STUDY THE EFFECT OF WELDING PARAMETERS OF TIG

WELDING OF PLATE

1
 ABSTRACT

The object of the present work is to research the dissimilar material welding of
Aluminium alloy 6063 and different types of weld using stainless steel filler
metals. Gas tungsten arc welding with identical parameters and procedures was
used to carry out single V groove butt welding. The mechanical properties were
performed. And to evaluate Toughness and hardness analysis to performed in
the weld region. And evaluate the tensile strength of the material.

2
 CHAPTER 1

INTRODUCTION

3
 CHAPTER 1

INTRODUCTION

The requirements for the pharmaceutical and biotechnology industries

are relatively high and the materials of construction for processing vessels and
piping systems must demonstrate outstanding corrosion resistance and clean
ability to ensure the purity and integrity of the drug product. Materials
must be capable of withstanding the temperature, pressure, and corrosive nature
of the production environments as well as all sanitizing and cleaning
procedures. In addition, candidate materials must have good weldability and
must be capable of meeting the industry’s surface finish requirements.

The primary material of construction for processing equipment in the

pharmaceutical and biotechnology industries is Type 316L austenitic stainless
steel and inconel steel. The corrosion resistance, weldability, electro polishing
properties, and availability of the 316 grade and alloy steel P12 make it an ideal
candidate for most pharmaceutical applications. Although Type 316 performs
well in many process environments, users are continually looking to enhance
the properties of When process environments are too aggressive for Type 316,
users have either accepted the increased maintenance costs of a 316 system and
aluminium alloy 6061 steel.

The project starts with chemical analysis of materials and preparation of

WPS based on thermal and mechanical properties. Finally the strength of
material is calculated and compared with the ASME and AWS value. In
welding by controlling the parameters of thermal property mechanical

4
deviations are reduced and so weld with fewer defects could be obtained and
also the service life of material will be increased.

DISSIMILAR MATERIAL WELDING:

In modern steel constructions it is extremely important, and sometimes

unavoidable, to perform a durable dissimilar metal weld between low alloyed or
carbon steel and stainless steel. A schematic picture of a dissimilar metal weld
is presented. When welding such dissimilar metal welds the choice of filler
metal plays a big role and usually has a composition differing from both of the
parent metals. The composition of the weld metal will therefore be a mix of the
parent metals and the filler metal at some specific ratio.

During welding of dissimilar metal welds it is important to control the

composition of the weld metal. From assumptions that the weld metal consists
of a mix of the parent metals and the filler metal the composition can be
estimated. Narrow control of the resulting weld metal composition is important
to decrease the risk of defects in the weld, such as hot cracks or sigma phase
formation. The composition is also important to control so that the weld metal
properties corresponds the required ones. The filler metal normally used in
dissimilar metals welds. If the welds are exposed to high temperatures or an
intense thermal cycle, nickel based alloys are usually used as filler metal.

In a dissimilar metal weld between carbon steel and stainless steel it is

important to reduce the dilution with the carbon steel, in order to obtain a good
microstructure. It is therefore common to not point the arc directly on the
carbon steel side, but rather to angle the torch slightly toward the stainless steel.
Another important factor to optimize during welding of a dissimilar metal weld
is the inter pass temperature, i.e. the actual temperature in the already present
weld bead before welding starts during multi pass welding. Welding dissimilar

5
metal welds faces many characteristic problems caused by structural changes
and several constitutional changes can occur during welding. Changes in the
dilution ratio of the parent metals are possible and affected by the welding
conditions. During welding a stable manufacturing and good crack resistance is
important. If the dilution between the filler metal and parent metals increases,
the ferrite content will decrease in the case of welding low alloyed or carbon
steel to stainless steel with a filler metal of over-alloyed austenitic stainless
steel. If the amount of stainless steel diluted to the weld metal increases the
structure can be fully austenitic and the risk of hot cracking increases
significantly. On the other hand, if the dilution with the low alloyed steel
increases a structure with more martensite is created which is a hard and brittle
structure. If the ferrite content becomes too high, thermal ageing during
operation at elevated temperatures may lead to a transformation of the ferrite to
sigma phase or as spinodal decomposition. The sigma phase is very brittle, due
to this joints used in systems that operates at high temperatures should have as
low ferrite content as possible.

