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Materials Today: Proceedings 5 (2018) 18475–18481 www.materialstoday.com/proceedings

ICMPC_2018

Fabrication and Characterization of Weldments AISI 304 and AISI

316 Used in Industrial Applications
Rahul Kantb*, Rutash Mittala, Chandan Kumarb, Bharat Singh Ranab, Manish Kumarb,
Rajnish Kumarb
a
Department of Mechanical Engineering, Malout Institute of Management and Information Technology, Malout, Distsrict-Muktsar Sahib
152107, Punjab, India.
b
I.K.Gujral Punjab Technical University, Jalandhar, Punjab, India

Abstract

Gas tungsten arc welding (GTAW) and Shield metal arc welding (SMAW) are processed by using E347-16 electrode and filler wire to prepare
the dissimilar weldments. The aim of study was to measure the effect of welding parameters: current, voltage, gas flow rate, nozzle to plate
distance on tensile strength (TS), grain structure and hardness. The arc voltage and welding current was selected as 40,60 and 80V and 30,45 and
60amp respectively. The welding speed was selected as 4, 8, 12cm/sec. There is zero cracks, porosity, blow holes, spatter found in welding
process of plate no. 2(AISI 304 &AISI 316 with ER-309L) using non consumable tungsten electrode with argon gas and also the microstructure
study shows that the welding is self cooled welding structure with fine austenitic structure and very little heat affected zone found in this process.
TIG welded dissimilar joint has best joint strength, uniform hardness variation as well as joint integrity.

© 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.

Keywords: AISI 304 and AISI 316, Microstructures; welding; Tensile strength; Hardnes

1.Introduction
Dissimilar metal joints are used in various engineering applications such as nuclear power plant, coal fired boilers,
automobile manufacturing industry etc [1]. Very often joining of dissimilar metals utilizes pressure welding instead
of other joining methods. Dissimilar materials have been joined by different welding methods which include shield
metal arc welding (SMAW), gas tungsten arc welding (GTAW), fusion welding, pressure welding, explosion
welding, friction welding, diffusion welding, brazing, and soldering [2,3]. Among the other welding processes,
SMAW is a versatile

* Corresponding author.
E-mail address: kantrahul19@gmail.com

2214-7853 © 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.
18476 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481

process which is extensively used in manufacturing of variety of ferrous and non-ferrous metals as it greatly
improves the quality characteristics of the weldments as observed by I Z Ibrahim et al [4]. AISI 316 austenitic stainless
steels are
widely used in many industrial applications due to its excellent corrosion resistance, fabricability, and they possess
good mechanical properties at elevated temperatures [5,6,7].The availability market along with cheaper cost has make
them popular[7].Typical uses of 316 stainless steels include steam generating plants as piping and super heater material.
The stainless steel (SS) 316L is a chromium-nickel-molybdenum austenitic stainless steel developed to provide
improved corrosion resistance to SS 304/304L in moderately corrosive environments. Type 316L is an extra low carbon
version of Type 316 that minimizes harmful carbide precipitation due to welding. The addition of molybdenum
improves general corrosion and chloride pitting resistance [8, 10]. The austenitic stainless steel 316L is selected because
the material contains low carbon and it has a good weldability factor [6]. Hsieh et al. [11] discussed the microstructure
study of dissimilar gas-tungsten arc welding (GTAW) of AISI 304 and AISI 430 stainless steels. The massive ferrite
preferred to precipitate at the austenite phases and ferrite-austenite interface boundaries. The hardness of weld metals
was higher than the base metals, and it was attributed to the massive ferrite precipitation. Shanmugam et al. [12] studied
the effect of different filler metals (AISI 308L, AISI 430 and AISI 2209 filler metals) on the microstructure and
mechanical properties of 409 stainless steel joints. The authors have shown that the microstructure in the austenitic and
the ferrite weld metals was fully austenitic and ferrite, respectively. According to their findings, the coexistence of
ferrite and austenite in the microstructure presented the best mechanical properties of the weld metal at room
temperature. Mukherjee et al. [13] compared the microstructure and mechanical properties of 409 stainless steel welds
obtained by type 316L and 308L filler metals. They showed that two major factor affecting the microstructure was heat
input. Type 308L specimen yielded better mechanical properties and higher amounts of martensite. Velasco et al. [14]
found that the yield strength of austenitic and duplex stainless steels could be decreased after welding in concrete
structures. Palani et al. [15] had made an extensive analysis on significances of process parameters on quality
characteristics of weldments and stated that proper selection of welding parameters were very important to
eliminate/avoid weld defects and to obtain desirable weld properties in weldment.

