CHAPTER 1

INTRODUCTION

Welding of dissimilar weldments are widely used in industry because of its benefits
which reduce the cost of raw material and increase the capability of design flexible
and strength. Use of dissimilar materials will increase the hardness of material when
compared with parent materials. Here we are using dissimilar weldments of
AISI4130 & AISI4140 of low alloy steels. While compared both are different material
but some properties are similar. AISI4140 and AISI4130 both are chromium-
molybdenum alloy steels, comes to AISI4140 is widely used in structural automotive,
petroleum and gas industries it has higher strength and also used as bolts, coupling,
gears in industry and has high corrosion resistance in other hand AISI4130 is used
in aircraft landing gears. When comes to aerospace or craft projects should take
into amount of difficulties of transportation a load against the gravity while take-off
and landing, to reduce this friction it has made an efficient way that decrease the
cost of material and increase the safety. Although AISI4130 is lighter in weight when
compared to-general steels and its higher specific strength ratio enable the
engineers to reduce the weight of design. Both steels have high carbon content plus
addition to this Cr and Mo, and AISI4130 is good weldable compared to AISI4140.
Coming to filler (NICKLE CHROMIUM MOLY-10) (ERNiCrMo-10) is used as a filler.
If filler Is not properly selected some of weld defects have been shown such as
solidification and liquification cracks in the fusion zone may occurs in the weld joint.
Taguchi method was proposed by Dr. Guich Taguchi and it was developed on the
basis of orthogonal array by this experiment it gives much reduced variants for the
experiments with optimum setting of control parameters. The Taguchi method was
involved in the identifying proper control factor and obtain the optimum results.
These orthogonal array methods were used to make a set of experiments and result
of these experiments were used to analysis the data; Taguchi was composed in 8
steps of planning. This method was used to reduce the occurring defect and failure
of product. This experiment had based on Taguchi (L9) orthogonal array.

1
1.1 WELDING

Welding is a process of joining of two metals and here we are using TIG welding.
TIG welding is also called as GAS TUNGSTUN ARC WELDING and it an arc
welding process, which use of non-consumable tungsten electrode to produce the
weld between the two metals. In TIG welding inert shield gas is used (argon or
helium) are used to protect the weld area and electrode from oxidation and
atmospheric contamination. TIG welding is used to weld commonly stainless steel
and non-ferrous metals and other types of materials. The TIG welding is a difficult
welding process and it was as like as torch welding process and is used for high
resistance for corrosion and cracking up to long period and it is one of the primaries
uses in aerospace industry. Welding of dissimilar metals is a new introduction and
is more difficulties to TIG welding because to fuse a form as strong bond is not easy
so filler is used to attach a strong bond.

1.2 CLASSIFICATION OF WELDING

The process of welding is classified into three types they are

1.2.1 Homogeneous welding

Welding of thick plates using filler metal used as per needs according to
thickness of plate. The filler material used to provide better strength to the joint. In
this process filler material is same as base metal. Different types of homogeneous
welding process commonly used are:

• Arc welding – Filler material generally used as consumable electrode for

manual arc welding and metal inert gas welding.
• Gas welding – An external filler rod is required for gas welding.
• Plasma arc welding – In case of Plasma arc welding also an external
filler rod is necessary for welding.
• Thermit welding – In case of thermit welding a molten material from some
chemical reaction is added.
In case of homogeneous welding solidification occurs directly by growth mechanism
without nucleation stage.

2
1.2.2 Heterogeneous welding
A filler material different from the base material is used for welding. The
solidification in heterogeneous weld takes place in two stages i.e. nucleation and
growth. Since, Homogeneous and Heterogeneous welding process required
external filler material therefore an arrangement for this filler rod feeding (in case of
automated system) make the process complex and costly.

1.2.3 Autogenous welding

A weld joint can be developed just by melting of edges of plates or sheets.
This type of welding used especially if plate thickness is less than 5 mm. No filler is
added during autogenous welding. All types of solid phase welding, resistance
welding and fusion welding without filler rod corresponding thin category of welding
are examples of this category. Following are some specific advantages of
autogenous welding process:
• Suitable for high production rate.
• Heating of the workpiece is confined to very small parts which results in
• less distortion.
• Possible to weld dissimilar metals as well metal plates of different
thickness
• High speed welding is possible.
• Since no external material is used, the process is very economical.
• Since no filler rod is used, process can be automated easily.

Various types of Autogenous welding process

• Resistance welding – Among these process resistance welding is

limited for specific application and not useful for thick plate and
complicated shape. Further for welding different thickness plate
different diameter electrode is required.
• Laser beam welding – Laser Beam Welding process is very expensive
process not for small industry.
• Electron Beam Welding – Similar to Laser Beam Welding process,
Electron Beam Welding process is also very expensive process.

3
 • Friction Stir Welding – Friction Stir Welding is mainly limited to low
melting temperature and soft material.
• Gas welding without filler rod f) TIG welding without filler rod

1.3 TUNGSTEN-INERT GAS WELDING

Tungsten Inert Gas welding is also known as Gas tungsten arc welding (GTAW),
is an arc welding process that uses a non-consumable tungsten electrode to
produce arc. The welded area is protected from atmospheric contamination by an
inert shielding gas (argon or helium), and a filler is normally used to weld thick plate.
The electrode is no consumable since its melting point is about 3400oC. In tungsten
electrode 1 to 2% thorium and zirconium are added to improve electron emission,
arc stability and current carrying capacity. A constant current welding power supply
produces energy which is conducted across the arc through a column of highly
ionized gas and metal vapours known as plasma. Heat input in GTAW does not
depend on the filler material rate. Consequently, the process allows a precise control
of heat addiction and the production of superior quality welds, with low distortion and
free of spatter.

1.3.1 Principle of TIG welding

In TIG welding process, the electrode is non consumable and purpose of it only to
create an arc. The heat-affected zone, molten metal and tungsten electrode are all
shielded room atmospheric contamination by a blanket of inert gas fed through the
GTAW torch. Fig. 1 shows schematic diagram of the working principle of TIG
welding process. Welding torch consist of light weight handle, with provision for
holding a stationary tungsten electrode. In the welding torch, the shielding gas
flows by or along the electrode through a nozzle into arc region. An electric arc is
created between electrode and the workpiece material using a constant current
welding power source to produce energy and conducted across the arc through a
column of highly ionized gas and metal vapours. The electric arc produce high--
temperature and heat can be focused to malt and join two different parts of
workpiece.