Factor for dissimilar metal welding:

The weld metal composition is usually not uniform throughout the weld,
especially in multi pass welds. A composition gradient is likely to arise in the
weld metal between the two parent metals. The solidification procedure of the
weld metal is influenced by the dilution and the composition gradients, this is
important with respect to hot cracking. When designing a dissimilar metal weld
final weld metal and the mechanical properties must be considered. The factors
that usually are responsible for failure of dissimilar metal welds are:

 Alloying problems and formation of brittle phase and limited mutual

solubility of the two metals
 Widely differing melting points

6
  Differences in thermal expansion coefficients
 Differences in thermal conductivity

When designing a butt weld to a dissimilar metal weld, attention must be given
to the melting characteristics of the both parent metals and the filler metal, as
much as to the dilution effect. Large joints will permit better control of the
molten weld metal, decrease the dilution and provide room for control of the arc
for good fusion. It is important that the joint design provides appropriate
dilution for the first few passes. It is not unusual for dissimilar metal welds to
have a failure in shorter time than the expected lifetime. Most of the failures of
a dissimilar metal weld between austenitic steel and low alloyed steel occur in
the HAZ on the low alloyed steel side, close to the weld interface. These
failures usually fulfill one or more of the following criteria:
 High stresses resulting in creep at the interface between the weld metal
and parent metals due to differences in thermal expansion.
 A weakening in the HAZ on the low alloyed or carbon steel side due to
carbon migration from the low alloyed steel side to the austenitic steel
side.
 Oxidation at the interface that is accelerated by the presence of the
stresses induced by the welding.
A chemical composition gradient is likely to arise in the weld metal and
especially close to the parent metals. If the dissimilar metal weld is operating at
an elevated temperature inter diffusion between the parent metals and weld
metal is possible which could result in a modified microstructure. This is can
happen when an austenitic stainless steel is used as a filler metal. Chromium
that has a greater affinity to carbon than iron, therefore it is likely for the carbon
to diffuse from the parent metal to the weld metal during temperatures above
425 °C. Carbon migration usually takes place during post-weld heat treatment
or when operating at elevated temperatures or cryogenic environment. The

7
parent metals and the weld metal has different corrosion behaviors that must be
considered when producing a dissimilar metal weld. For example a galvanic cell
could be created and trigger corrosion of the most anodic metal or the most
anodic phase in the weld. Corrosion at a micro structural level is possible in the
weld metal that usually consists of several different micro structural phases. To
avoid galvanic corrosion the composition of the weld metal could be changed to
provide a cathodic protection to the parent metal that is the most vulnerable to
corrosion attack. A cathodic protection is a good option as long as it does not
threaten the mechanical properties of the dissimilar metal weld.

Properties of various Materials:

Material Density(kg/m³) Young’s Poisson’s ratio

Modulus(GPa)

Steel 7850 210 0.30

Stainless Steel 8000 190 0.30

Cast Iron 7300 110 0.26

Aluminium 2700 70 0.33

Copper 8800 110 0.34

Magnesium 1800 45 0.35

Titanium 4500 110 0.34

Nickel 8900 200 0.31

Inconel 8800 200 0.32

Monel 8400 180 0.31

8
Thermal Properties of Various materials:

Material Thermal Thermal Specific Heat

Expansion conductivity
W\mK

Steel 11 50 486
Stainless Steel 11 20 550
Cast Iron 11 40 544
Aluminium 23 208 900
Copper 17 385 385
Magnesium 26 90 1050
Titanium 9 10 550
Nickel 14 70 450
Inconel 13 10 410
Monel 14 20 427

9
 CHAPTER 2
LITERATURE SURVEY

10
 CHAPTER 2
LITERATURE SURVEY

MIKE WILSON, (Banbury, UK) (2007) “TIP TIG: new technology for
welding”, industrial robot: an international journal, vol. 34 Iss : 6, pp.462 – 466.
DOI: 10.1108/01439910710832057. The paper aims to report a new technology
on TIG. The study finds that the technology provides significant cost savings to
the user. TIG provides improved quality of their product and reduces their cost

BHEL JOURNAL VOLUME 27 No.2 (SEP 2006).ISSN 0970-1540.