2. Dissimilar metal welding

Despite the widespread application of dissimilar metal joining, there is a history of weld-related failures
associated with dissimilar joints. Hence more focus to be given in order to eliminate the defects during welding
process. Wang et al. [16] investigated on Characterization of microstructure, mechanical properties and corrosion
resistance of dissimilar welded joint between 2205 duplex stainless steel and 16MnR. Mechanical properties of
joints welded by the two kinds of welding technology are satisfied. However, the corrosion resistance of the
weldments produced by GTAW is superior to that by SMAW in chloride solution. They concluded that GTAW is
the suitable welding process for joining dissimilar metals between 2205 duplex stainless steel and
16MnRArivazhagan et al. [17] investigated on AISI 304 austenitic stainless steel to AISI 316 low alloy steel
dissimilar joints by gas tungsten arc, electron beam and friction welding. The results of the analyses revealed that the
joint made by EBW has the highest tensile strength (681 MPa) than the joint made by GTAW (635 Mpa) and FRW
(494 Mpa). Moreover, the impact strength of weldments made by GTAW is higher compared to EBW and FRW.
Hsieh et al. [18] studied Precipitation and strengthening behavior of massive 6-ferrite in dissimilar stainless steels
during massive phase transformation. The purpose of this study is to discuss the micro structural evolution and
mechanical property of the weld metal in the dissimilar stainless steels during the gas tungsten arc welding (GTAW)
process. The massive precipitates and austenite phases were observed in the weld metal during the dissimilar
stainless steels welding process. Fuentes et al. [19] investigated Crack growth study of dissimilar steels (Stainless -
Structural) butt- welded unions under cyclic loads. The research shows the study of the mechanisms of emergence
and propagation of fatigue cracks caused by mechanical tension stress fluctuations in dissimilar steels butt-welded
joints. Results showed a proper mechanical steel behavior under cyclic loads, in spite of showed high values of
micro hardness, mainly in the fusion line between the welding and 304L stainless steel, as well inclusions between
the structural and the stainless one Nicholas et al. [20] investigated the subject of sensitization in un stabilized
ferritic/martensitic dual phase 11-14% Cr steel in some detail after a number of failures in service due to accelerated
corrosion and concluded that sensitization could occur due to a number of different mechanisms which were
 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481 18477

dependent on the heat treatment, no of thermal cycles and phases present in the material. All the detected modes of
sensitization could be prevented by stabilization with titanium or niobium and suitable design of the material
composition to produce a suitably high ferrite factor. N. Arivazhagan et al. [17] studied investigation on AISI304
austenitic stainless steel to AISI 316 low alloy steel dissimilar joints by gas tungsten arc, Electron beam and Friction
welding. For each of the weldments, detailed analysis was conducted on the phase composition, microstructure.
The welding of the material AISI 304 with AISI 316 is done by using SMAW and TIG welding process. There are 6
plates(3 each of AISI 304 and AISI 316) from which 2 pairs are weld by using TIG welding process with two
different filler materials and remaining 2 plates are welded by using SMAW welding process. We give these plates
coding as plate no. 3,2 and1. The procedure of the welding the material in three different steps is as follows. Firstly
we created the V corners(about 70 deg.) to feed the electrode material and then we need to set the material in proper
position and parallel to each other that’s why the material doesn’t slide or deflect from its position. To prevent this
slide or deflection we did setting and tacking of the material.