4
 Fig:1.1: Schematic diagram of working principle of TIG welding

1.3.2 Different types of welding current

Both the direct current (DC) and alternating current (AC) may be used for TIG
welding. When the work is connected to the positive terminal of DC welding machine
and the negative terminal to an electrode the welding set up is said to have straight
polarity. When work is connected to negative and electrode to positive terminal then
the welding set up is said to have reversed polarity.

Table 1.1 Comparison of different welding current polarities

Sl. Property DC, electrode DC, electrode AC
No. positive negative
1 Penetration Shallow Deep Intermediate
2 Heat generation 2/3rd at electrode, 1/3rd at electrode,
1/3rd at workpiece 2/3rd at workpiece 50% on both
3 Metal deposition High Low Intermediate
rate
4 Thickness of work Thin sheets Thick sheets Intermediate
5 Stable smaller arc Easier Easier Difficult
6 Arc blow Serve serve Intermediate

1.3.3 Advantages of TIG welding process

• Concentrated arc produced for control heat input to the workpiece. It
resulting in a narrow heat-affected zone.

5
 • This process is done without use of flux, therefore no slag formation
during welding process.
• No Sparks or Spatter because of no transfer of metal across the arc
during TIG welding.
• Compared to other arc welding processes like flux cored welding, fewer
amounts of fumes or smokes are produced.
• Welding of thin material is possible.
• Welding dissimilar type material is possible.
• Welding of different types of metal and metal alloys are possible by
proper control
• Welding of different types of metal and metal alloys is possible.

1.3.4 Disadvantages of TIG welding process

▪ Low travel speeds than other welding processes to make the process
slow.
▪ Low filler material deposition during welding compare to other arc
welding process.
▪ High skills are required for manual welding process.
▪ Welding equipment cost is higher than other arc welding process.

1.3.5 Applications of TIG welding process

▪ The offshore industry
▪ The petrochemical industry
▪ Power plants
▪ The chemical industry
▪ The food industry
▪ The nuclear industry
▪ Automobile
▪ Aerospace
1.4 WELDING PROCESS PAPAMETERS OF TIG WELDING

• Welding current – Constant current type power source is used for TIG welding
process. The preferred polarity for TIG welding process depends upon the type

6
 of workpiece material being welded. Direct Current (DC) with straight polarity is
used for Cu alloy and stainless. DC with reverse polarity is used for magnesium.
The Alternating Current (AC) is more versatile in welding for steel and aluminium.
Fixed current mode varies the voltage to maintain a constant arc current.
• Arc voltage - This can be fixed or adjustable depending on the equipment used
for TIG welding. Some metals require a specific voltage range for welding. A high
initial voltage is required for easy arc initiation. It also allows for a greater range
of working tip distance between electrode and workpiece. Too large voltage, can
lead to greater variability in workpiece quality.
• Shielding Gas – Shielding gas is required for TIG welding to protect weld area
from atmospheric contamination. If atmospheric gases (oxygen and nitrogen) are
come in contact with tungsten electrode, arc or welding metal cause fusion
defect and porosity. Various shielding gases are available including mixtures of
argon, helium and hydrogen. Mostly argon is used as a shielding gas for TIG
welding. The choices of shielding gas affect depth of penetration, surface weld
profile, strength, brittleness and hardness.
• Gas flow rate – A uniform flow of inert gas is required to shield the molten metal.
Gas flow rate can vary, proper selection of flow rate is required for ensure weld
quality and improve efficiency. The value of gas flow rate is dependent on the
thickness of the workpiece material to be welded. Lower flow rate required for
manual welding than automatic welding process.
• Welding speed – The amount of energy transferred per unit length of weld is
inversely proportional to the welding speed. Maximum value of welding current
with low speed provides maximum heat energy to the weld. Compare with the
high welding speed in TIG welding low welding speed reduces the tendency of
porosity.

1.5 TIG welding on Mild Steel

TIG welding is widely used for fabrication of different types of materials like
aluminium, mild steel and stainless steel. Maximum 6 mm thick mild steel plate can
be weld by TIG welding. Mild Steel weld by TIG welding is more precise and cleaner
than other arc welding process like manual arc welding or Metal Inert Gas welding.
Mild steel is ductile material and can be easily machined. Welding of mild steel plate
7
required to give different structural shape to produce various machine components.
TIG welding is capable of achieving highest qualities weld and most versatile. TIG
welding provides high integrity that is required at the root and in conjunction with
weld speed. TIG welding machine are available in high current rating as well as low
current rating. TIG welding provides 150 A to 350 A range of current which is useful
for welding of thick mild steel plate. Table 2 and 3 shows mechanical properties and
percentage composition of mild steel respectively.

Table 1.2 Mechanical properties of Mild Steel

Mechanical Property Mild Steel
Density 7.85 g/cc
Young’s Modules 190 - 210 GPa
Tensile strength 394.7 MPa
Carbon percentage < 1.5 % C
Hardness 111 HB
Yield strength 294.8 MPa

Table 1.3 Percentage composition in Mild Steel

Alloy Percentage (%)
Chromium 0.069
Nickel 0.01
Carbon 0.18
Manganese 0.8
Sulphur 0.04
Phosphorus 0.04
Silicon 0.4
Fe Balance

8
 CHAPTER 2
LITERATURE SURVEY

Madadian.H, et al, (2016) Mechanical Properties of Dissimilar Welds between AISI

4130 and GOST09ch16N4B, Mechanical properties of dissimilar weld joints
between GOST09ch16N4B (a martensitic stainless steel) and AISI 4130 thin sheets
made by gas tungsten arc welding (GTAW) were studied using ER410NiMo and
ER100S-G filler metals in post weld heat treated condition, Heat treatment cycles
consisted of austenitization at 900, 950 and 1000 °C for 1 h and this was followed
by oil cooling and tempering at 400 and 500 °C for 1 h, Tensile tests and
microhardness measurements were carried out to evaluate the mechanical
properties. The base metals, heat affected zones (HAZs) and fusion zones were
observed by optical microscope and scanning electron microscope (SEM) equipped
with energy dispersive spectroscope (EDS),it shows that Tensile samples were
fractured in the base metals, Based on the results, it was found that the joints
strength and microhardness profiles were almost independent, and Fracture of all
tensile specimens occurred in the base metals and it was shifted from6
GOST09ch16N4B to AISI 4130 by increasing the tempering temperature.

