ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

Optimization of Process Parameters of Stainless-Steel 304L Weld Based

on Mechanical Properties, Microstructural Evolution and mode of
Temperature Distribution.

Abstract - This paper aims to optimize the process parameter of MIG welding on butt-welded 304L stain-
less steel material. The study examines effect of welding current, welding voltage, and welding speed on
quality of butt-welded joints. The quality characteristics of metallographic analysis of weld zone and Heat
affected zone, Mechanical properties of tensile test and hardness test are measured for output of good joint
strength. The mechanical properties and microstructural outcomes of the experiments are studied using
ANSYS to find out the significance of input parameters on output. Microstructure revealed changes in
solidification structure, grain formation, and distribution when the heat increased and cooling decreased. The
mechanical properties of yield stress, tensile stress, % elongation was affected by the microstructural change.
Calculated thermal stress decreases the residual stress of the weldment. Increment of welding current and
welding speed variations has a significant effect on mechanical properties and microstructure evolution of
welded material.

Keywords: Austenitic SS 304L, MIG welding, Mechanical properties, Microstructure, Grey

Taguchi, Thermal simulation, Ansys.

1. Introduction joined together by some type of welding process

[1]. In recent years, the welding industry has
Welding technology at current level provides wide
substantially advanced in terms of a large variety of
range of applications used in the farm, mining,
welding processes suitable for diverse applications
construction, railway and locomotive equipment,
in order to reduce rework and rejection for a given
manufacture of automobiles, home appliances,
task [2]. Existing welding procedures are adjusted
electronics components, and furnaces, pressure
to deliver the greatest outcomes for a certain task or
vessel, boilers, air conditioning units, and hundreds
application. However, maintaining quality in
of other products we use in our daily lives are also
welding remains a difficult issue [3-5]. This is due

1
to the large number of variables present in the
manufacturing process. Variation in the raw
material (composition, thickness, internal faults,
etc.), variation in the surface condition (presence of
dust, grease, oil, etc.), change of operator, variation
in the spacing between two to be welded pieces,
variation in welding speed, and possibly variation
in electrodes [6]. One of the most important joining
processes in the industry is metal inert gas welding.
MIG welding can be used to join identical materials
as well as those that are dissimilar. This approach is
often used to adjust the thickness of sheets from
thin to thick. Joint consistency is defined by a
variety of factors, including the joint's tensile
strength, microstructure, hardness, and penetration.
Different welding input process variables or their
combinations, such as welding voltage, welding
current, wire feed rate, welding speed, and so on,
affect these factors. MIG welding can be used as a
manual welding operation as well as an automatic
process. The main advantage of MIG welding is the
automatic continuous feeding filler wire. It can also
be used to join unalloyed steel, aluminum alloy, and
stainless steel [7]. The different types of welding
input process parameters welding current, welding
voltage, welding speed, nozzle distance, wire feed
rate, gas flow rate and torch angle etc. play a very
significant role in determining the quality of a weld
joint. All welding processes are used in general to
produce a welded joint with the required weld-bead
characteristics, good mechanical qualities, and low
distortion. The effect of arc voltages, current,
welding speed, wires feed rate and nozzle-to-plate
2
distance on weld quality and microstructure of
welded joints [8] studied on 304L stainless steel
welded by MIG welding for investigation of
mechanical properties and microstructural
characterization [9]. A numerical simulation with
sequential coupled thermal-mechanical finite
element model has been performed for analyzing
the temperature field, residual stresses and
distortions. For the detailed validation of
applicability of the proposed model, simulated and
experimentally measured weld pool shape, residual
stresses and distortions were compared [10].
Through the analysis of MIG groove welding
process and welding experimental result, a
complete two-dimensional mathematical model of
weld section molten pool characteristics was
established. Use Gaussian heat source distribution
to describe the weld heat source, introduced the
welding speed to establish transient heat source
model on the cross section [11]. In this paper, a
numerical analysis of multi-pass single V-groove
weld in butt joint (three passes) of AISI 304L
stainless steel, using the conventional MIG/ MAG
process is presented.
The numerical simulations were performed by
ANSYS® Multiphysics software, considering a
moving heat source with Gaussian type
distribution, convection and radiation heat transfer
on the surfaces and temperature-dependent material
properties, for both mechanical and thermal
simulations [12].
The focus of this studies is, in searching of
obtaining optimal process parameter
investigating the microstructural characterization
and mechanical properties of welded material in
MIG welding application and predicting of thermal
simulation result effect on mechanical properties
and microstructural evolution of welded material.
2. Material and methods
The stainless-steel 304L material otherwise known
as ASTM A240 stainless steel sheet was studied.
Electrode wire SS308Si was selected for welding
process which has the same properties of chemical
and mechanical properties with the parental
material to be welded.
2.1 Experimental work
For this study, butt welding joint technique of SS
by 304L sheet metal welded at different welding
parameters of welding current, welding voltage and
welding speed. ..From standard stainless-steel sheet
metal 18 pieces of 100 x 100x 5mm are prepared
and milled 300. A scientific approach for the
combination effect of process parameter on the
output of planning the experiments is carried out by
statistical design of experiments. Taguchi based
design of experiment (DOE) is designed using the
OA orthogonal array. Hence, in this study, L9
orthogonal array is selected based on having 3
columns and 9 experiments runs as shown in table
2.3. Prepared sample -In accordance with to table
2.4 the weld samples are prepared for tensile,
hardness and microstructural image test.

