Welding in the World

https://doi.org/10.1007/s40194-018-0582-x

RESEARCH PAPER

Microstructures and their distribution within HAZ of X80 pipeline

steel welded using hybrid laser-MIG welding
Limeng Yin 1,2 & Jinzhao Wang 1 & Xizhang Chen 3 & Cheng Liu 1 & Arshad Noor Siddiquee 4 & Gang Wang 1 &
Zongxiang Yao 1

Received: 21 January 2018 / Accepted: 14 March 2018

# International Institute of Welding 2018

Abstract
Large microstructure gradient in the heat-affected zone (HAZ) in the joints of large thick material welded by the hybrid laser-MIG
welding technology reduces the in-service reliability and durability of the welded structure. It is of great importance to charac-
terize and analyze how the microstructure distribution and evolution occur in the HAZ of the laser-MIG hybrid welded joints
fabricated with X80 pipeline steel. In this article, the HAZ is found to comprise these characteristic zones, namely banded
microstructure HAZ (BMHAZ), fine-grained HAZ (FGHAZ), transitional microstructure HAZ (TMHAZ), and coarse-grained
HAZ (CGHAZ). The zone of the HAZ contains quasi-polygonal ferrite (QF), M-A component, polygonal ferrite (PF), and bainite
ferrite (BF). From the base metal side towards the weld center with the decrease in the distance, the size of the M-A components
decreases and its distribution is more dispersed, while the content of QF decreases in the HAZ. The average diameter of the
original austenite grain increases gradually and so does the content of lath microstructures.

Keywords Laser-MIG hybrid welding . X80 pipeline steel . Microstructure . HAZ

1 Introduction section welds arise due to lager weldment volume, dendrite

Laser-arc hybrid welding derives synergy of the constituent
process and possesses distinct advantages such as greater pen-
etration, smaller amount of filler material, higher welding
speed, and better quality and adaptability [1]. It is, conse-
quently, more suitable to welding large-diameter thick-wall
pipeline in comparison to traditional low-energy density arc
welding technology [2–4]. Main joint quality issues in thick
Recommended for publication by Commission II - Arc Welding and
Filler Metals
* Limeng Yin
yeenlm@cqust.edu.cn
1
School of Metallurgy and Materials Engineering, Chongqing
University of Science and Technology, Chongqing 401331, China
2
State Key Laboratory of Advanced Welding and Joining, Harbin
Institute of Technology, Harbin 150001, Heilongjiang, China
3
School of Electrical and Mechanical Engineering, Wenzhou
University, Wenzhou 325035, China
4
Department of Mechanical Engineering, Jamia Millia Islamia (A
Central University), New Delhi, India
formation, greater variation in microstructure, and coarse-
grained structure [3, 4]. Further, parts with a thick section have
a heat sink effect causing a high cooling rate (and rapid solic-
itation too) which leads to complex changes in the heat-
affected zone (HAZ) of welds [5, 6]. While the weld pool
regions are rapidly solidified, the HAZ undergoes grain coars-
ening and metallurgical changes [7–9]. These microstructural
changes adversely affect the in-service performance such as
reliability and durability of the welded joints of thick steel
pipeline [10–12]. Process hybridization using laser-metal inert
gas (MIG) welding alleviates such concerns to some extent as
the high-intensity laser improves penetration without much
increase in weld pool volume and limiting the amount of net
heat input [13]. Joint strength eventually depends on the mi-
crostructure evolution over entire bead geometry, as the failure
may be imminent at the weakest region even though the rest of
the zones may remain stronger [5, 9]. This paper has made an
attempt to better apprehend microstructural evolution and dis-
tribution phases. In this work, large-diameter thick X80 steel
pipes were welded using hybrid laser-MIG welding; micro-
structure evolution and distribution phases in the HAZ are
analyzed and presented. Results of the present work are highly
useful in providing theoretical basis for the general