Sare Celik*, et al, (2009) Investigation of the mechanical properties and

microstructure of friction welded joints between AISI 4140 and AISI 1050 steels, in
this study, joiningofAISI4140 steel (medium carbon and low alloy steel)
andAISI1050steel (medium carbon steel) was successfully achieved. It was done
by friction welding process. The highest tensile strength acquired in the welded
specimens is 6% higher than parent AISI 1050 steel and the lowest tensile strength
obtained was 1.9% lower than the parent AISI 1050 steel. Mechanical properties,
macro and micro structural investigation of materials joined with this process were
completed; joint strength was tested and optimum welding parameters were
obtained. The tensile strength of the welded specimens was detected very close to
that of parent materials. Hardness of the weld zone was obtained higher than the
hardness of that of parent materials. here no cracks or blank spaces in optical and
SEM observations.
9
Won-Bae Lee, et al, (2004) Effects of copper insert layer on the properties of friction
welded joints between TiAl and AISI 4140 structural steel, Friction welding
characteristics between TiAl and AISI 4140 have been investigated in this study. It
is a fraction welding in the view point of tensile strength, the highest tensile strength
between TiAl and AISI 4140 was acquired by using pure copper as insert metal. The
highest tensile strength, 375 MPa, at room temperature was acquired relative to
those of other welding methods. In case of direct bonding between TiAl and AISI
4140, the crack was formed through the interface due to the brittle reaction products.

Kuang-Hung Tseng, et al, (2015) Effect of thermal stability of powdered oxide on

joint penetration and metallurgical feature of AISI 4130 steel TIG weldment, this
study investigates the joint penetration and metallurgical features of AISI4130 steel
and it was done by TIG welding process and in this study the author refers to the
joint penetration with low alloy steels. It shows that the microstructures and
microhardness of the weldment were carried out and also the results were
compared and it shows a greater penetration. TIG welding with Moo3 or CrO3 will
increases the down weld Lorentz flow. This weld increases or improves the joint
penetration of AISI4130 steel when compared with welding with TIG welding without
power oxides, TIG welding with high thermal stability oxides may generate a heavy
slag floating on the surface of molten metal. The heavy slag layer hinders thermal
energy transfer from the electric arc to the molten pool during-PF welding. Looking
at the microstructure and microhardness of AISI 4130 steel TIG weldment produced
with or without powdered oxide, the microstructure of the BM consists of ferrite and
pearlite, which has the lowest microhardness. The microstructure of the HAZ
consists offerrite, pearlite, and martensite/austenite, which reveals a heterogeneous
distribution of microhardness in the weldment. The microstructure of the WM mainly
consists of martensite, which has the highest microhardness. 6. The hard
microstructures formed in the WM and CGHAZ of AISI4130 steel weldment
exhibited a considerable microhardness value (N370HV).

Souza Netoa. F, et al, (2015) An Analysis of the Mechanical Behaviour of AISI 4130
Steel after TIG and Laser welding process, in this paper the author refers the

10
mechanical behaviour of AISI 4130 Steel after TIG and laser welding process, For
the mechanical characterization of laser and TIG welds, tensile and hardness tests
were performed. Microstructural characterization through optical microscopy was
realized as well, in the fusion zone (FZ) and heat-affected zone (HAZ). In the present
study, the weld was autogenous and a post weld heat treatment was conducted to
evaluate its influence on mechanical properties. This treatment proved to improve
the ductility of the steel and reducing the embrittlement in the welded region and
also observed that thicknesses of the FZ and HAZ in the TIG welds were ten times
larger than in the laser, the hardness values observed in FZ and HAZ were similar
in both cases and also tensile strength after the heat treatment process shows
similar to the base material.

Jaiteerth R. JOSHI a, et al, (2019) A comparative evaluation of microstructural and

mechanical behaviour of fiber laser beam and tungsten inert gas dissimilar ultra-
high strength steel welds. Investigated for the dissimilar weldments of 18% Ni
maraging steel 250 and AISI 4130 steel. It is a fiber laser beam and tungsten inert
gas welding process. And done by characterized through optical microstructures,
microhardness survey across the weldment and evaluation of tensile properties.
Laser beam weld joints have shown higher weld joint efficiencies as compared to
both continuous current and pulsed current TIG weld joints.

Ali Emamian1, et al, (2010) Effects of Filler wire Composition along with Different
Pre- and Post-Heat Treatment on Mechanical Properties of AISI 4130 Welded by
the GTAW Process, mechanical properties of AISI 4130 steel and it is a GTAW
process. Tensile, side bends and impact tests (for weld zone and HAZ) have been
conducted and Results show that using low-carbon filler wire along with pre- and
post-heat resulted in outstanding mechanical properties, Low carbon filler wire
shows better results in terms of decreasing the risk of crack formation.

CHIEN-CHUN WANG, et al, (1996) Effect of Post weld Treatment on the Fatigue
Crack Growth Rate of Electron-Beam-Welded AISI 4130 Steel. This article studies
the effect of n-chamber electron beam and ex-chamber furnace post weld treat-
ments with AISI 4130 Steel, and by Electron-Beam-Welding. evaluated by tensile

11
testing and microstructure, in addition, the ductility, strength, and microhardness of
the weldment also reflect this tempering effect and furnace post weld heat treat-
ments temper the centreline weld microstructure to become tempered martensite.
This results from the tempering effect to produce the tempered martensite and the
change of residual stress state from initial tensile to final more compressive stress.

Mohammad W. Dewana, et al, (2013) Effect of post-weld heat treatment and

electrolytic plasma processing on tungsten inert gas welded AISI 4140 alloy steel.
The material used in this is AISI 4140 alloy steel and the process is tungsten inert
gas welding process and An electrolytic plasma process (EPP) has been developed
to improve corrosion behaviour and wear resistance of structural materials, the
testing done with experiment was study the effects of PWHT and EPP on the
residual stresses, micro-hardness, microstructures, and uniaxial tensile properties
are explored on tungsten inert gas (TIG) welded AISI-4140 alloys steel with SAE-
4130 chromium–molybdenum alloy welding filler rod. For rational comparison all of
the welded samples are checked with non-destructive Phased Array Ultrasonic
Testing (PAUT) and to ensure defect-free samples before testing and SEM analysis.
The results show the reduction in ductility, tensile strength, and toughness is
common in TIG-welded low alloy steel for the development of tensile residual
stresses and martensitic microstructures in HAZ and weld zone. Consequently, as-
welded (AW) samples showed about 39% and 37% reduction in failure strain and
toughness values, respectively, compared to the base metal. EPP-treatment might
be a good candidate technology to improve tensile strength by relieving of post-weld
tensile residual stresses, as well as imparting corrosion resistant property of TIG
welded low alloy and high strength steel structures.