“Advances in Materials for Advanced Steam cycle power Plants” by Kulvir
singh. Development of stronger high temperature materials is the prime
requirement. This article reviews the potential benefits, operational experiences,
the present trend and the advances in materials that require special attention, in
respect to power plants with super critical steam conditions.

“STANDARD TECHNICAL FEATURES OF BTG SYSTEM FOR

SUPERCRITICAL 660/800MW THERMAL UNITS”, Government of India
Ministry of Power Central Electricity Authority New Delhi .July
2013.”Supercritical technology is an established and proven technology with
500 supercritical units. Ultra supercritical parameters with pressure of 250-
300Kg/cm2 and main steam temperature 600-610oc. Research is underway to
further increase the stream temperature to 700oC

DAVID A. METZLER, supplement to the welding journal, June 2012

Sponsored by the American Welding Society and the Welding Research
Council. Strain-Age Cracking Susceptibility of Ni Based Super alloys as a
Function of Strain Rate, Temperature, and Alloy Composition.

11
 Gyun Na et al. aluminium alloy 6061 Stated that residual stress is one of
the most important factors but its effect on high-cycle fatigue is of more concern
than the other factors. Residual stress is a tension or compression that exists in a
material without any external load being applied, and the residual stresses in a
component or structure are caused by incompatible internal permanent strains.
Welding, which is one of the most significant causes of residual stress, typically
produces large tensile stresses, the maximum value of which is approximately
equal to the yield strength of materials that are joined by lower compressive
residual stresses in a component. The residual stress of welding can
significantly impair the performance and reliability of welded structures.

Chengwu et al. In their work on weld interface microstructure and

mechanical properties of alloy steel dissimilar welding, the microstructure near
the interface between Cu plate and the intermixing zone was investigated.
Experimental results showed that for the welded joint with high dilution ratio of
copper, there was a transition zone with numerous filler particles near the
interface. However, if the dilution ratio of copper is low, the transition zone is
only generated near the upper side of the interface. At the lower side of the
interface, the turbulent bursting behaviour in the welding pool led to the
penetration of liquid metal into Cu.

Khan et al. aluminium alloy 6061 Came to the conclusion that

formation of ferrite along the austenite grain boundary in the heat affected zone
on austenite side is observed. At the same time, microstructures are composed
of two-phase ferrite and martensite with intra-granular carbide on ferrite side.
Also the variation in local micro-hardness observed across the weld depends on

12
the fraction intermix of each base metal and the redistribution of austenite- and
ferrite-promoting elements in the weld. Itoh et al. Got a patent on the joined
structure on the metallic materials. This invention relates generally to a joined
structure of dissimilar metallic materials having different characteristics. More
specifically, the invention relates to a joined structure of a current carrying
contact or arching contact which are used for, e.g., a power breaker, or a coating
end structure of a metal base and a coating material for improving conductivity
and heat resistance.
Delphin et al. aluminium alloy 6061 stated that the choice of hardening
model is important. It is believed that kinematic hardening is a better choice
than isotropic hardening in low cycle simulations i.e. in a few-pass welding
process, as in the present study. For the case of weld residual stresses in
combination with high thermal stresses, it is found that the plasticity induced by
the thermal stresses is not sufficient to suppress the influence of weld residual
stresses on CTOD, even for very high thermal loads. The residual stresses can
be relaxed by unloading from a primary tensile load. Mai and Spowage did their
work on characterisation of dissimilar joints of steel kovar, copper-steel and
aluminium-copper.