Table 1 The chemical
composition of X80 pipeline steel C Mn P S
(wt%)
0.074 1.51 0.023 0.007
development of the process in general and hybrid approach in
particular especially for the girth welding of land pipelines
that is largely employed in the oil and gas industry.
2 Experimental procedures
2.1 Materials and consumables
Samples in size 100 mm × 50 mm × 18.4 mm were taken from
welding X80 steel pipes with a diameter of 1219 mm and a
thickness of 18.4 mm. Chemical composition of the X80 steel
is given in Table 1. The microstructures consist of as received
X80 steel consisted of quasi-polygonal ferrite (QF), small
amount of polygonal ferrite (PF), and dot-like martensite-aus-
tenite component (M-A component, as shown in Fig. 3a).
Generally, the strength of QF is better than that of PF, but both
are not enough, and the M-A component has deleterious effect
on the toughness of X80 steel. In addition, a solid filler wire,
1.2 mm in diameter, conforming to AWS A 5.8: ER80S-G
specification was used as electrode for all the hybrid welds.
Pure argon (Ar) was employed for shielding which was sup-
plied through the MIG torch and laser co-axial nozzle.
2.2 Process equipment
The process equipment comprised of hybrid welding head,
mounted on a precision six axis robotic arm (KUKA KR 60
HA). The robotic arc is configured to perform necessary mo-
tions required for welding as per welding procedure specifi-
cation (WPS) through hybrid laser-MIG welding control soft-
ware. The laser module of the hybrid welding system (Fronius
LaserHybrid 10 kW) contained a disc laser (TRUMPF
TruDisk 10002) with a maximum output power of 10 kW.
The MIG module of the equipment consisted of a full digital
Fig. 1 a Principle of laser-MIG 1.shielded gas
hybrid welding. b X80 pipeline nozzle
steel cross-section of joint 2.tip
3.electrode
4.droplet
5.arc plasma
6.solidified
material
7.melt pool
8.keyhole
9.workpiece
Weld World
Si Nb V Ti N Cr Mo Ni
0.281 0.018 0.016 0.012 0.002 0.066 0.319 0.129
MIG welding power source. The nozzle of the hybrid welding
system is shown in Fig. 1a. The preparation and commission-
ing of hybrid welding control procedure as well as parameter
settings were accomplished with the KUKA robot hybrid
welding control software and the equipment control panel.
2.3 Experimental methods
The welding specimens were thoroughly cleaned prior to
welding. The welding was performed in flat position (PA)
using three characteristic passes, namely (a) root pass, (b) fill
pass, and (c) cover pass. The root passes were performed with
a virgin laser and the MIG module was not engaged. The laser
beam for all passes was used in defocused mode. The laser
beam was employed vertically and the MIG arc trailed the
laser beam. The trailing MIG arc was maintained inclined with
a travel angle between the arc and the laser beam φA = 35°.
The process parameters employed for the hybrid welding are
given in Table 2. These parameters were identified through a
set of rigorous experimentations. The welding process param-
eters as specified in the Table 2 produced a full-penetration
weld as shown in Fig. 1b.
The welding of X80 steel specimens was performed with
Y-groove joint configuration (8 mm root face and 20° groove
angle). The samples for microstructural examinations were
machined using by wire electric discharge machine
(WEDM). The microstructural samples were machined using
WEDM as per the scheme shown in Fig. 2. The metallograph-
ic samples of 30 mm × 20 mm × 18.4 mm were machined
using WEDM. The microstructural samples so machined were
then polished by following standard microstructural examina-
tion procedure and were etched using 4% nital solution (for
3~8 s). The bead shape measurements and microstructural
examination were performed using optical microscopy (OM)
and scanning electron microscopy (SEM). OM was performed
10.laser beam 11. shielding
gas
arc angle
A 12.laser
induced plasma
amount Ddef
defocusing
welding direction
laser-wire
distance DLA
5mm
Weld World

Table 2 Laser-MIG hybrid

welding process of X80 pipeline Weld Laser power Welding Wire feed Defocusing Laser-arc
steel pass (kW) speed (m/min) speed (m/min) distance (mm) distance (mm)