Podgornik. B, et al, (1991) Wear and friction behaviour of duplex-treated AISI 4140
steel. The material used in this is AISI 4140 alloy steel, the specimens were
investigated with respect to their microhardness, surface roughness, scratch
adhesion and dry sliding wear resistance and Metallography, scanning electron
microscopy and profilometry were used to analyse the worn surfaces in order to
determine the dominant friction and wear characteristics of the samples
investigated. Although previous investigations showed a negative effect of the
compound layer, it was found that a precisely controlled plasma nitriding process
12
can lead to a dense, uniform and highly adherent compound layer with a positive
effect on the wear properties of pre-nitride and hard-coated AISI 4140 steel.

Khani Sanij⇑ .M.H, et al, (2012) The effect of single and double quenching and
tempering heat treatments on the microstructure and mechanical properties of AISI
4140 steel. The material used in this is AISI 4140 alloy steel, it is a double quenching
and tempering (DQT) with conventional quenching and tempering (CQT) heat
treatment processes on microstructure and mechanical behaviour of a commercially
developed hot rolled AISI 4140 type steel. Comparison of microstructure and
mechanical properties of DQT and CQT. Optical and scanning electron
microscopies have been used to follow impurity concentration and microstructural
changes, and their relation to the associated mechanical properties. The results
indicate that the improvement of mechanical properties particularly impact
toughness of DQT heat treated specimens is much higher than that of the CQT
condition, the results show that f austenite grain boundary as well. (4) The DQT
treatment is less sensitive to temper martensite embrittlement followed by tempering
heat treatment because of a lower distribution of impurity elements of S and P
segregated at the prior austenite grain boundaries. or almost an identical hardness
and strength following CQT and DQT heat treatment processes, the DQT condition
results in a significant improvement of 23% in impact toughness as compared to the
CQT condition.

Paulo J. Modenesi, et al, (2000) TIG welding with single-component ¯uxes, Gas
tungsten arc welding is fundamental in those applications where it is important to
control the weld bead shape and the metallurgical characteristics. This process is,
however, of low productivity, particularly in the welding of large components. The
activated ¯ux TIG (ATIG) welding process, developed by the Paton Welding Institute
in the 1960s, is now considered as a feasible alternative to increase the process
productivity, the literature does not present the ¯ux formulations for ATIG welding,
the few formulations that were found to have a complex nature. The present work
evaluates the use of ATIG welding for the austenitic stainless steels with ¯uxes of
only one major component. The changes in weld geometry were compared to
variations in the electrical signals from the arc and the arc shape. The effect of the
¯ux on the weld microstructure was also studied. The results indicate that even the
13
very simple ¯ux that was used can greatly increase the penetration of the weld bead.
# 2000 Elsevier Science S.A. All rights reserved.

Ahmet Durgutlu, et al, (2004) Experimental investigation of the effect of hydrogen in

argon as a shielding gas on TIG welding of austenitic stainless steel, the effect of
hydrogen in argon as shielding gas was investigated for tungsten inert gas welding
of 316L austenitic stainless steel. The microstructure, penetration and mechanical
properties were examined. Pure argon, 1.5%H –Ar and 5%H –Ar 22 were used as
shielding gas. The highest tensile strength was obtained from the sample which was
welded under shielding gas of 1.5%H –Ar. After bending test, cracks, tearing and
surface defection were not observed on the samples that were welded under all
three-shielding media, for tensile strength, the best result is obtained from 1.5%H –
Ar as gas shielding. Cracks, tearing and surface defection were not with naked eye
observed after bending the samples welded under all three-shielding media. For all
shielding media, hardness of weld metal is lower than that of the HAZ and base
metal. Penetration profile examinations for all three different shielding gases show
that penetration depth and weld bead width increase with increasing hydrogen
content.

14
 CHAPTER 3
AIM AND SCOPE

3.1 AIM
The aim of this project is to analyse the effect of TIG welding process
variables such as welding current, welding voltage, torch speed, based on the
strength (to find the suitability of weldment in corrosive and high temperature
environment) for the selected filler (ERNiCrMo10) by means of evaluating methods
such as destructive mechanical tests, non-destructive tests and metallographic
studies and weld bead geometry (to control the angular and linear distortions, to
increase the weld penetration depth and also to increase the productivity, in a
specific thickness of AISI4130 and AISI4140 dissimilar weldments using a different
combinations of process parameters selected based on L9 orthogonal array.

3.2 SCOPE
TIG quality is strongly characterized by the weld bead geometry. Bead geometry is
important in terms of weld quality, and the quality of weldment is defined in terms of
mechanical properties such as strength and toughness. Therefore, it is very
important to select the welding process parameters for obtaining optimal weld bead
geometry with adequate mechanical properties. Even though many investigations
have been carried out on automatic TIG of austenitic stainless steels most of the
available data scattered and proprietary in nature. Hence data need to be generated
for specific requirement and for using novel techniques in automatic TIG further
refinement of the process parameters is feasible to reduce defects and enhancing
the weld quality. So, the present study is mainly focused on the influence of shielding
gas and process variables of automatic TIG using on AISI4130 andAISI4140
weldments. It is proposed to produce weldments by using sufficient current rating,
keeping in mind reduced heat input and refined microstructure. To obtain quality
and sound weldments in automatic TIG process and to achieve uniform grain size
and mechanical properties, the essential process parameters will be investigated.

15
Main objective of this work is to find an optimal welding variable of AISI4130 and
AISI4140 which will ensure increased productivity, high strength, good quality and
sound weldments. It has been observed that the mechanical properties are sensitive
to microstructure of weld metal, which is appreciably affected by the welding process
parameters like low and high currents. For different current rating tensile strength
will be studied by using transverse tensile test. Attempts are made to study the effect
of welding process variables based on the tensile strength. Based on tensile
strength welding parameters will optimized. Investigation is planned to carry out trial
welding using 30 Nos of 304L to obtained optimal parameters. (like current, voltage,
shielding gas, arc length, torch travel speed, shielding gas flow rate etc.) Main
investigation will be conducted on specimens by using optimized parameters to
analyse and to evaluate mechanical properties like maximum load, ductility,
elongation of the specimen, tensile stress and reduction in cross sectional area, &
metallurgical studies by optical microscope and scanning Electron Microscope
(SEM) on base metal near weld, heat affected zone, weld metal and micro hardness,
residual stress etc., for Welding Procedure Qualification (WPQ).

