Materials Transactions, Vol. 52, No. 12 (2011) pp.

2197 to 2204
#2011 The Japan Institute of Metals

Microstructure Evolution of Laser Repair Welded

René 77 Nickel-Based Superalloy Cast
Huei-Sen Wang1; * , Chih-Ying Huang1 , Kuen-Sen Ho2 and Sian-Jhih Deng1
1
Department of Materials Science and Engineering, I-Shou University, Kaohsiung, 84001, Taiwan, R. O. China
2
Department of Mold and Die Engineering, National Kaohsiung University of Applied Sciences,
Kaohsiung, 80711, Taiwan, R. O. China

This study performed repair-welding tests on René 77 Nickel-based superalloy by adopting a Nd:YAG pulsed laser technique, coupled
with René 41 filler wire and various welding parameters. After welding, the microstructure evolution, crack behavior and mechanical properties
of the welds were determined by a combination of scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS),
transmission electron microscopy (TEM), and micro-hardness test. The experimental results showed that, due to suffering from different thermal
histories during the conduction of the multi-pass welding process, the microstructures within the welds had split into six zones. In terms of
cracking behavior, no cracks formed in the weld fusion zone (WFZ) or the heat-affected zone (HAZ) under appropriate welding parameters;
however, setting the laser energy too high resulted in weld centerline cracking or intergranular cracking in the weld fusion zone. Moreover,
various types of liquation cracks may occur at the interface between the WFZ and the HAZ. [doi:10.2320/matertrans.M2011264]

(Received August 29, 2011; Accepted September 27, 2011; Published November 16, 2011)
Keywords: super alloy, welding, microstructure, crack

1. Introduction with good metallurgical bonding, low dilution, and a narrow

René 77 is a precipitation hardening ( 0 strengthening
phase-Ni3 (Al, Ti)) and solid solution strengthening (Cr, Mo,
Fe, Co elements) Ni-based superalloy,1) with a designed
service temperature of between 730 C900 C, often applied
to hot gas turbine engine parts, such as vanes and blades, due
to its remarkable hot corrosion resistance and excellent high
temperature strength. Similar to every Ni-based superalloy
cast component, some non-critical defects such as surface
cracks may occur during the investment casting or after
service. These cracks may substantially result in a capital loss
or reduction in service life. For economic considerations,
these non-critical defects may be scraped and repaired by the
welding techniques.
Among the welding techniques, the Gas Tungsten Arc
Welding (GTAW or TIG) welding process is widely used for
surface crack repairs of the precipitation hardening super-
alloy cast, due to its lower facility cost. Earlier attempts were
conducted2,3) to investigate the heat-affected zone (HAZ) or
interface liquidation crack after the GTAW or TIG welding
process. For a superalloy containing high Al and Ti
concentrations ( 0 formers), due to the presence of the
strengthening phase, ordered Ll2 Ni3 (Al, Ti)  0 phase, the
repaired cast tends to be susceptible to hot cracking in the
weld metal and liquation cracking in the HAZ during the
traditional GTAW or TIG repair welding process. Suscepti-
bility to cracking was attributed mostly to large shrinkage
stresses caused by the higher energy input of the TIG welding
techniques, as a result of large amounts of rapid  0
precipitation during the cooling process. Recently, a few
studies,4–6) indicated that a laser welding process, a lower
energy input, high energy density, and a partial heating
process, might eliminate the abovementioned problems and
create a porosity-free and crack-free weldment, described
*Corresponding author, E-mail: huei@mail.isu.edu.tw
HAZ.
However, most of those studies focused on the cracking
characterization at the interface of the weld fusion zone
(WFZ) and the HAZ. Very few papers have systematically
discussed the microstructure evolution in the WFZ and HAZ
of the laser welds. For instance, as a multi-pass laser welding
process is conducted, due to the different portions of the WFZ
or HAZ experiencing different thermal histories during the
laser repair welding, they may display specific differences in
their microstructures. The WFZ and HAZ may be further
sub-divided into multiple regions. Therefore, the repaired
René 77 cast under pre-selected Nd:YAG (Neodymium-
doped Yttrium Aluminum Garnet) laser welding parameters
was conducted in this study. After welding, the micro-
structure development, crack behavior, and mechanical
properties of the various regions in WFZ and HAZ were
investigated.
2. Experimental Method
This experiment used a set of nickel-based superalloy
René 77 turbine vanes (Table 1 shows the composition). The
outer shroud was cut off, and then machined into 30 mm 
15 mm  2 mm test specimens for laser repair welding. The
specimen surface was cleaned with alcohol prior to repair
welding.
For the filler wire selection, matching the chemical
composition of the base metal is generally desirable.
However, for a highly strengthened nickel alloy cast (e.g.,
René 77), creating a small diameter laser wire with the same
chemical composition as the base metal is difficult to achieve,
and is not cost effective. The use of a substitute filler material
for the nickel-based gas turbine vane repair has become
acceptable. A general overview of substitute filler materials
for the nickel-based alloy repair process can be found in
Gandy et al.7) In this study, based on the suggestion from GE
2198 H.-S. Wang, C.-Y. Huang, K.-S. Ho and S.-J. Deng