2.1 AISI 304 :

The material is selected is grade AISI 304 which is class of Stainless steel and Austenitic type material, it’s
common name is Chromium-Nickel steel. This is the most versatile and one of the most widely applied of the 300
series stainless steels. It has excellent forming and welding characteristics. The carefully controlled analysis of Type
304 enables it to be deep drawn more severely than Types 301 and 302 without intermediate heat softening. AISI
304 also has outstanding welding characteristics. Post-weld annealing is not required to restore the excellent
performance of this grade in a wide range of mildly corrosive conditions. Chemical composition of selected malarial
presented by Table 1.
Table 1. Chemical composition of AISI 304.
Elements C Mn Si Cr Ni P S
Weight % 0.060 0.86 0.031 18.350 8.200 0.0310 0.010

2.2 Electrode E347-16:-

Super stainless E347-16 electrodes are used to weld stainless steels such as Types 301, 302, 304, 305, and 316.
Weldcote Metals E347-16 electrodes provide corrosion resistance and physical properties equal to or greater than the
steels for which they are recommended. E347-16 is a super low carbon stainless steel electrode with titanium
calcium type coating.As the carbon rate in the weld mental is no more than 0.04%. It shows good inter-crystalline
corrosion resistant properties (Table 2).
Table 2. Chemical composition of Electrode E347-16
Elements C Mn Si Cr Ni P Cu Nb Mo S
Weight% 0.02 0.7 0.7 19 9.5 0.02 0.07 0.04 0.05 0.01

316/316L is an 18/8 austentic steel enhanced with an addition of 2.5% Molybdenum, to provide superior
corrosion resistance to type 304 stainless steel.316/316L has improved pitting corrosion resitanance and has
excellent resistance to sulphates, phosphates and other salts.316/316L has better resistanance than standared 18/8
types to sea water, reducing acids and solution of chlorides, bromides and iodides as shown in below Table 3 and
Table 4,5.
Table 3. Composition of filler rod 316L.
Elements C Mn Si Cr Mo Ni P S
Weight% 0.04 1.6 0.05 19 2.5 12.5 0.03 0.03

Table 4. Composition of filler rod 309L.

Elements C Mn Ni Mo Cu Si P S
Weight% 0.06 24 13 0.75 0.75 0.50 0.03 0.03
18478 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481

3. Results and discussion

3.1 Microstructure analyses

Microstructural examination is generally performed by using optical microscopes to magnify features of the
material under analysis. We see the microstructure of weld zone and base metal by optical microscopic test.
Microstructure shows non uniform mix (i.e. equiaxed, columnar) Austenitic Structure in the welded zone. In AISI
316 side no heat affected zone is observed, but in AISI 304 side grain coarsening observed at some areas on the heat
affected zone. On the base metal at x100 we observed that austenitic grain structure is uniformly distributed as
shown in below Fig 1 (a-c) and Fig 2 & 3 (a-c).

A. AISI 316/304,TIG

Fig. 1(a) Fig. 1(b) Fig. 1(c)

B . AISI316/304 ,TIG

Fig. 2(a) Fig.2(b) Fig. 2(c)

WZ, HAZ, Base metal AISI304 WZ, HAZ, Base metal AISI316 Welded zone

C . AISI316/304 , SMAW

Fig. 3(a) Fig. 3(b) Fig. 3 (c)

WZ and Base Metal AISI 304 WZ and Base Metal AISI 316 Welded Zone

3.2 Hardness test

Hardness is the resistance of a material to permanent indentation. It is important to recognize that
hardness is an empirical test and therefore hardness is not a material property. The hardness values are
reported using the proper symbol HV indicating the test scale performed. We use Vickers Hardness test
to check out the hardness of base metal, near weld zone, weld zone. The Vicker’s (HV) test formally
known as the diamond pyramid hardness (DPH) test. The Vicker’s test has two distinct force ranges,
(i.e. 10 g and 1000 g) to cover all testing requirements. The indenter is the same for both ranges
therefore Vickers hardness values are continuous over the total range of hardness for metals (typically
HV100 to HV1000) as shown in below Fig 4 (a-c) and Fig 5,6 ,7 .
 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481 18479