16
 CHAPTER 4
MATERIALS AND METHODS
4.1MATERIALS
AISI 4140 is a chromium-molybdenum alloy steel. The metal content
provides smart hardness penetration, and therefore the metal content ensures
uniform hardness and high strength. AISI 4140 chrome-molybdenum steel may be
oil hardened to a comparatively high level of hardness. The fascinating properties
of the AISI 4140 embody superior toughness, smart plasticity and smart wear
resistance within the quenched and tempered condition AISI4130 is a low alloy steel
containing chromium and molybdenum as a strengthening agent and the steel had
good strength and toughness, the carbon content is normally 0.30% and `with this
relatively low carbon content the alloy is excellent from the fusion welding stand
point.ERNiCrMo-10 is a filler metal and was used to weld the Nickel-chromium-
molybdenum material-based alloy and also used to weld duplex and super duplex
stainless steel.

Fig: 4.1: Base metal AISI4140

Fig: 4.2: Base metal AISI4130

17
 Table 4.1 Chemical composition of base and filler metals

Base Metal Composition (% weight)

C Mn Cr Mo Fe Nb Ni Cu
AISI 4130 0.4 0.27 1.04 0.64 - - 0.18 0.02

AISI4140 0.45 0.672 1.041 0.092 - - 0.144 -

ERNiCrMo- 0.013 0.56 22.5 13.9 2.6 - - -

10 (filler)

Table 4.2 Optimization Parameters of L (9) Orthogonal array

Voltage Current Speed

10 120 125

10 135 150

10 150 175

12 120 150

12 135 175

12 150 125

15 120 175

15 135 125

15 150 150

18
4.2 EXPERIMENTAL DESIGN
The experiment done by using of TIG welding machine, here we taken 9 welded
samples of AISI with 15cmx2.3cmx0.4 with the help of L (9) orthogonal array .The
samples are cut by use of wire electrical discharge machining process and it shows
high precision metals and it can makes more positive cutting shapes electrical
discharge between wire and work piece then it was welded with using of TIG welding
and the gap between the two dissimilar weldments of AISI4130 & AISI 4140 is
0.7cm.The process is an arc welding process which use of non- consumable
tungsten electrode to produce the weld between two metals. Then the welded metal
is grinded, grinding is a process of abrasive machining which uses of grinding wheel
as a cutting tool and grinding is use to grind the material then the rough surface was
removed by grinding process to make a smooth surface, then it was tested with help
of tensile test and it was shown in (table 3&6) the Tensile testing is also known as
tension testing; the theme of tensile testing is used to determine the material that
how they behave under the tension load. To determine ultimate tensile load the
material is typically pushed to its breakage point then its hardness was calculated
by using of Brinell hardness and was shown in the (table 9&10) and also
microstructures are shown in (fig 1&2), so the Microhardness testing is used to
determine the hardness of material or resistance to penetration.

4.3 WELDING
Welding is a process of joining two similar or dissimilar metals by fusion, with or
without application of pressure and with or without use of filler metal. Weldability of
the material depends upon various factors like the metallurgical changes that occur
due to welding, change in hardness of material, in and around the weld and the
extent of cracking tendency of the joint. A range of welding processes have been
developed so far using single or combination of factors like pressure, heat and filler
material used.
TIG welding was performed by maintaining different gap between the workpieces to
be welded and study the effect of this gap on the welding performance mainly weld
bead geometry and tensile strength of the weld.

19
4.3.1 Experimental setup
For the present project work an autogenous welding set up has been
developed to perform welding with a fixed velocity with the application of filler
material. A movable vehicle is used to hold TIG torch. The distance between
workpiece and torch tip will remain constant the welding process. The speed of
movable vehicle is controllable and can be varied according to the requirement of
the welding speed and amount of heat required. Figure 4.3 shows experimental
setup for present work. The welding setup for autogenous TIG welding process
consists following components:
• Welding torch
• Electrode
• Filler
• Power supply
• Inert gas supply unit
• Movable vehicle holding the welding torch
• Welded sample
• Rail Track

Fig: 4.3: Experimental setup of TIG welding

20
• Welding torch – TIG welding torch is capable for both automatic and manual
operation. The automatic and manual torches are similar in construction. The
manual torch has a handle while the automatic torch normally comes with a
mounting rack. The internal metal parts of a torch are made of hard alloys of
copper or brass in order to transmit current and heat effectively. The size of the
welding torch nozzle depends on the amount of shielded area desired. The main
purpose of TIG torch is to carry the welding current and shielding gas to the weld.
For present work a manual torch has been fixed with the movable tracker using
clamp arrangement to make it automated. Figure 4.4 shows welding torch of
autogenous TIG welding setup.

Fig: 4.4: Welding torch

• Electrode – A non-consumable tungsten electrode is used in TIG welding

process. The tungsten electrode held firmly in the centre of the torch and around
the electrode a constant flow of shielding gas. The electrode used in GTAW is
made of tungsten or tungsten alloy due to its highest melting temperature among
the pure metals. Tungsten electrode is surrounded by a gas nozzle. This gas
nozzle is generally made of ceramic material. For present experiment 2.4 mm
diameter tungsten electrode has been used.
• Filler – (NICKLE CHROMIUM MOLY-10) (ERNiCrMo-10) Is used as a filler, if
filler Is not properly selected some of weld defects are been shown such as
solidification and liquation cracks in the fusion zone may occurs in the weld joint
alloy and also used to weld duplex and super duplex stainless steel.

