Finite element study of thermal behaviour in ultra-low nickel Cr-Mn ASS welded with SMAW & GMAW techniques Sachin Ambade, Chetan Tembhurkar, Devendra Shahare Nuclear Energy and Technology, 2025 Cr-Mn Austenitic Stainless Steel (ASS) are utilized in nuclear reprocessing plants, fast-breeder reactors, pressurised water reactors and boiling water reactors because of their ease of fabrication and welding. In this study two fillers were used, ER308L and ER308L-16, to weld ultra-low nickel Cr-Mn ASS using gas metal arc welding (GMAW) and shielded metal arc welding (SMAW) process. The simulation of the welding processes was carried out for the evaluation of stresses induced in the welding. The heat input is employed at the weld bead for modelling and analysis. From analysis, it was found that the weld bead width is less in GMAW as compared to SMAW. The transient thermal and structural analysis was carried out for evaluation of stresses in the weld using ANSYS. The weld for both welding methods was analysed using varying welding speeds. It was revealed that as the welding speed increases there is a decrease in Von-Mises stresses in the weld.
Cold metal transfer welding of 316L/430 dissimilar stainless-steel welds Chetan Tembhurkar, Sachin Ambade, Ravinder Kataria, Jagesvar Verma, Abhijeet Moon Anti Corrosion Methods and Materials, 2025 Purpose This paper aims to examine dissimilar joints for various applications in chemical, petrochemical, oil, gas, shipbuilding, defense, rail and nuclear industry. Design/methodology/approach This study examined the effects of cold metal transfer welding on stainless steel welds for 316L austenitic and 430 ferritic dissimilar welds with ER316L, ER309L and without (autogenous) fillers. The microstructural observation was done with an optical microscope. The mechanical test was done to reveal the strength, hardness and toughness of the joint. The electrochemical polarization tests were done to reveal intergranular and pitting corrosion in the dissimilar joints. Findings This microstructural study shows the presence of austenitic and ferritic phases with vermicular ferrite for ER309L filler weld, and for ER316L filler weld specimen shows predominately martensitic phase in the weld region, whereas the autogenous weld shows lathy ferrite mixed with martensitic phase. Mechanical test results indicated that filler welded specimen (ER316L and ER309L) has relatively higher strength and hardness than the autogenous weld, whereas ER316L filler weld exhibited the highest impact toughness than ER309L filler weld and lowest in autogenous weld. The electrochemical corrosion results displayed the highest degree of sensitization (DOS) in without filler welded specimen (45.62%) and lower in case of filler welded specimen ER309L (4.95%) and least in case of ER316L filler welded specimen (3.51%). The high DOS in non-filler welded specimen is correlated with the chromium carbide formation. The non-filler welded specimen shows the highest pitting corrosion attack as compared to the ER316L filler weld specimen and relatively better in ER309L filler welded specimen. The highest pitting corrosion resistance is related with the high chromium content in ER309L composition. Originality/value This experimental study is original and conducted with 316L and 430 stainless steel with ER316L, ER309 and without fillers, which will help the oil, shipbuilding and chemical industries.
Microstructure, mechanical properties and sensitization of ultra-low nickel Cr–Mn austenitic stainless steels Sachin P. Ambade, Chetan K. Tembhurkar, Awanikumar Patil, Atul V. Tidke, Sagar D. Shelare, Chander Prakash, Milos B. Djukic, Nima Khosravi, Prabhu Paramasivam Journal of Materials Research and Technology, 2024 The present study deals with the effect of SMAW and GMAW process with different welding speeds on microstructural, mechanical and intergranular corrosion properties of ultra-low nickel Chrome-Manganese austenitic stainless steel. The microstructural analysis was performed by optical microscope. The Fisher Ferritscope was used for determining ferrite content in the weldment. The microstructural analysis shows that size of dendrites of δ ferrite and width of HAZ decreases in order to increase in welding speed. It was found that more δ-ferrite in weldment of SMAW weld as compared to weld metal of GMAW weld. It was also found that when welding speed increases, tensile strength, impact strength and hardness values decrease for both the welding processes. From, U-bend test it was found that the welded joints are strong enough to withstand bend at 1800 without any cracks for both the welding processes. It was also found that Cr-Mn SS weld becomes susceptible to intergranular corrosion on welding. For both the welding processes, the degree of sensitisation value decreases with respect to increase in welding speed for both the welding processes as evaluated by DLEPR test. It was also found that the weld joint of GMAW process is more susceptible to intergranular corrosion than that of SMAW process.
Experimental investigation of microstructural, mechanical and corrosion properties of 316L and 202 austenitic stainless steel joints using cold metal transfer welding Sachin Ambade, Chetan Tembhurkar, Akshay Rokde, Santosh Gupta, Sagar Shelare, Chander Prakash, Lovi Raj Gupta, Vladimir A. Smirnov Journal of Materials Research and Technology, 2023 The objective of the current experimental study is to investigate influence of dissimilar welding between 316 L Austenitic and 202 Austenitic Stainless Steel. This is achieved through the utilization of Cold Metal Transfer (CMT) Welding in conjunction with the GTAW mode. Various welding approaches are employed, including the use of ER316L and ER309L fillers, as well as a no-filler (autogenous) welding technique. Microstructural observation shows martensitic formation in the interface region. The tensile test was conducted by using Universal Testing Machine for the weldment and found that ER316L filler (721 MPa) has higher strength than ER309L (672 MPa) and autogenous weld (528 MPa). Charpy impact test was used to determine toughness of the weldment and found that ER309L Filler weld has toughness (87 J) which is higher than ER316L filler weld (5 4 J) and autogenous weld (23 J). Vicker's hardness test shows that autogenous weld hardness (avg. 193.34 HV) which is highest than ER309L filler (avg.188 HV) and ER316L filler weld (avg. 184.67 HV). The intergranular corrosion test by double loop electrochemical potentiokinetic reactivation (DLEPR) test shows sensitization at highest degree for autogenous weld (18.25 %) than ER316L filler weld (9.22 %) and ER309L filler weld (7.28 %).