Table 1 Composition of the ‘‘as received’’ René 77 cast. Table 2 Composition of René 41 wire.

Element Ni Cr Mo Al Ti Co Element Ni Cr Mo Al Ti Co
Mass% 58.4 14.63 4.2 4.3 3.4 14.5 Mass% 54.42 18.54 9.33 1.58 3.21 10.56
Element Fe Zr Si S C Mn Element Fe B Si S C Mn
Mass% 0.5 0.06 0.2 0.015 0.07 0.15 Mass% 1.63 0.005 0.05 <0:0005 0.07 0.03

Table 3 Repair welding parameters adopted in this experiment.

Laser Pulse Peak Spot Shielding

Frequency Speed Shielding
Parameter voltage duration power size gas flow
(Hz) (m/s) gas
(V) (ms) (W) (mm) (l/mm)
Pure
A 170 4.6 1  103 14 1  103 0.4 5
Argon
Pure
B 180 4.6 1:3  103 14 1  103 0.4 5
Argon
Pure
C 190 4.6 1:6  103 14 1  103 0.4 5
Argon

aviation internal special print report-(No. 1536M51), René

41 (composition shown in Table 2) 0:5 mm wire was
selected as the filler material due to its similar composition
to René 77, and because of better formability in creating a
smaller diameter wire for the laser welding.
To optimize the laser pulse shape, various welding
parameters was empirically investigated. Welding Condition
A, B and C shown in Table 3 were pre-selected parameters in
this study. Conditions A and B were selected due to those
parameters produce crack-free welds. If the energy input is
slightly higher than Condition B (e.g. Condition C), the crack
more likely form in the weld. Furthermore, to obtain a
constant welding speed, the welding process was assisted by
a semi-automatic trolley. Five welding beads were deposited
to conduct the repair welding process. Each welding bead
was overlapped by the successive melt bead. The overlapping
ratio of the track is approximately 30%. The ratio was chosen
by considering the processing efficiency and surface homo-
geneity. After the repair welding, the sectioned pieces were
prepared by grinding, polishing, and etching with a 70%
phosphoric acid electrolyte solution. The microstructures in
the HAZ and WFZ were then studied by optical microscope
(OM), Hitachi scanning electron microscopy (SEM) equip-
ped with an energy dispersive X-ray spectroscopy (EDS) and
Philip Tecnai G2 transmission electron microscopy (TEM).
Vicker’s micro-hardness in the HAZ and WFZ was measured
using a micro-hardness tester under a load of 100 g.