Table 2.1 Mechanical properties of 304L grade stainless steel [13]

Grade Tensile length (MPa) Yield strength (MPa)

% Elongation Hardness (HRB)
304L 550 220 45 92

Table 2.2 Chemical compositions percentage of SS 304L and wire SS308Si [13].
Composition, %(a)
Type UNS NO. C Mn Si Cr Ni P S
304L S30403 0.03 2.0 1.00 18.0-20.0 8.0-12.0 0.045 0.03
Wire SS308Si 0.014 1.78 0.85 19.67 10.4 0.015 0.001

Table 2.3 Level of control factors for MIG welding Table 2.4 L9 OA (3*3) for input value parameter.

Expt. No Current Voltage (V) mm/s W. S Current (Amp) Voltage (V) Speed (mm/s)

Level 1 100 21 3.33 1 21 3.33

2 100 22 3.57
Level 2 120 22 3.57
3 23 3.85
Level 3 140 23 3.85 4 21 3.57
5 22 3.85
120
6 23 3.33
7 21 3.85
8 22 3.33
140
9 23 3.57

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A total of twenty-seven (27) tensile I-test (figure
2.3) was carried out based on ASTM E8 (figure
2.2). The tensile test was carried out using the
Bairoe computer-controlled electro hydraulic
universal testing machine and the I-test (figure 2.4)
Figure 2.4 Tensile tests result after testing
was measured 3 times and take an average result.
The microstructural test was done using a 3D 2.2 Numerical method

optical scanning microscope for analysis of the Welding process is considered as a thermal
microstructural image (WZ and HAZ). mechanical-metallurgical coupled problem. The
Microstructural samples (figure 2.1c) were finite element method (FEM) is used for predicting
produced from welds per ASTM E23. The hardness the temperature history and its effect on mechanical
test (figure 2.1c) was carried out using a Rockwell properties and microstructural evolution. For this
hardness tester and 3 times for parental metal, WZ study, A two-dimensional (2D) heat transfer model
and HAZ were taken. was considered for the analysis of the MIG
welding. Sequentially linked thermo-mechanical
model is used for prediction of thermal result,
cooling rate, and stresses. In order to predict, the
surface Gaussian heat source model is generally
Figure 2.1 a) Welded samples (100x200x5mm) of material b) Prepared
used by considering a thin plate, where the
samples (20x200x5mm) for I specimen test c) Samples (20x40x5mm)
for microstructural and hardness test.
distribution along the thickness is not considered
[14, 15-16]. Thermal simulation on Butt-joint
welding process is done by finite element method
ANSYS workbench 2021 R2 software to illustrate
the thermal effect. Temperature-dependent SS
Figure 2.2 Tensile specimen (ASTM E8/E8M-13a tensile test 304L material [15] is considered in the finite
standards) element model for prediction and for analysis of its
effect on experimental output. The finite element
mesh (figure 3.21) was selected for uniform and
coarse mesh, to minimize the time of calculation.