21
 Fig :4.5: Filler – (NICKLE CHROMIUM MOLY-10) (ERNiCrMo-10)

• Power source – A constant current power source is used for TIG welding
process. Direct current with straight polarity is used for welding of mild steel
plate. Work material is connected to the positive terminal of DC welding machine
and negative terminal to an electrode holder, this welding condition is said Direct
Current with straight polarity. The DC power supply used for TIG can be steady
or pulsed. For present work DC power supply in steady condition has been used
where current is fixed and consequently voltage can vary to maintain a stable
arc.
• Inert gas supply unit – A gas cylinder is used to supply Argon gas to the welding
torch. Argon gas is supplied from gas cylinder with a suitable gas flow rate. Gas
flow is controlled by regulator and valve. The purpose of supplying inert gas is
to shield the weld zone in order to protect it from atmospheric contamination
which leads to welding defects. For present experiment gas flow in the range 12-
15 l/min has been flown.
• Movable vehicle – A movable setup is used to provide constant welding speed
for TIG welding operation. This movable tractor is used to hold the welding torch.
It also helps in maintaining a proper gap between tip of the tungsten electrode
and welded area of the workpiece. Manually it is difficult to maintain a constant
weld speed and gap between electrode and workpiece. So, with the help of a

22
 portable moving tractor welding speed and gap between workpiece and
electrode can be easily controlled. Figure 4.6 shows a movable vehicle to hold
the welding torch.

Fig: 4.6: Movable vehicle holding the welding torch

• Rail track – Vehicle is move over this rail track in a straight path. Rail track is
properly clamped by C clamp with the table
• Welded sample –The workpiece after welding

Fig: 4.7: After welding (AISI4130 &AISI4140)

23
4.4 EDM (ELECTRICAL DISCHARGE MACHINING)

In wire electrical discharge machining (WEDM), also known as wire-cut EDM and
wire cutting, a thin single-strand metal wire, usually brass, is fed through the work
piece, submerged in a tank of dielectric fluid, typically deionized water. Wire-cut
EDM is typically used to cut plates as thick as 300mm and to make punches, tools
and dies from hard metals that are difficult to machine with other methods. The wire,
which is constantly fed from a spool, is held between upper and lower diamond
guides. The guides, usually CNC-controlled, move in the X-Y plane. On most
machines, the upper guide can also move independently in the Z-U-V axis, giving
rise to the ability to cut tapered and transitioning shapes (circles on the bottom,
square at the top for example). The upper guide can control axis moments in x-y-u-
v-i-j-k-l-. This allows the wire-cut EDM to be programmed to cut very intricate and
delicate shapes. The upper and lower diamond guides are usually accurate to
0.004mm (0.16mils) , and can have a cutting path or kerf as small as 0.021mm
(0.83mils) using Ø 0.02mm (0.79mils) wire, though the average cutting kerf that
achieves the best economic cost and machining time is 0.335mm (13.2mils) using
Ø 0.25mm (9.8mils) brass wire. The reason that the cutting width is greater than the
width of the wire is because sparking occurs from the sides of the wire to the work
piece, causing erosion. This *overcut* is necessary, for many applications it is
adequately predictable and therefore can be compensated for (for instance in micro-
EDM this is not often the case). Spools of wire are long-an 8kg spool of 0.25mm
wire is just over 19 kilometres in length. Wire diameter can be as small as 20 µm
(0.79mils) and the geometry precision is not far from ± 1 µm (0.039mils). The wire-
cut process uses water as its dielectric fluid, controlling its resistivity and other
electrical properties with filters and deionizer units. The water flushes the cut debris
away from the cutting zone. Flushing is an important factor in determining the
maximum feed rate for a given material thickness. Along with tighter tolerances,
multi axis EDM wire-cutting machining centres have added features such as multi
heads for cutting two parts at the same time, controls for preventing wire breakage,
automatic self-threading features in case of wire breakage, and programmable,
machining strategies to the optimize the operation. Wire-cutting EDM is commonly
used when low residual stresses and desired, because it does not require high
cutting forces for removal of material. If the energy/power per pulse is relatively low

24
(as in finishing operations), little change in the mechanical properties of a material
is expected due to these low residual stresses, although material that has not been
stress-relieved can distort in the machining process. The work piece may undergo
a significant thermal cycle, its severity depending on the technological parameters
used. Such thermal cycles may cause formation of a recast layer on the part and
residual tensile stresses on the work piece, if machining takes place after heat
treatment, dimensional accuracy will not be affected by heat treat distortion.

Fig:4.8: Wire cut EDM machine

4.4.1 Basic principle of EDM process

EDM machining is carried out by means of electric sparks that jump between
tow electrodes subjected to a voltage and submerged in a dielectric fluid. Thus, the
voltage applied to them must be enough to create an electric field higher than the
dielectric rigidity of the fluid used in the process as a consequence of this electric
field, positive ions and electrons are accelerated, producing a discharge channel
that becomes conductive, it is just at this point when the spark jumps causing
collisions between ions and electrons and creating a channel of plasma. A sudden
drop of the electric resistance of the previous channel allows that current density

25
reaches very high values producing an increase of ionization and the creation of a
powerful magnetic field. These effects make a little part of metal volume melt or
even vaporise. In these conditions, that is, ions and electrons crashing among them
and therefore creating high temperatures in both poles, a gas all or bubble is formed
around the plasma channel and then begins to grow providing just at the end of the
discharge a large ball of gas. In this situation, electric current is shutoff and the
plasma channel collapses producing the spark to disappear. Due to the sudden
decrease of internal pressure of the gas ball, the dielectric fluid breaks it making the
ball implodes, that is, explode inwards. As a consequence of this implosion, an
ejection of molten metal is carried out and, afterwards, this ejected molten materials
solidifies in the form of little balls formed the so called EDM splinter or debris. Fig
1.4 shows working principle of EDM.

4.4.2 Advantages of wire cut EDM

• ELECTRICALLY CONDUCTIVE- any material that is electrically

conductive can be cut, regardless of its hardness.
• TAPS- taps or drills can be readily removed from the work piece NO
STRESSES- it does not create stresses in work material, since the tool
never comes into contact with the work piece.
• BURR FREE process.
• FRAGILE and thin sections can easily be machined without
deformation.
• INRICATE contours or cavities in hardness steel can be cut without the
need for heat treatment to soften and re harden.
• LOWER COST- better dies and molds can be produced at a lower cost.

4.4.3 Applications of wire cut (EDM)

• Ideal for low volume quantities of parts that require tight
manufacturing tolerances.
• Extrusion dies.
• Blanking punches.
• Metal and tool fabrication.

26
4.4.4 Limitations of wire cut (EDM)
• Only able to machine conductive materials.
• More expensive process than convectional milling or turning.
• Tool life is no longer.
• Power consumption is high.
• Cycle time is more.