13
 CHAPTER-3
SELECTION OF MATERIAL

14
 CHAPTER-3
SELECTION OF MATERIAL

 ALUMINIUM ALLOY 6063

1. ALUMINIUM ALLOY 6063

Fig. Aluminium alloy

Aluminium is a light metal ( = 2.7 g/cc); is easily machinable has wide variety
of surface finishes; good electrical and thermal conductivities; highly reflective
to heat and light.

 Versatile metal - can be cast, rolled, stamped, drawn, spun, roll-formed,

hammered, extruded and forged into many shapes. Aluminium can be
riveted, welded, brazed, or resin bonded.
 Corrosion resistant - no protective coating needed, however it is often
anodized to improve surface finish, appearance.

15
  Al and its alloys - high strength-to-weight ratio (high specific strength)
owing to low density.
 Such materials are widely used in aerospace and automotive applications
where weight savings are needed for better fuel efficiency and
performance.
 Al-Li alloys are lightest among all Al alloys and find wide applications in
the aerospace industry.

History, properties and alloys

The history of the light metal industry, as that of many other industries in this
century, is one of notable and ever accelerating expansion and development.
There are few people today who are not familiar with at least some modern
application of aluminium and its alloys. The part it plays in our everyday life is
such that it is difficult to realise that a century ago the metal was still a
comparative. The excellent corrosion resistance of pure aluminium is largely
due to its affinity for oxygen; this results in the production of a very thin but
tenacious oxide film which covers the surface as soon as a freshly cut piece of
the metal is exposed to the atmosphere. This oxide coating is of great
significance in the production of practically every type of surface finish for the
metal. It is, of course, the basis of what is probably the most corrosion-resistant
finish of all, namely, that group of finishes which involves the technique of
anodic oxidation in its varied forms.

Development of aluminium alloys

The chief alloying constituents added to aluminium are copper, magnesium,

silicon, manganese, nickel and zinc. All of these are used to increase the
strength of pure aluminium. Two classes of alloys may be considered. The first

16
are the 'cast alloys' which are cast directly into their desired forms by one of
three methods (i.e., sand-casting, gravity die casting or pressure die casting),
while the second class, the 'wrought alloys', are cast in ingots or billets and hot
and cold worked mechanically into extrusions, forgings, sheet, foil, tube and
wire. The main classes of alloys are the 2000 series (Al-Cu alloys), which are
high-strength materials used mainly in the aircraft industry, the 3000 series (Al-
Mn alloys) used mainly in the canning industry, the 5000 series (Al-Mg alloys)
which are used unprotected for structural and architectural applications, the
6000 series (Al-Mg-Si alloys) which are the most common extrusion alloys and
are used particularly in the building industry, and the 7000 series (Al-Zn-Mg
alloys) which are again high strength alloys for aircraft and military vehicle
applications. The alloy used in any particular application will depend on factors
such as the mechanical and physical properties required, the material cost and
the service environment involved. If a finishing treatment is to be applied, then
the suitability of the alloy for producing the particular finish desired will be an
additional factor to be taken into account. The great benefit of aluminium is that
such a wide variety of alloys with differing mechanical and protection
properties is available, and these, together with the exceptional rang e of
finishes which can be used, make aluminium a very versatile material

Aluminium alloy selection and applications

This monograph contains an outstanding introductory description of the

properties of wrought and cast aluminium alloys and the enormous variety of
their applications. From transportation and packing to construction,
infrastructure and aerospace, the versatility of aluminium as a practical material
is amply documented. The text is richly illustrated with numerous applications
which demonstrate the enormous flexibility and the wide range of applications
for aluminium alloys. This publication will be invaluable to engineers, designers

17
and students unfamiliar with the variety of aluminium alloys and to those faced
with an alloy selection decision. It outlines many of the issues to consider in
selecting an alloy for a specific application and environment. Starting with a
description of the aluminium alloy designation system, the text describes the
major alloy series, outlines their primary chemical constituents, mechanical
properties and major characteristics, and provides numerous examples of
specific alloys in use. In summary, this monograph provides a lot of clarity to
the process of selecting alloys for various applications.