3. Results and Discussions

3.1 Microstructure of the ‘‘as-received’’ cast René 77

As shown in Fig. 1(a), in addition to the  matrix, René 77
consists of typical diced cube shape  0 intermetallic phases
(average grain size is 0.3 mm), evenly distributed within the
dendrite or interdendrite area. Smaller volume fractions of
carbides (see Fig. 1(b)) and - 0 eutectic phases (see
Fig. 1(c)) are also present. The energy dispersive X-ray
spectroscopy (EDS) compositional analysis shows that Fig. 1 Cast René 77 microstructure of (a)  and  0 phases; (b) TiC carbide;
carbides are predominantly the MC-type, enriched in Ti and (c) eutectic phase.
 Microstructure Evolution of Laser Repair Welded René 77 Nickel-Based Superalloy Cast
elements. The - 0 eutectic phase, typically formed from
micro-segregation during the final solidification of the
casting process, is observed along the interdendritic area.8)
3.2 Microstructure changes after laser repair welding
This study conducted the repair welding process by
depositing five welding beads. A new incoming melt bead
overlapped a solidified weld bead in succession. After the
second-pass welding, the experiment repeated the solid-
ification mode of the successive weld bead. Figure 2
illustrates the microstructure change after a two-pass weld
which simplifies and describes the multi-pass welding.
Figure 2 also shows that due to the different portions of the
welds undergoing a different thermal history during Nd:YAG
Fig. 2 Microstructure illustration of René 77 after Nd:YAG repair
welding. The first three regions, along with Region Five, are within the
weld fusion zone (WFZ). Region Four is the heat affected zone (HAZ), and
Region Six is the unaffected parent metal (PM).
Fig. 3 The microstructure solidification morphology within Region One. (a) At short distance away the weld fusion line, (b) at the center
of Region One, (c) at the surface of Region One, and (d) Fig. 3(b) at a higher magnification of 20;000.
2199
laser repair welding, they display specific differences in their
microstructures, and thus, are metallurgically divided into six
major regions. The first three regions, along with Region
Five, are within the WFZ. Region Four is the HAZ, and
Region Six is the unaffected parent metal (PM). The
microstructures in relation to each of these regions are
described as follows:
3.2.1 Region one
The region marked as Region One is the fusion area that is
not reheated, and has a primary microstructure of the WFZ.
Due to the low power of Nd:YAG laser welding, the selected
welding conditions did not produce the significant difference
in the morphology of solidification microstructure within
Region One. Many studies9,10) have indicated that the
morphology of solidification microstructure in this area is
affected by the temperature gradients (G) and grain growth
rate (R) differences. The ratio of temperature gradient over
grain growth rate (G/R) is called the solidification parameter.
If G/R rises, the final solidified pattern tends to be planar/
columnar/cellular grains; alternately, lower G/R leads to
dendrites or equiaxed dendrites. Due to the low power and
high density of laser welding, higher temperature gradients
(G) are present after repair welding, resulting in a higher
G/R. Therefore, columnar and cellular grains dominate the
solidified structures within the region. Figure 3 shows the
microstructure solidification morphology within Region One
as long and narrow, and the parallel line where the columnar
grains are primarily growing along the heat flow direction
(see Fig. 3(a)). Earlier study indicated,11) as the HAZ
liquation initiated, that a crack may propagate along the
parallel line-shaped grain boundaries into the WFZ. The
long columnar grain in Region One may be susceptible to
2200 H.-S. Wang, C.-Y. Huang, K.-S. Ho and S.-J. Deng

Fig. 4 The TEM observation in Region One: (a) bright field image (BFI) and (b) the corresponding selected area diffraction (SAD) pattern
of  phase in the [001 ] zone axis obtained from welding Condition A; (c) bright field image (BFI) and (d) the corresponding selected area
diffraction (SAD) pattern of  phase in the [1 1 0] zone axis obtained from welding Condition C.