4.5 GRINDING
Grinding is a process of abrasive machining process which uses of grinding
wheel are grinder as a cutting tool and grinding is used to grinding the material with
good accuracy of shape, dimension and surface. After welding the rough surface
was moved by grinding process, here we are using surface grinding. In surface
grinding rotating abrasive wheel is used to remove the material and making a
smooth surface grinding is used in like cast iron and some other types of steels.

Fig: 4.9: Grinding machine

4.6 TESTING PROCEDURES

Tensile testing is also known as tension testing, the theme of tensile testing is used
to determine the material that how they behave under the tension load. To determine
ultimate tensile load the material is typically pushed to its breakage point. Tensile

27
test was calculated by the amount of force that applied to the sample and the
elongation (∆L) of that sample should measure through the test the material
properties expressed in term of stress and strain. By tensile testing the following
properties are determined like young’s modulus, yield strength, Poisson’s ratio and
strain-hardening. The total experiment was done in (UTM) universal testing machine
and the tensile test was used to determine the effectiveness and also behaviour of
a material and when an elongation or stretching force act on it and also the testing
was done on under optimum temperature and pressure condition.

4.6.1 Tensile Test

Sample preparation for tensile testing for tensile testing of welded samples were
cut into I shape as per ASTM A29. Tensile testing of the weld specimens was carried
out in an INSTRON Universal Testing Machine (UTM) with maximum load capacity
of 600 KN. The tensile testing involved fixing the sample in UTM properly and then
applying a gradually increasing force until shape transformation occurs in the
specimen and it finally break.

Fig :4.10: Schematic Diagram of specimen for tensile testing

4.6.2 Process

The test process involves placing the test specimen in the testing machine and
slowly extending it until it fractures. During this process, the elongation of the gauge
section is recorded against the applied force. The data is manipulated so that it is

28
not specific to the geometry of the test sample. The elongation measurement is used
to calculate the engineering strain, ε, using the following equation,

ε=ΔL/L0 =L- L0/ L0

where ΔL is the change in gauge length, L0 is the initial gauge length, and L is the
final length. The force measurement is used to calculate the engineering stress, σ,
using the following equation,

σ=Fn/A

where F is the tensile force and A is the nominal cross-section of the specimen. The
machine does these calculations as the force increases, so that the data points can
be graphed into a stress–strain curve .

Fig: 4.11: work piece after tensile testing

Table 4.3 Dimension for tensile test as per ASTM E8 standard

Overall length- 300mm

Width of grip section 23mm

Weld gap 7mm

Overall height 4mm

29
 Fig: 4.12: INSTRON Universal Testing Machine (UTM)

4.7 MICROHARDNESS
Microhardness testing is used to determine the hardness of material or
resistance to penetration. When the tested samples were small or thin or when the
sample is in a composite sample are to be measured and also it provides the
precision, and detail information about the surface features and also find micro-
structures, multi-phase, non-homogenous. The test is used to measure the surface
core hardness on carburized and as well as surface condition. There are two types
of testing. They are Brinell hardness test and other Vickers hardness test. Here we
are using Vickers hardness test is also known as hardness test and used for small
pots and tin sections etc. and this method was based on the optical measurement
machine and is used to test the wide range of materials, but the sample material
must be polished highly to measure the size of impression. In Vickers scale a square
based pyramid shaped diamond is used for testing.

4.7.1 Brinell hardness

Method of measuring the hardness of a material by pressing a chromium-steel or

tungsten-carbide ball (commonly one centimetre or 0.4 inch in diameter) against the
smooth material surface under standard test conditions (generally between 300 to

30
3000 kilograms of force for 5 to 30 seconds). The hardness is expressed in Brinell
Hardness Number (BHN) computed by dividing the load in kilograms by the area
of indentation made by the ball measured in square millimetres. American Society
for Testing and Material's standard BH test is ASTM E-10. For measurements up to
BHN 500, Brinell hardness is equal to 0.96 times the Vickers hardness.

𝟐𝐅
𝐇𝐁 =
𝛑 𝐃(𝐃− √𝐃−𝐝)

Test Method Illustration

D = Ball diameter
d = impression diameter
F = load
HB = Brinell result

4.8 SEM /EDAX

Electron micron means mainly in two types they are transmission electron
microscope, scanning electron microscope. Transmission electron microscope
allowed to study the inner structures and scanning electron microscope is used to
visualize the surface of objects. Scanning electron microscope produces image
sample by scanning focused beam of electrons by raster scan pattern. The electrons
interact with atoms produces various signals contains information about the various
sample surface and we can see in SEM topography, morphology, composition and
cryptographic information. The advantages of SEM are wide array applications are
three dimensions morphology and topographical it is easy to operate with proper
training, EDAX popularly known as Energy Dispersive Spectroscopy technique, is

31
used for identification of different elements present in the sample. Therefore, this
can be used for studying the composition of the samples

4.8.1 principle of SEM

The signals used by a scanning electron microscope to produce an image result

from interactions of the electron beam with atoms at various depths within the
sample. Various types of signals are produced including secondary electrons (SE),
reflected or back-scattered electrons (BSE), characteristic X-rays and light
(cathodoluminescence) (CL), absorbed current (specimen current) and transmitted
electrons. Secondary electron detectors are standard equipment in all SEMs, but it
is rare for a single machine to have detectors for all other possible signals.

4.8.2 Process of SEM

In a typical SEM, an electron beam is thermionically emitted from an electron

gun fitted with a tungsten filament cathode. Tungsten is normally used in thermionic
elec4tron guns because it has the highest melting point and lowest vapor pressure
of all metals, thereby allowing it to be electrically heated for electron emission, and
because of its low cost. Other types of electron emitters include lanthanum
hexaboride, cathodes, which can be used in a standard tungsten filament SEM if
the vacuum system is upgraded or field emission guns (FEG), which may be of
the cold-cathode type using tungsten single crystal emitters or the thermally
assisted Schottky type, that use emitters of zirconium oxide.

Fig:4.13: SEM process

32
 CHAPTER 5
RESULTS AND DISCUSSION

Table 5.1 AISI4130&AISI4140(Tensile testing)

Tensile
Voltage Current Speed Strength SNRA1 MEAN1
10 120 125 394.55 51.92204 394.55
10 135 150 411.23 52.2817 411.23
10 150 175 443.9 52.9457 443.9
12 120 150 423.45 52.53604 423.45
12 135 175 431.06 52.69075 431.06
12 150 125 387.65 51.7688 387.65
15 120 175 422.34 52.51324 422.34
15 135 125 383.85 51.68323 383.85
15 150 150 421.56 52.49719 421.56

Table 5.1 represents the tensile test of AISI and was done with help of L (9)
Orthogonal array and the tested values shows a maximum optimized value with
Voltage 10, current 150, speed 175 and this value is referred to further experiment
of hardness.