Effect of aluminium

Aluminium and aluminium alloy are gaining huge industrial significance

because of their outstanding combination of mechanical, physical and
tribological properties over the base alloys. These properties include high
specific strength. High wear and seizure resistance, high stiffness, Better high
temperature strength, controlled thermal expansion coefficient and improved
damping capacity.
Corrosion of aluminium

Whilst aluminium and its alloys generally have good corrosion resistance,
localised forms of corrosion can occur, and it is important to understand the
factors contributing to these of corrosion. Corrosion may be defined as the
reaction between a metal and its immediate environment, which can be natural
or chemical in origin. The most recognisable form of corrosion is, perhaps, the
rusting of iron. All metals react with natural environments but the extent to
which this happens can vary; for noble metals like gold the amount is
insignificant whereas for iron it is considerable. Aluminium is no exception but,
fortunately, it has the propensity of self passivation and for many applications
corrosion is not a problem.

18
PROPERTIES OF AL-ALLOY

(i) Heat treatable and age hardenable.

(ii) High strength efficiency due to high strength to weight ratio

(iii) Good weldability

(iv) Good corrosion resistance

(v) Good thermal conductivity

APPLICATIONS OF AL- ALLOY

Alloy 6063 is perhaps the most widely used because of its extrudability, it is not
only the first choice for many architectural and structural members, but it has
been the choice for the Audi automotive space frame members. A good example
of its structural use was the aluminum bridge. (Gilbert Kaufman, 2000). The
alloy has versatile application as given below

 Pressure vessels
 Pipelines
 Cryogenic tanks
 Door beams, seat tracks, racks, rails
 Electrical cable towers
 Petroleum and Chemical Industry Components (The excellent
combination of high strength combined with superior corrosion resistance
plus weldability makes a number of aluminum alloys ideal for chemical
industry applications, even some involving very corrosive fluids)

19
MATERIAL PROPERITIES OF ALUMINIUM ALLOY 6063

Properties Value
Elastic Modulus 69000 N/mm2
Poisson's Ratio 0.33
Thermal Expansions Co-efficient 2.4x10-5 /K
Thermal Conductivity 170 w/mk
Specific Heat 1300 J/kg k

WELDING PROCEDURE SPECIFICATIONS:

Gas : ARGON
Rod : ER304L (Filler Rod)
Flow Rate : 4-6L/min
Current : 60-110A
Speed : LOW SPEED
Class Diameter Range : 1.6mm
Voltage : 10-12V
Polarity : DCEN-Direct Current Electrode Negative
Bead : Weaving Bead
Heat Input : Medium Heat Input

20
NEED OF WPS

In the existing system the WPS, it does not contain any details regarding
the mechanical and thermal properties for the welding process. Hereby we are
going optimize the WPS for TIG and SMAW based on the mechanical and
thermal properties considerations in order to reduce the Stress, Thermal stress,
Residual stress achieve good weld strength. Welding could be done without
preparation of WPS, but which may results in improper weld or with defects
like weld decay, knife line attack and stress corrosion cracking. To avoid such
cases WPS is followed in all industries. Sometimes improper welding will
increase the strength due to this the life time of materials may be changed. To
overcome those weld defects WPS is optimized, use extra low carbon electrode,
avoiding hylogen family

21
 Chapter-4

WELDING PROCESS

22
 Chapter-4

WELDING PROCESS

Welding is a fabrication process that joins materials by causing coalescence in

which heat is supplied either electrically or by mean of a gas torch,. This is
often done by melting the work pieces and adding a filler material to form a
pool of molten material (the weld pool) that cools to become a strong joint,
with pressure sometimes used in conjunction with heat, or by itself, to produce
the weld. This is in contrast with soldering and brazing, which involve melting a
lower-melting-point material between the work pieces to form a bond between
them, without melting the work pieces. Welding is also the least expensive
process and widely used now a days in fabrication. Welding is also called as
secondary manufacturing process.