liquation cracking or intergranular cracking, and is highly

sensitive to heat input via the laser parameters; this
phenomenon was observed when welding Condition C was
used, as described in Section 3.3.1. In addition to columnar
grains, cellular grains are present in the center or at the
bottom of Region One (see Fig. 3(b)).
The product of the temperature gradient (G) and grain
growth rate (R) is shown as G  R,10) and is the cooling rate
that governs the size of the final solidified grain. In Region
One, a rapid cooling rate causes the spacing of the grains
to constitute approximately 2–5 mm, less than that of the
original superalloy substrate (approximately 300–400 mm)11)
or the conventional TIG welding process (approximately 30–
50 mm). Further examination of the Region One surface
Fig. 5 Hardness profiles in René 77 welds.
shows that the surface grains are even finer (about 2 mm) due
to the fast cooling rate (see Fig. 3(c)). Figure 3(d) shows a
higher magnification of Fig. 3(b). The  0 phase is not clearly
apparent within the grain area, even at 20;000. Region One C (the higher energy input) were employed. TEM results
might mainly consist of the  phase, supersaturated with  0 confirm the inference of the SEM that the region consists of
phase elements (e.g., Al and Ti). To confirm this inference, the majority of the  austenite phase. Thus, from the Vicker’s
this study conducted more precise transmission electron micro-hardness test results (see Fig. 5), hardness in this
microscopy (TEM) examinations. Figures 4(a) to 4(d) show region is softer in comparison to the HAZ and PM, which is
the TEM bright field images (BFIs), and the selected area attributed to the disappearance of the  0 phase in Region One.
diffraction patterns (SADs) of Region One when welding In addition to the  phase matrix, several white and nano-
Condition A (the lower energy input) and welding Condition size particles (see Fig. 3(d)) are mainly distributed along
 Microstructure Evolution of Laser Repair Welded René 77 Nickel-Based Superalloy Cast
Fig. 6 The UZs located in the outer extremities of the Region one obtained from the welding (a) Condition A, (b) Condition B, and (c)
Condition C. (d) An example of EDS line scan (Mo composition profile from welding Condition C) across the fusion boundary of a René 77
welded with René 41 filler wire; (e) an example of the UZ observed in the successive pass remelt area obtained from welding Condition C.
the grain boundaries, suggested by earlier study11) that the
particles are MC-type carbides. This type of carbide typically
forms at the end of solidification by eutectic-type reactions
with the  matrix, and is typically distributed along the grain
boundary region.12,13)
3.2.2 Region two and region three
The region marked as Region Two is the unmixed zone
(UZ) located in the outer extremities of Region One.
Figures 6(a)–6(c) show the UZs of three welding conditions.
As shown in the figures, the higher energy inputs were used,
the wider UZs were obtained.
The UZ in Region Two is a boundary layer12) which shares
a similar composition with PM. Figure 6(d) shows EDS line
scans (Mo composition profiles) across the fusion boundary
of a René 77 welded with René 41 filler wire, suggesting
stagnant melted René 77 based metal unmixed with René 41
filler wire.
The formation of the UZ can be attributed to the lower
energy power of the Nd:YAG laser welding process. During
the Nd:YAG welding process, the filler wire may preferen-
tially absorb the majority of input energy. The remainder of
the energy is sufficient to melt parts of the PM, but too weak
for thorough mixing with the melted filler wire.12)
In the UZ, the phase-to-cellular grains transition, with
barely visible side arms, occurs near the weld fusion line.
The grains grow epitaxially from the fusion line, along the
easy-growth direction to the next fusion line.
In cases of multi-pass welding, the second pass weld bead
would remelt the ratio of the first pass weld bead, and repeat
the first pass solidification mode. As shown in Fig. 6(d), the
UZ solidification mode occurs in the second pass (Region
Three in Fig. 2) remelt area. Like Region Two, the selected
welding conditions did not exhibit significant difference in
the morphology of solidification microstructure in Region
Three; however, if the higher energy inputs were used, the
wider Region Three resulted.
2201
3.2.3 Region four and region five
The area marked as ‘‘Region Four’’ is the heat-affected
zone (HAZ). For a conventional TIG welding process, which
has high power, a slow cooling rate, and a wide heat exposure
area, a wide HAZ can form. The HAZ in the TIG weld is
further divided into several zones, such as the grain coarsen
of  0 , the partial reversion of  0 , and the full reversion of  0 .10)
An Nd:YAG laser welding process creates a high temperature
gradient, and therefore, the HAZ is not as evident under
common OM; however,  0 grain changes in the HAZ can be
observed under the higher magnification of the SEM. As
demonstrated in Figs. 7(a)–7(c), the  0 grains around the
WFZ produced by the selected welding conditions, are only
slightly coarsened; this slightly affects the hardness in this
area (see Fig. 5).
When joined by a multi-pass welding, the successive pass
overlap results in a HAZ in the previous weld pass, which
is marked, ‘‘Region Five’’. Similar to Region Four, Region
Five from the selected Nd:YAG laser welding conditions is
not clear, with only slightly coarsened grains. Figure 7(d)
shows an example of Region Four obtained from welding
Condition C.
3.3 Weld-cracking examination after laser repair
welding
The repair welding results show that no defects occur after
repair welding in welding Conditions of A and B; however,
in Welding Condition C, the use of higher power causes
cracking in both the WFZ and the HAZ of Welding Condition
C. Observations of cracks in the WFZ and the HAZ are
detailed below:
3.3.1 Cracks at interface of the HAZ and the WFZ
In this study, the HAZ cracks involve various liquation
cracks derived from the intergranular  0 phase, MC-type
carbide, and - 0 eutectic phases, and usually occur at the
interface of the WFZ and HAZ.
2202 H.-S. Wang, C.-Y. Huang, K.-S. Ho and S.-J. Deng
Fig. 7 The heat-affected coarsened  0 phase in Region Four obtained from the welding (a) Condition A, (b) Condition B, and
(c) Condition C, (d) a slightly coarsened grains observed in Region Five obtained from welding Condition C.
High-power density characteristics of the Nd:YAG laser
welding heat or cool the alloy more rapidly compared to other
traditional welding processes (e.g., the TIG welding process);
non-equilibrium is obtained. It is well known11) that rapid
heating may increase the liquidus of an alloy to several tens
or even hundreds of degrees. Especially if a higher energy
input is used, this promotes even more severe localized
melting of the intergranular  0 phase and low temperature -
 0 eutectics or dissolution of carbides in the HAZ. During
subsequent rapid cooling, the higher heat input further
induces the greater thermal strain and higher shrinkage stress
by rapid solidification. As a result of these factors, the cracks
originating from the intergranular  0 phase (see Fig. 8(a)),
- 0 eutectics (see Fig. 8(b)), or carbides (see Fig. 8(c))2,3,14)
located on the weld fusion line and propagating along the
parallel line-shaped grain boundaries into the WFZ.
3.3.2 Examination of WFZ cracking defects
This study examined two types of WFZ solidification
cracking: (1) intergranular cracking at the interface of the
overlapping joint in multi-pass welding (see Fig. 9(a)); and
(2) weld centerline cracking at the weld bead (see Fig. 9(b)).
Research failed to discover evident liquation in either
cracking patterns, and both cracks occurred at a slight higher
welding power (Parameter C).
As stated in 3.2, when a new incoming welding pass
overlaps a solidified weld bead, an UZ and a HAZ appear at
the interface of the overlapping joint. Once solidification
stress and welding thermal stress in these zones exceed the
material strength, intergranular cracking occurs easily at the
overlapping joint.
Weld centerline cracking at the weld bead is primarily
located where the weld metal finally solidifies, as the melting
point and strength decrease easily,12,13) due to lower melting
point solute buildup in this zone, as well as greater thermal
stress derived from the higher welding power, which initiates
cracking at the weld centerline area.
In summation, the WFZ and HAZ cracking formations
are mainly the compounded results of material strength and
crack driving force in the zone (including stress or strain).
Therefore, less liquation, less stress buildup, or less strain
during welding should reduce occurrences of cracking.
Cautious choices of laser welding parameters become a
significant factor. In this study, the use of Conditions A and B
obtained crack-free WFZs and HAZs (see Fig. 10), though
the intergranular  0 phase, or carbides, were present on the
weld fusion lines of both laser welded samples.
4. Conclusions
This study performed repair welding on the René 77 by
Nd:YAG laser welding under various parameters, coupled
with a René 41 filler wire, and upon completion, examined
the microstructure and cracking behavior. The conclusions
are as follows:
(1) As the multi-pass welding process is conducted, differ-
ent portions of René 77 welds undergo diverse thermal
exposures during Nd:YAG laser repair welding. The
welds have specific dissimilarities in their microstruc-
tures, and thus, are divided into six zones.
(2) As Nd:YAG laser welding causes higher temperature
gradients, the primary microstructure morphologies
within Region One (the area in a solidified weld that
is not reheated by the successive melt bead) are
columnar or cellular. Furthermore, a faster cooling rate
leads to the finer microstructures in this region after
Nd:YAG laser welding.
 Microstructure Evolution of Laser Repair Welded René 77 Nickel-Based Superalloy Cast 2203