Fig:5.1: Graph Signal to Noise Ratios

33
 Fig:5.2: Graph of Mean

Table 5.2 Signal to Noise Ratios

Level Speed(rpm) Current(i) Voltage(v)

1 51.79 52.32 52.38
2 52.44 52.22 52.33
3 52.72 52.40 52.23
Delta 0.93 0.19 0.15
Rank 1 2 3

Table 5.3 Mean

Level Speed(rpm) Current(i) Voltage(v)

1 388.7 413.4 416.6
2 418.7 408.7 414.1
3 432.4 417.7 409.3
Delta 43.7 9.0 7.3
Rank 1 2 3

Table 5.2 represents the Response Table for Signal to Noise Ratios and its shows
Larger is better and it was abbreviated as (SNR or S/N) and was used to know the
ratio of signal to the noise power its units were expressed as (DECIBELS) and the

34
level of desired signals to level of background was compared, Table 5.3 represents
the response for Mean for AISI

Table 5.4 Brinell hardness

Location Weldment AISI4130 AISI4140

1 240 217 260
2 240 220 255
3 238 221 262
4 239 216 258
5 242 218 265

Chart Title
300

250

200

150

100

50

0
1 2 3 4 5

Weldment AISI4130 AISI4140

Graph:5.3: Brinell hardness

The table 5.4 represents Brinell hardness test, here we taken five locations and
three areas of testing of parent material and on the weldment. In AISI4130 we taken
five hardness values and 4140 we taken five hardness values and also, we have

35
taken welded area. By adding both sides with carbon will get the welded area with
highest values.

(a)Welded zone

(b) AISI4130 base metal

(c) AISI4140 base metal

Fig:5.4: Micro structures of AISI

Fig:5.4 represents the microstructures of AISI, in (a) the line refers to the welded
zone, in (b) refers to AISI4130 and in (c) refers to AISI4140. The lines in (a) shows

36
dendrites formation the second part of dendrites formation shows poor when
compared to first formation so that the weldment shows lower tensile strength when
compared to parent material, it is suggesting that filler may be varied in future to get
more strength and joint. Similarly, there is inclusion of carbon form to AISI4130 &
AISI4140 in the weld region so hardness is improved.

SEM/ EDAX Analyzer Test

High-resolution image of the samples has been obtained through scanning electron
microscopy. A highly focused electron beam is allowed to fall on the sample
specimen and the scattered electrons were detected and used to form the high-
quality images as shown in Fig 5.5 and Fig 5.6. In fig 5.5 shows that The above fig
represents the microstructures of SEM, in Fig:5.4 represents the centre of weld zone
SEM images illustrating the micro structures of the different heat treatment samples
are provided in the figure , independently of air pressure and type of sand the
quenched temperature samples figure , A describes fine carbide inclusions are
evenly distributed in the structure in addition to mar-ten site and austenite carbide
particles in the micro structures are known to act as barriers to the penetration of
abrasive particles into the material and fig 5.6 represents the interface of parent
metal and weld zone The lines shows dendrites formation the second part of
dendrites formation shows poor when compared to first formation so that the
weldment shows lower tensile strength when compared to parent material, it is
suggesting that filler may be varied in future to get more strength and joint. Similarly,
there is inclusion of carbon form to AISI4130 & AISI4140 in the weld region so
hardness is improved

Fig:5.5: Centre of weld zone

37
 Fig:5.6: interface of parent metal and weld zone

Table:5.6: Chemical composition of AISI4130

Element Weight% Atomic%

CK 2.48 10.49
Cr K 10.98 10.78
Mn K 1.02 0.95
Fe K 83.68 76.22
Ni K 1.84 1.59

Chart Title
90

80

70

60

50

40

30

20

10

0
CK Cr K Mn K Fe K Ni K

Weight% Atomic% Series 3

Fig:5.7: Graph represents the Chemical composition of AISI4130

38
Table 5.6 Represents the chemical composition of AISI4130 here there is high
content of properties had raise when compared to base metals.

Table:5.7: Chemical composition of AISI4140

Element Weight% Atomic%

Si K 0.44 0.86
Cr K 10 10.62
Mn K 0.56 0.56
Fe K 88 87.02
Ni K 1 0.94

Chart Title
100
90
80
70
60
50
40
30
20
10
0
Si K Cr K Mn K Fe K Ni K

Weight% Atomic% Series 3

Fig:5.8: Graph represents the Chemical composition of AISI4140

Table 5.7 Represents the chemical composition of AISI4140 here there is high
content of properties had raise when compared to base metals.

39
 (a) Interface of Parent and Weld zone of EDAX

(b)Centre of Weld Zone

Fig:5.9: Microstructures of EDAX

Fig:5.9: Represent the micro structures of EDAX so (a) represents the interface of
parent metal and weld zone of EDAX, A highly focused electron beam is allowed to
fall on the sample specimen and the scattered electrons were detected and used to
form the high-quality images as shown Fig:5.9.In (a) The middle line represents the
weld zone dendrite formation with good when compared to second metal the
formation is some what poor.(b) Represents the centre of weld zone and here it
shows carbon content at the centre of weld zone.

40
 CONCLUSION

In this experiment an endeavour has made on welding of unique weldment of

AISI4140 and AISI4130 as a base metals of low carbon steels which are been likely
comparable with properties and utilizing ERNiCrMo-10(NICKEL CHROMIUM
MOLY-10) as a filler material. From the results of the tensile test, the highest tensile
strength of TIG-welded joints AISI4130 and AISI 4140 was carried out Voltage 10,
current 150, speed 175, higher tensile strength is 443.9. All of the TIG-welded
specimens have lower tensile strength compared to parent material (AISI base
metal). Joint strength and Brinell hardness profiles were almost independent of
austenitization temperature. By adding both sides with carbon will get the welded
area with highest values. The Hardness of the weld zone was showed higher than
that of hardness of that of parent materials. It was shown that is no cracks or blank
spaces in the optical and SEM observations. Grain size reduction occurred at the
HAZ’s of both base materials. It was observed that transition of materials at the weld
zone occurred in SEM inspection analyses and by the EDAX analyses the chemical
composition shows high compared to parent material.

41
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44