WELDING PARAMETERS

Tungsten inert-gas arc welding

Tungsten inert-gas arc welding (TIG) is a fusion welding method that was
developed in the late 1930’s. The TIG-method is characterized by its high
quality weld metal deposits, great precision, superior surfaces and excellent
strength. TIG is the most common welding method used for pipes and tubes
with a wall thickness from 0.3 mm and upward. In the TIG-method a non-
consumable electrode of tungsten or tungsten alloy is used, in comparison to
other common welding methods where the filler metal also is the electrode.

Filler rod (Ref-A.W.S)

E 304 Corrosion resistant

E 316, 304L, 330 High and low temperature strength

23
E 410, 420 Abrasion resistant

E304-16 electrodes are used to weld unstabilized 18-8 stainless steels such as
Types 301, 302, 304, 305, and 308. E308-16 electrodes provide corrosion
resistance and physical properties equal to or greater than the steels for which
they are recommended. Typical applications include dairy, distillery and
restaurant equipment, and chemical tanks.

To prevent oxygen in the air from oxidizing the weld pool and the heated
material, a shielding gas is used during TIG-welding. The shielding gas is also
important to promote a stable metal transfer through the arc, the shielding gas
commonly used for TIG-welding is argon. The root side of the weld also needs
protection from oxidizing in form of a backing gas during the production of the
first weld beads. The backing gas helps the weld bead to form correctly and
keep the weld bead from becoming porous or crack.

The TIG-welding method has some great advantages, they are:

 Produces a high quality and a low-distortion weld

 Free of splatter that is associated with other methods
 Can be used with or without filler metal
 Can be used in a wide range of power supplies
 Can weld almost all metals, including dissimilar metal welds
 Gives precise control of welding heat.

24
SELECTION OF FILLER RODS

E304 l filler rod properties:

 All position stainless steel electrode for 304L or equivalent steels

 Excellent corrosion resistance in oxidizing environments such as nitric
acid
 High resistance to inter granular corrosion
 Smooth bead appearance
 Easy slag release
 High Toughness and strength.

TIG-METHOD IS A VERY HIGH QUALITY WELDING METHOD

THERE ARE SOME LIMITATIONS :
 Creates lower deposition rates than consumable electrode arc welding
processes
 Demands somewhat more skill and welder coordination than gas metal
arc welding or shield metal arc welding when welding manually
 Less economical than consumable electrode arc welding for sections
thicker than 9.5 mm
 Challenging in draughty environments due to difficulty in shielding the
weld zone properly
 Tungsten inclusions can be created if the electrode make contact with the
weld pool

25
INFLUENCE OF CURRENT

Dc electrode negative (DCSP) is one in which the work piece is

connected to positive and the electrode is connected to negative. In this type
70% of heat goes to work and 30% to electrode. In this type we can get deep
and narrow penetration.

Dc electrode positive (DCNP) is one in which the work piece is connected to

negative and the electrode is connected to work piece. In this type 35% of heat
goes to work and 65% to electrode. In this type we can get wide and shallow
penetration. Alternating current (AC BALANCED) is one in which the 50% of
heat goes to work and 50% to electrode. In this type we can get medium
penetration. But the capacity of electrode is good when compared to DCEP.

26
WELDING POSITION

PIPE

1G pipe rotated / welder fixed 5G pipe fixed welder rotated

45.

2G pipe vertically Pipe inclined fixed welder rotated

Fixed welder rotated

HORIZONTAL POSITION

The horizontal welding position is also known as the 2G or 2F. It is

slightly harder to do than the flat weld as gravity is trying to pull the molten
metal down towards the ground. But it is still easy to do.

27
VERTICAL POSITION
This is the one that we all have trouble with the dredded vertical up weld.
This is also called the 3G or 3F, and you can go up or down. As mention before
going up in this position is called the vertical up weld and going down is the
vertical down.

OVERHEAD POSITION
The overhead welding position is just that, overhead. The welding
position here is also known as the 4G or 4F.

DOWNHAND POSITION
The flat welding position when welding like this is called the 1G or 1F. It
is the most basic and easiest welding position.