Fig. 9 WFZ solidification cracking (a) intergranular cracking at the

interface of the overlapping joint in multi-pass welding; and (b) weld
centerline cracking at the weld bead.

Fig. 8 Various HAZ liquation cracking derived from (a)  0 phase; (b) TiC
carbide; (c)  þ  0 eutectic phase.

(3) The SEM and TEM observations indicate that Region

One consists of the majority of the  austenite phase,
and  0 precipitate appears almost absent in this zone.
Thus, hardness in this zone is softer in comparison to
the HAZ and PM areas.
(4) Due to the low power of the Nd:YAG laser, the HAZ is
narrow, and has only a slight coarsening of the  0 phase
or grains in this zone.
(5) When Nd:YAG laser welding power is improperly
controlled, the intergranular  0 phase, carbide, or
( þ  0 ) eutectic phase, as derived from liquation
cracking, can easily occur at the interface of the WFZ
and HAZ.
(6) Two major WFZ cracks are in this study: the first is an
intergranular cracking at the interface of the over-
lapping joint in the multi-pass welding. The second
is a weld centerline cracking at the weld bead. The
Fig. 10 The use of the welding (a) Conditions A and (b) Condition B
formation of the cracks in this zone and welding power, obtained crack-free WFZs and HAZs, though the intergranular  0 phase,
cracking region composition, and welding stress or or carbides, were present on the weld fusion lines of both laser welded
strain are primarily closely related. samples.
2204 H.-S. Wang, C.-Y. Huang, K.-S. Ho and S.-J. Deng
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