The heat source model was applied based on time-

stepped transient analysis by changing their
Figure 2.3 Tensile tests prepared
coordinates at every time step. Rodrigo M, et.al,
[17] proposed to apply the Gaussian distributed

4
heat source, a popular one among the second-
generation models, to approximately express the
heat flux in the heating spot. For the normal
welding process, the Gaussian distributed heat
source model can provide precise enough results.
The heat flux q(r), with a distance r from the heat
source center, is expressed by:
−3𝑟2 2 Q is the heat flux (Watts/m2), V is the welding arc
( ) 3𝑄 (−3𝑟2 )
𝑞(𝑟) = 𝑞𝑚𝑎𝑥 𝑒 𝜋𝑅2 = 𝜋𝑅2
𝑒 𝑅 ……2.1
Figure 3.22 Heat source Mode
3. Results and discussion
3.1 Microstructural evolution examination
The weld metal deposited for 100Amp show
dendritic microstructure having primary growth in
the direction of heat flow. The microstructure
formed at 3.85mm/s appears to be finer in
comparison that developed at 3.33mm/s and
3.54mm/s. The microstructure of weld metal
obtained at lower heat input of 0.441kJ/mm
(100Amp) reveals greater proportion of residual δ
ferrite as shown in figure 3.1 in comparison to
formed at 3.33mm/s and 3.54mm/s of heat input
where 𝑞𝑚𝑎𝑥 is the maximum heat flux in the center
of the heat source, and Q is the heat flux of the arc.
The overall heat output Q is calculated as a product
of both the current, voltage, and heat transfer
efficiency η from a source into the material [18-19].
𝑉𝑥𝐼
𝑄=( ) 𝑥 𝑎𝑟𝑐 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑜𝑓 𝑀𝐼𝐺 𝑤𝑒𝑙𝑑𝑖𝑛𝑔 ….2.2
𝐴
voltage (V), I is the welding arc current (A) and A
is the surface weld area contact (m2).
Figure 2.5 Finite Element meshing of the weld samples
0.431KJ/mm (100Amp) and 0.419KJ/mm (Amp) as
shown in figure 3.1 a and b. This can be attributed
to higher cooling rate with decrease of heat input
giving lesser time for δ → γ transformation and
consequently greater proportion of δ ferrite is
retained.
An increased heat input (120 Amp & 140Amp),
microstructure of welded sample grain formation
and distribution becomes coarser with different
dendritic and interdendritic structure is formed.
This is further explained that the microstructure of
5
 Figure 3.1 Microstructural image result in 100Amp A) 3.33mm/s and voltage 21V, B) 3.57mm/s and 22V and C) 3.85mm/s and 23V.

technique in to a single objective quality parameter

and optimization technique. GRA uses
experimental data, i.e., measured features of
product quality characteristics, are first normalized
on a scale of zero to one. The grey relational
coefficient is then computed using normalized
results of the experiment to determine the
correlation between the predicted and observed
experimental data. After that, by combining the
grey relational coefficients for selected responses,
the cumulative grey relational grade is obtained.
The determined grey relational grade plays a role in
determining performance feature of the multiple
Figure 3.2 Microstructural image result D) 120Amp, 3.57mm/s
response procedure and minimizes the multiple-
and voltage 21V, E) 120Amp, 3.85mm/s and 22V and f)
120Amp 3.33mm/s and 23V. G) 140Amp, 3.85mm/s and response process optimization to a single-response
voltage 21V, H) 140Amp, 3.33mm/s and 140Amp 22V and problem [22, 23, 24].
I) 3.57mm/s and 23V.
The aim of this study is to find the better output
304L austenitic stainless steel is mainly composed
result of mechanical properties based on
of austenite (γ- Fe) under the condition of
experimental result. For better output of
equilibrium solidification. During non-equilibrium
experimental result table 3.1, larger the better S/N
rapid solidification condition, the high cooling rate
(𝜂) equation Eq. 3.1 is used. Where 𝜂 is the number
will result in incomplete δ → γ transformation and
of experiment replications and 𝑦𝑖𝑗𝑘 is the response
some metastable δ-Fe shall remain untransformed
variable value of the ith performance characteristic
[20, 21].
in the jth experiment at the kth trial.
3.2 Mechanical properties
𝑆 1 1
(𝜂) = −10 log 10 ∑𝑛𝑖 …………….. 3.1
𝑁 𝑛 𝑦 2 𝑖𝑗𝑘
The multi objective output of tensile and hardness
test result was analyzed through grey relational