28
 CHAPTER-6

MECHANICAL PROPERTY TEST

29
 CHAPTER-6

MECHANICAL PROPERTY TEST

AFTER WELDING STRENGTH MEASUREMENT

TENSILE TEST

Tensile test is used to determine the tensile strength of the specimen, %

elongation of length and % reduction of area. Tensile test is usually carried out
in universal testing machine.

A universal testing machine is used to test tensile strength of materials. It is

named after the fact that it can perform many standard tensile and compression
tests on materials, components, and structures. The specimen is placed in the
machine between the grips and an extensometer if required can automatically
record the change in gauge length during the test. If an extensometer is not
fitted, the machine itself can record the displacement between its cross heads on
which the specimen is held. However, this method not only records the change
in length of the specimen but also all other extending / elastic components of the
testing machine and its drive systems including any slipping of the specimen in
the grips. Once the machine is started it begins to apply an increasing load on
specimen. Throughout the tests the control system and its associated software
record the load and extension or compression of the specimen.

Tensile Specimens and Testing Machines

Consider the typical tensile specimen. It has enlarged ends or shoulders for
gripping. The important part of the specimen is the gage section. The cross-
sectional area of the gage section is reduced relative to that of the remainder of
the specimen so that deformation and failure will be localized in this region.

30
The gage length is the region over which measurements are made and is
centered within the reduced section. The distances between the ends of the gage
section and the shoulders should be great enough so that the larger ends do not
constrain deformation within the gage section, and the gage length should be
great relative to its diameter. Otherwise, the stress state will be more complex
than simple tension. Detailed descriptions of standard specimen shapes are
given in Chapter 3 and in sub-sequent chapters on tensile testing of specific
materials.

Tensile Strength
The tensile test of the composites was performed as per the ASTM D3039
standards. The test was done using a universal testing machine (Tinius Olsen
H10KS).The specimen of required dimension was cut from the composite cast.
The test was conducted at a constant strain rate of 2 mm/min. The tensile test
arrangement is shown in figure

31
 Tensile test is used to determine the tensile strength of the specimen, %
elongation of length and % reduction of area. Tensile test is usually carried out
in universal testing machine.

A universal testing machine is used to test tensile strength of materials. It is

named after the fact that it can perform many standard tensile and compression
tests on materials, components, and structures. The specimen is placed in the
machine between the grips and an extensometer if required can automatically
record the change in gauge length during the test. If an extensometer is not
fitted, the machine itself can record the displacement between its cross heads on
which the specimen is held. However, this method not only records the change
in length of the specimen but also all other extending / elastic components of the
testing machine and its drive systems including any slipping of the specimen in

32
the grips. Once the machine is started it begins to apply an increasing load on
specimen. Throughout the tests the control system and its associated software
record the load and extension or compression of the specimen. Tensile test is
used to find out

Tensile strength

Yield strength

% Elongation

% Reduction

HARDNESS TEST

A simple and economical way to characterize the mechanical properties

and microstructure is by performing hardness measurements. By performing
hardness measurements the highest and lowest levels of hardness can be
determined. In dissimilar metal welds the hardness level of parent metals and
weld metal are determined. The most interesting part is where the transition
from parent metal to weld metal takes place and in the root bead of the weld. A
cross-section from each sample is taken transverse the weld by mechanical
cutting. It is important that the preparations of the samples do not affect the
surface metallurgical by hot or cold work. After the samples are cut they are
grinded and polished in order to make as good preparation as possible

33
The numbers of indentations need to be enough to assure that hardened and
softened zones are tested, i.e. that the indentations do not affect each other. This
gives the metals ability to show resistance to indentation which show it’s
resistance to wear and abrasion. Hardness testing of welds and their Heat
Affected Zones (HAZs) usually requires testing on a microscopic scale using a
diamond indenter. The Vickers Hardness test is the predominant test method
with testing being applied to HAZ testing in some instances. Hardness values
referred to in this document will be reported in terms of Vickers Number, HV.