Root pass 8 2 – −5 –
Fill pass 5 2 7 −5 1
Cover pass 6 1 7 −5 1

on a metallurgical microscope (Axio Imager M2 m) and SEM
was performed on a scanning electron microscope (Hitachi
S-3700 N). The quantitative analysis of the micrographic im-
ages was performed using image analysis software (Image-
Pro Plus).
3 Results and discussion
3.1 Heat-affected zone of X80 pipeline steel
Under the inert shielding environment, synergy between dual
heat sources generates narrow yet intense plasma [14]. At a
reasonable laser-wire distance (DLA), a full-penetration and
narrow weld pool is developed by melting of the base metal
(BM) and the wire. With BM thickness being large, the molten
metal pool cools down rapidly producing a sound joint. The
synergy is the main driving force for a deep and narrow weld
bead, but since the heat input is intense, the adjacent HAZ
undergoes significant changes in structure and metallurgy.
The laser beam is deep and narrow while the MIG arc is
relatively broad and shallow [15, 16]. This creates a contrast
between the characteristics of lower and upper portions of the
weld pool. The upper portion of the pool bears a combined
effect of the arc and the laser whereas the lower portion expe-
riences more effect of the laser. As shown in Fig. 2a, the size
of arc-acted HAZ (AHAZ) in the upper region is bigger than
that of the laser-acted HAZ (LHAZ) in the lower region of the
joint.
The variation in energy distribution in the thickness direc-
tion may affect the variation in joint properties along the
thickness too. Consequently, under the same heat transfer con-
dition, the upper and lower portions of the HAZ undergo
different heating and cooling cycles which must be reflected
as difference of microstructure distribution along the thickness
in the HAZ of hybrid welded joints. It is important to examine
the nature of variation in the microstructure of HAZ of laser-
MIG hybrid joints in order to find ways to alleviate undesired
effects. Moreover, the widths of the AHAZ and LHAZ have a
significant difference in size. Extremely inhomogeneous mi-
crostructure distribution was found from the stitching SEM
image of X80 pipeline steel cross-section laser-MIG hybrid
joint (Fig. 1b). This inhomogeneity seriously affects the per-
formance of the welded structure.
3.2 Microstructures of different zones in the HAZ
The microstructure of the weld cross-section revealed signif-
icant variation in the structure of the HAZ that exists between
weldment and BM. Based on the distribution and extent of
actually existing structure, the HAZ is characterized and sche-
matically depicted in Fig. 2b. As shown in the figure, the
structure consists of a banded microstructure (BMHAZ)
which lies adjacent to the BM, fine-grained HAZ (FGHAZ)
next to BMHAZ, and coarse-grained HAZ (CGHAZ) which
lies between FGHAZ and weldment. The transitional micro-
structure HAZ (TMHAZ) lies between FGHAZ and CGHAZ.
Four regions (i.e., BMHAZ, FGHAZ, TMHAZ, and CGHAZ)
in upper and lower portions of the joint (i.e., AHAZ and
LHAZ respectively) were examined in detail by employing
OM, SEM, and quantitative analyses. For analysis, test sam-
ples were taken at 2 mm (for AHAZ) and 10 mm (for LHAZ)