Effect of number of welding passes on the microstructure, mechanical and intergranular corrosion properties of 409M ferritic stainless steel Sachin Ambade, Chetan Tembhurkar, Awanikumar Patil, Diwesh Babruwan Meshram World Journal of Engineering, 2022 Purpose This paper aims to study the effect of number of welding passes on microstructure, mechanical and corrosion properties of 409 M ferritic stainless steel. Shielded metal arc welding (SMAW) process is used to weld two metal sheets of 409 M having 3 mm thickness as bead-on-plate with single, double and triple passes. Microstructures were observed at transverse section with the help of optical microscope and with increasing number of passes grain growth, and the width of heat-affected zone (HAZ) increases. The results of tensile tests revealed that as number of passes increases, there is reduction in tensile strength and ductility. Double loop electrochemical potentiokinetic reactivation (DL-EPR) test revealed that as number of passes increases, the degree of sensitization increases. This is due to the deposition of chromium carbides at the grain boundaries and the associated depletion of chromium. Design/methodology/approach Three welded plates of single, double and triple pass were welded by SMAW process. From three welded plates (single, double and triple passes), samples for microstructural examination were cut in transverse direction (perpendicular to welding direction) with the help of wire-cut electrical discharge machine (EDM). The welded plates were sliced using wire-cut EDM along transverse direction for preparing optical microscopy, tensile testing, microhardness and DL-EPR testing specimens. Findings From the microstructure, it was observed that the large grain growth, which is dendritic, and the structure become finer to increase in number of welding passes. As number of passes increases, the width of HAZ increases because of the higher temperature at the welded zone. The tensile strength decreases to increase the number of welding passes because of grain coarsening and chromium carbide precipitation in sensitized zone and wider HAZ. The maximum microhardness value was observed for single-pass weld as compared to double- and triple-pass welds because of the fast cooling rate. The degree of sensitization increases to increase the number of passes because of chromium carbide deposition at the grain boundaries. Originality/value The authors declare that the manuscript is original and not published elsewhere, and there is no conflict of interest to publish this manuscript.
Shielded metal arc welding of AISI 409M ferritic stainless steel: study on mechanical, intergranular corrosion properties and microstructure analysis Sachin Ambade, Chetan Tembhurkar, Awanikumar P. Patil, Prakash Pantawane, Ravi Pratap Singh World Journal of Engineering, 2022 PurposeThe purpose of this study is on AISI 409 M ferritic stainless steel (FSS) which is developing a preferred choice for railway carriages, storage tanks and reactors in chemical plants. The intergranular corrosion behavior of welded SS 409 M has been studied in H2SO4solution (0.5 M) with the addition of NH4SCN (0.01 M) with different heat input. As this study is very important in context of various chemical and petrochemical industries.Design/methodology/approachThe microstructure, mechanical properties and intergranular corrosion properties of AISI 409 M FSS using shielded metal arc welding were investigated. Shielded metal arc welding with different welding current values are used to change the heat input in the joints resulted in the microstructural variations. The microstructure of the welded steel was carefully inspected along the width of the heat-affected zone (HAZ) and the transverse-section of the thin plate.FindingsThe width of heat affected zone (3.1,4.2 and 5.8 mm) increases on increasing the welding heat input. Due to change in grain size (grain coarsening) as HAZ increased. From the microstructure, it was observed that the large grain growth which is dendritic and the structure become finer to increase in welding heat input. For lower heat input, the maximum microhardness value (388HV) was observed compared with medium (351 HV) and higher heat input (344 HV), which is caused by a rapid cooling rate and the depleted area of chromium (Cr) and nickel (Ni). The increase in weld heat input decreases tensile strength, i.e. 465 MPa, 440 MPa and 418 MPa for low, medium and high heat input, respectively. This is because of grain coarsening and chromium carbide precipitation in sensitized zone and wider HAZ. The degree of sensitization increases (27.04%, 31.86% and 36.08%) to increase welding heat input because of chromium carbide deposition at the grain boundaries. The results revealed that the higher degree of sensitization and the difference in intergranular corrosion behavior under high heat input are related to the grain growth in the HAZ and the weld zone.Originality/valueThe study is based on intergranular corrosion behavior of welded SS 409 M in H2SO4 solution (0.5 M) with the addition of NH4SCN (0.01 M) with different heat input which is rarely found in literature.
Experimental and finite element analysis of temperature distribution in 409 M ferritic stainless steel by TIG, MIG and SMAW welding processes Sachin Ambade, Ravinder Kataria, Chetan Tembhurkar, Diwesh Meshram Advances in Materials and Processing Technologies, 2022 In this study, three different arc welding processes, namely tungsten inert gas (TIG), metal inert gas (MIG) and shielded metal arc welding (SMAW) processes, are used to weld 409 M ferritic stainless steel. K-type thermocouples are located in the area of heat-affected zone by drilling blind holes in a plate at a distance of 3 mm and 7 mm from the weld line, revealing the contours of the temperature distribution of the weld. The experimental results are compared with the results of simulations using ANSYS by Goldak heat source model. The temperature is experimentally measured in the heat-affected region with the help of a thermocouple. The temperature distribution profile by the finite element method using ANSYS is compared with the experimental temperature distribution profile with the heat source. The experimental and simulation results for TIG, MIG and SMAW welding processes have been found to be excellent.