Hardness result Hardness result Hardness

result
AISI304 &AISI316 with ER 309 AISI304 &AISI316 with ER 316L AISI304 & AISI316 with ER-309L

Base metal (316) -338 HV Base metal (316)-318 HV Base metal(316)-302HV

Base metal (304)- 330 HV Base metal(304)-340 HV Base metal(304)- 318HV
Weld Zone- 350 HV Weld Zone – 320 HV Weld Zone- 370HV
Heat Affected Zone- 239.5 Heat Affected Zone-243 Heat Affected Zone-250

Fig. 4(a) Fig. 4(b) Fig. 4(c)

AISI316/304 ,TIG AISI316/304 ,TIG AISI316/304 , SMAW

3.3 Tensile test

Tensile testing, also known as tension testing, is a fundamental materials science test in which a sample is
subjected to uni-axial tension until failure. The Tensile testing of the stainless steel is done with the help of the
universal testing machine. The various results like percentage elongation, elastic limit and the yield point because of
the brittle nature of the welding joint which is not possible to find the various values of the tensile strength so that
the maximum breaking load is give in this result to find the actual strength of the material joint with different king
of welding techniques. According to the result the result of tensile test specimen no. 2 which is welded by TIG
welding and Filler rod 309L , current 40-60 amp (low voltage) have maximum tensile strength of 596.40N/mm2 .

Tensile result (TIG) Tensile result (TIG)

Ultimate Tensile Strength – 435.00N/mm2 Ultimate Tensile Strength – 596.40N/mm2

Fig.5 Fig.6
AISI316/304 AISI316/304
Tensile result of AISI316/304 (SMAW)
Ultimate Tensile Strength-594.10N/mm2

Fig. 7

The primary goal of this project report is to fabricate and characterize the welding joints of dissimilar materials
used in power plants and other industries. We have welded AISI-304 metal with AISI-316 metal by using different
type of welding procedures and with different welding parameters like electrodes, speed, voltage, current etc.
18480 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481

Mechanical characterization of these joints has been done by tensile testing, visual observation along with
microstructures and hardness variation. The final outcome of our entire research is as follows:
Table 5. Different Properties and Characterization Of AISI 316 AND 304.
Material Spec. Electrode Welding TESTING Result
no. /filler technique
wire used
Average Hardness Value (BHN) Ultimate Microstructure
tensile of weld zone
strength

(N/mm2)

BM 304 BM WZ HAZ
316 (Avg)

Shows
formation of
Plate Stainless TIG 330 338 350 239.5 435.70 mixed grain From
no.1 steel austenitic all test
filler wire structure. results
(316L) Self cooled it has
dendritic been
formation found
AISI-
also that the
304
observed. arc
with welding
Shows mixed used in
AISI- grain the
316 Plate Stainless TIG 318 340 320 243 536.00 austenitic work
no.2 steel structure. gives
filler wire Formation of better
(309L) self cooled results.
dendritic
structure also
observed.

Shows fine
austenitic
Plate Electrode SMAW 318 302 370 250 594.40 grain
no.3 E347-16 structure.HA
Z shows
coarse
grained
ausenitic
structure.
 Rahul Kant et al./ Materials Today: Proceedings 5 (2018) 18475–18481 18481

4. Conclusions

From the experimental study the following conclusions are drawn:

● The hardness of the specimen no. 3 weld zone gives the hardness value of 370 HV which shows that the welding
of the plate 3 is giving satisfactory hardness.
● The Ultimate tensile strength of specimen no. 2 is 536 N/mm2. This shows the breaking capacity of the
weldments no. 2 is maximum and more than the remaining two specimens (specimen no.1 & 3).
● The microstructure examination of specimen number 1 and 2 gives the small heat affected zone which is small in
width, because of using Tungsten Inert Gas (TIG) Welding process.
● There is zero cracks, porosity, blow holes, spatter found in welding process of plate number 2 using non
consumable tungsten electrode with argon gas and also the microstructure study shows that the welding is self
cooled welding structure with fine austenitic structure and very little heat affected zone found in this process.

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