Fig. 2 Schematics of the weld 1.652

a b 0.379
profile and its different zones in
the HAZ
2

AHAZ
AHAZ
10

BMHAZ
FGHAZ

WELD
BM
18.4

LHAZ
LHAZ
30

0.378
unit:mm 0.752

Fig. 3 Optical microstructure of a - BM b - BMHAZ
the AHAZ (1—PF, 2—QF, 3—
MA, 4—BF). a BM, b BMHAZ,
1 3
c FGHAZ, d TMHAZ, and e
3 2
CGHAZ
2 3
distances from the surface as shown by red boxes in Fig. 2a. It
is found that the width of BMHAZ in AHAZ and LHAZ is
nearly equal in size (0.379 mm wide in AHAZ, and in
0.378 mm wide in LHAZ). However, the size of combined
regions of FGHAZ and CGHAZ in AHAZ is twice as great as
that in LHAZ (as shown in Fig. 2b, it is 1.652 mm wide in
AHAZ and 0.752 mm in LHAZ).
Similarly, the microhardness distribution as given in Fig. 7
demonstrates that the microhardness undergoes a transforma-
tion from weldment to BMHAZ. The average microhardness
of combined FGHAZ and CGHAZ regions contributes to the
one third of the total average hardness. The transitional region
between FGHAZ and CGHAZ is also represented as the
TMHAZ, because the width of FGHAZ and CGHAZ is much
larger than that of BMHAZ and the microstructure transitions
from FGHAZ to CGHAZ are not uniform. This variation in
the structure and microhardness can be understood through
microstructural analysis. The resulting microstructures in
characteristic zone in AHAZ which have undergone different
thermal cycles are shown in Fig. 3. The banded ferrite is
formed in X80 steels in which strengthening phase M-A com-
ponents are dispersed in the grain boundaries by thermo-
mechanically controlled processing (TMCP) [17, 18]. Due to
incomplete austenitization and high cooling rates in the
BMHAZ, the region with higher energy formed the M-A com-
ponent bands, and the lower energy region retained the orig-
inal banded ferrite microstructure as shown in Fig. 3b [3, 4,
19]. The fine equiaxed ferrite with a few dot-like M-A com-
ponents in their interior appears during the complete
a b
dot-like M-A lath BF
granular M-A
original austenite banded M-A
grain boundary
Fig. 4 SEM micrograph of CGHAZ of the AHAZ (a), and FGHAZ of the
LHAZ (b)
Weld World
1 c - FGHAZ d - TMHAZ e - CGHAZ
2 2
4
4
1
2 3
3
recrystallization process in the FGHAZ, and most M-A com-
ponents gathered at grain boundaries (Fig. 3c) [8, 9, 20].
The grain boundaries of the original austenite with different
shapes and sizes became intermittent and indistinct, and the
segregation phenomenon of the granular M-A components
appears gradually, with the granular or block ferrite and lath
bainitic ferrite (BF) coming into existence and increasing in
the TMHAZ (Fig. 3d) [21]. The original austenite grain is
coarse and uniform in the CGHAZ; it has a clear polygonal
grain boundary (Fig. 4a) [22, 23]. There is small amount of
dot-like M-A components in the block QF formed during the
rapid cooling, while the fine BF appeared in the original aus-
tenite and the granular M-A components dispersed in the grain
boundaries and between the laths (Fig. 3e) [24–26].
As compared to AHAZ, in LHAZ, the banded microstruc-
ture is more obvious (Fig. 4b) and the microstructure gradient
is smaller. This contrast exists due to greatly different thermal
cycles in the two portions.
3.3 Quantitative analysis of microstructures in HAZ
The average area percentage, chord length, and perimeter of
QF, PF, M-A, or BF phases of each zone in AHAZ and LHAZ
were obtained using the Image-Pro Plus software. The micro-
structure obtained through the SEM image was processed by
the image processing software for measurement of M-A
Fig. 5 Quantitative analysis steps of metallographic examination
Weld World

70 QF PF MA BF
average area, 47~106 μm in perimeter, and 77 μm in average
perimeter, and the content of BF reached 63.6%, 33.6 μm2 in
the microstructure content (%)

60
the average area, 0.2~1.8 μm in the width of the lath BF, and
50
26 μm in maximum lath length in CGHAZ. Compared with
40 the AHAZ, a slight increase in the size and content of the M-A
30
components in the BMHAZ and an identical FGHAZ is found
in the LHAZ.
20