34
 INDENTOR

WORK PIECE

TABLE
ARM

TOUGHNESS TEST:

It is well understood that ductile and brittle are relative, and thus
interchange between these two modes of fracture is achievable with ease. The
term Ductile-to-Brittle transition (DBT) is used in relation to the temperature
dependence of the measured impact energy absorption. For a material, as the
temperature is lowered, the impact energy drops suddenly over a relatively
narrow temperature range, below which the energy has a considerably lower
value as a representative of brittle fracture.

The principal measurement from the impact test is the energy absorbed in
fracturing the specimen. Energy expended during fracture is sometimes known

35
as notch toughness. The energy expended will be high for complete ductile
fracture, while it is less for brittle fracture. However, it is important to note that
measurement of energy expended is only a relative energy, and can not be used
directly as design consideration. Another common result from the Charpy test is
by examining the fracture surface. It is useful in determining whether the
fracture is fibrous (shear fracture), granular (cleavage fracture), or a mixture of
both.

36
 Chapter-7
ADVANTAGES AND
APPLICATIONS

37
 CHAPTER-7

ADVANTAGES AND APPLICATIONS

 Non-ferrous metals with high strength and toughness

 Higher creep stress and rupture properties when compared with 304
 Ideal for high temperature services
 Overcomes sensitization and inter granular corrosion concerns
 Can be used in elevated temperature applications for ASME boiler and
pressure vessel code application
 Corrosion resistance, wear resistance
 Aerospace aircraft gas turbines
 Steam turbine power plants, medical applications
 Chemical and petrochemical industries
 Strength at elevated temperatures and Excellent Mechanical properties
 Magneto striction is a property of ferromagnetic materials that causes
them to change their shape when subjected to a magnetic field.
 Nickel-based alloys are used in many applications where they are
subjected to harsh environments at high temperatures. Nickel-
chromium alloys or alloys that contain more than about 15% Cr are
used to provide both oxidation and carburization resistance at
temperatures exceeding 760°C.

38
 Chapter-7
CONCLUSION

39
 CHAPTER-7

CONCLUSION AND DISCUSSION

In raw materials before welding the Strength calculated and also Micro and
chemical test is made to get the exact values of material composition. During
Welding Strength will be decreased as because due to the change of properties
and behavior of materials. After Welding Heat treatment is to be carried out to
maintain the strength of material. Finally Tensile, Toughness and Hardness test
are to be carried out.

40
 Chapter -8

REFERENCES

41
 CHAPTER -8

REFERENCES

 Parmar.R.S. “Welding Engineering and Technology”, Khanna publishers,

Delhi. (1997)
 O.P.Khanna,“Text book material science & metallurgy” Dhanpatrai
publications (1999)
 C.P.Sharma, “ Engineeringv material properties and application of metals and
alloys” PHI Learning Pvt Ltd, delhi 2013
 R.B.Choudry, “ Material science and metallurgy” Khanna publications 2011
 N.K.Srinivasan, “ Welding technology” Khanna publications 2012
 P.R.RAMANATHAN “ Piping and welding technology”, 2014.
 Wen-chun Jiang and Xue-wei Guan “A study of the residual stress and
deformation in the welding between half-pipe jacket and shell” Materials and
Design, Vol. 43, 2013, PP 213-219.

 Man Gyun Na, Jin Weon Kim and Dong Hyuk Lim “Prediction of Residual
Stress for dissimilar metals welding at nuclear plants using Fuzzy Neural
Network Models” Nuclear Engineering and Technology, Vol. 39, 2007, PP
337-348.

 M.M.A. Khan, L. Romoli, M. Fiaschi, G. Dini and F. Sarri “Laser beam

welding of dissimilar stainless steels in a fillet joint configuration” Journal of
Materials Processing Technology, Vol. 212, 2012, PP 856-867.

 Yoshiyasu Itoh and Kabushiki Kaisha Toshiba “Joined structure of dissimilar

metallic materials” Patent Publication Number, EP0923145A2, 1999.

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