an interlayer to research the microstructure and properties of laser direct welded and laser offset welded joints of Nb521 to GH3128 superalloy. Compared to previous research results, the tensile strength of laser direct welded joints is enhanced by 2.5 folds. There is a melting reaction layer at the position where the center welded joints are adjacent to the Nb521 base metal, and Ni ₃ Nb and Laves phases are present in the layer. The copper solid solution is located in the center of fusion zone, and Ni ₃ Nb-Laves hard particles are found. The phases near the side of GH3128 superalloy base metal are Ni solid solution, Cu solid solution, Ni ₃Nb/Cr ₂ Nb hard particles and high melting point alloy mixture. Macrosegregation at the laser offset welding fusion zone is more serious. The phases near the Nb521 base metal are Nb solid solution, Cu solid solution, Ni ₃ Nb and Cu/Cr eutectic structure. At the center of the fusion zone, Cu solid solution, Ni ₃Nb and Cu/Cr eutectic structure are observed. The phases near GH3128 base metal are Ni solid solution, Cr ₂ Nb phase and Cu solid solution. Mean Vickers hardness values of the direct welded fusion zone is 271.7 ± 129.8 HV, which reduces mismatching of hardness of the joints to a certain degree. As there are Laves phase and Ni ₃ Nb brittle phase in the melting reaction layer adjacent to Nb521 base metal, the microhardness value is up to 589.1 HV. The average microhardness of the offset welded fusion zone is 449.1 ± 217.4 HV, which is higher than the hardness of Nb521 and GH3128 base metals, due to increasing number of brittle phases in the joints. Strength values of the direct welded and offset welded joints are 418.7 ± 49.8 MPa and 364.3 ± 24.5 MPa respectively, which are separately 86.0% and 74.8% of Nb521 base metal. Fractures are all found to occur at the fusion zone on the side of Nb521. The direct welded joints exhibit mixed fracture characteristics with dimples and cleavage facets on the fracture, while the offset welded joints are characterized by brittle fracture.