10 3.4 Microhardness of different zones in the HAZ

0
BM BMHAZ FGHAZ
Fig. 6 Microstructures and contents in AHAZ
components. The features such as image area calibration, fea-
ture selection, binary division, and counting measurement
were employed in the quantification of M-A component as
shown in Fig. 5. The data acquired from the measurement of
M-A component from the microstructures in each zone of the
AHAZ is given in Fig. 6 graphically. It is obvious from the
chart given in Fig. 6 that the M-A components exist in all of
the zones; their contents greatly vary in each and consequently
may greatly influence the mechanical properties of the joint.
The actual measured data of the M-A content present in
AHAZ reveal that the average aggregate area of M-A contents
reached 2.0 μm2 which represents an increase from 3.2% in
the BM to 24.3% in the BMHAZ. The content of the quite
dispersive M-A components increased up to 28.9%, but the
size was 2.1 μm2 in FGHAZ. Furthermore, the original aus-
tenite grain boundary and the lath BF appear with the decrease
in the distance to the weld center. The original austenite grain
is 15~30 μm in diameter, 147~665 μm2 in area, 384 μm2 in
TMHAZ CGHAZ
The average microhardness of different zones in the AHAZ
and LHAZ is illustrated in Fig. 7. It is evident that the micro-
hardness of HAZ decreased first and then increased with the
decrease in the distance from the weld center. Moreover, the
microhardness gradient of LHAZ is larger, which is deter-
mined by the temperature gradient. The microhardness of
the FGHAZ is lower than that of BM, and the softening phe-
nomenon of the FGHAZ in LHAZ is weaker than that in
AHAZ. The microhardness of the CGHAZ in LHAZ is basi-
cally the same as that of the TMHAZ in AHAZ, and the
average microhardness of the CGHAZ in AHAZ is 302,
which depends on the relative content of ferrite and bainite
in HAZ. The error of microhardness measurement in the
TMHAZ region of LHAZ is a little large, which is mainly
due to the great difference of microhardness caused by the
large microstructural gradient, and the measurement error in
other zones is normal. The softening phenomenon of the laser-
arc hybrid welding joint HAZ is basically consistent with that
of traditional arc welding. Although the microhardness in
CGHAZ of the AHAZ is the same as that of arc welding joint,
the microhardness of TMHAZ is obviously higher because of
a lot of bainite formed at large cooling rate.

Fig. 7 Microhardness variation 320

trends in AHAZ (a) and LHAZ
(b)
300

280 HV0.2

260

240
BM BM

BMHAZ FGHAZ TMHAZ CGHAZ WELD BMHAZ FGHAZ TMHAZ CGHAZ WELD
220

4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

(a) AHAZ (b) LHAZ
Distance to the center of weld in (a) AHAZ, (b) LHAZ (mm)

4 Conclusions
1. The changes in microstructure from FGHAZ to CGHAZ
are not limited to quantity; PF vanishes and BF appears in
TMHAZ. In addition, the microstructure distribution in
TMHAZ of the AHAZ and the LHAZ also has a huge
difference.
2. Compared with the traditional arc welding, the laser-arc
hybrid welding optimizes the microstructures and their
distribution of the welded joints and has advantages of
both high quality and high efficiency in the larger thick
pipeline steel welding.
3. Structurally different four types of zones were obtained,
namely banded microstructural heat affect zone
(BMHAZ), fine-grained HAZ (FGHAZ), transitional mi-
crostructural HAZ (TMHAZ), and coarse-grained HAZ
(CGHAZ).
4. As compared to arc-driven upper heat-affected zone
(AHAZ), there are smaller microstructure gradients and
more obvious characteristics of the banded microstructure
but no coarse microstructure in the laser-driven lower
heat-affected zone (LHAZ).
5. The original austenite grain boundary is complete and
obvious, and a large number of lath BF emerge in the
CGHAZ of the AHAZ, which results in a significantly
higher microhardness of the CGHAZ than that of LHAZ.
6. From the base metal to the weld center, as distance de-
creases, the M-A components change from banded to gran-
ular or dot-like, and their distribution is more dispersed in
the HAZ of X80 joint. This change is closely related to the
effect of heat cycle on the HAZ during welding.
Funding information This research was supported by National Natural
Science Foundation of China (No. 51674056 and 51575401), the
Scientific and Technological Research Program of Chongqing
Municipal Education Commission (No. KJ1713344), the State Key Lab
of Advanced Welding and Joining at Harbin Institute of Technology (No.
AWJ-M15-05), and the Opening Project of Materials Corrosion and
Protection Key Laboratory of Sichuan Province (No. 2016CL15).
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