6
 Table 3.1 Tensile test and hardness test. The weighted average of multi-objective grey

𝜎𝑌𝑆 𝜎𝑈𝑆
relational coefficients (𝛿𝑖 (𝑘) for all sequences,
W. S %ε WZ HAZ
(Mpa) (Mpa) expresses the relationship between the ideal(best)
B. M 1521.0 1752.0 45.00 110.00 and actual normalized S/N ratio. Where ∆0𝑖 (𝑘) =∥
1 1270. 1352.0 22.78 102.9 105.5
𝑥0 ∗ (𝑘) − 𝑥𝑖 ∗ (𝑘) ∥ , 𝜑 is distinguishing
2 1279.0 1361.3 22.28 98.33 105.4
3 1401.0 1547.0 35.08 97.77 102.7 coefficient whose value lies in the range of 0 to 1
4 1367.3 1507.7 29.1 97.73 101.1 i.e., 0< 𝜑 < 1, but it is generally taken 0.5, ∆𝑚𝑖𝑛 (𝑘)
5 1374.3 1519.7 35.92 98.8 101.87
and ∆𝑚𝑎𝑥 (𝑘) is the minimum and maximum value
6 1304.8 1448.7 34.23 98.87 102.9
of ∆0𝑖 (𝑘).
7 1361.7 1471.0 31.06 98.27 101.13
8 1341.3 1410.3 30.00 98.27 103.37 ∆𝑚𝑖𝑛 (𝑘)−𝜑∆𝑚𝑎𝑥 (𝑘)
9 1340.7 1420.0 27.47 98.70 103.70
𝛿𝑖 (𝑘) = ∆0𝑖 (𝑘)−𝜑∆𝑚𝑎𝑥 (𝑘)
………………....3.3

1
A grey relational generating is performed by 𝛾𝑖 (𝑥0 ∗, 𝑥1 ∗) = ∑𝑛𝑖=1 𝑤𝑖 𝛿(𝑥0 ∗ (𝑘), 𝑥0 ∗ (𝑘)) …3.4
𝑛
normalizing using equn 3.2 for the experimental
Where 𝛾𝑖 (𝑥0 ∗, 𝑥1 ∗)is the GRG for the ith
data in the range between zero and unity.
experiment, 𝑤𝑖 is the weighting value of the ith
𝑥𝑖0 (𝑘)−𝑚𝑖𝑛 𝑥𝑖0 (𝑘)
𝑥𝑖 (𝑘) = ………………….3.2 performance characteristic and n is characteristics
𝑚𝑎𝑥 𝑥𝑖0 (𝑘)−𝑚𝑖𝑛 𝑥𝑖0 (𝑘)

performance number.
where 𝑥𝑖 (𝑘) is the value after the GRG, 𝑚𝑖𝑛 𝑥𝑖0 (𝑘)
The main effect analysis of GRG is obtained for
is the smallest value of 𝑥𝑖 (𝑘) for the 𝑘 𝑡ℎ response,
cumulative effect on tensile and hardness test result.
and 𝑚𝑎𝑥 𝑥𝑖0 (𝑘) is the largest value of 𝑥𝑖 (𝑘) for the
Table 3.3 shows the average of each response
𝑘 𝑡ℎ response. An ideal sequence x0(k) is for the
characteristic for each level of each factor.
responses.
Considering the highest GRG value for each
Table 3.2 Normalization of experimental data. parameter, the optimal combination of process
𝜎𝑌𝑆 𝜎𝑈𝑆 WZ HAZ parameters corresponds to the combination
W. S %ε
(Mpa) (Mpa) (HRB) (HRB) analyzed through the of means (ANOMA). Table
1. 0.000 0.000 0.037 1.000 1.000 3.4 and figure 3.3 shows Main effects of Grey
2. 0.067 0.048 0.000 0.116 0.977
Relational Grade response graph and table of
3. 1.000 1.000 0.938 0.008 0.357
4. 0.742 0.798 0.500 0.000 0.000
cumulative (tensile & hardness).
5. 0.796 0.860 1.000 0.207 0.174
6. 0.264 0.496 0.876 0.000 0.000
7. 0.699 0.610 0.644 0.104 0.008
8. 0.543 0.299 0.566 0.104 0.515
9. 0.538 0.349 0.380 0.188 0.591

7
 Table 3.3. Grey relation coefficient and Grey relational grade.

W. S 𝜎𝑌𝑆 (Mpa) 𝜎𝑈𝑆 (Mpa) % Elongation WZ HAZ GRG Rank

.
1. 0.333 0.333 0.342 1.000 1.000 0.6681 2
2. 0.349 0.344 0.333 0.361 0.957 0.5005 5
3. 1.000 1.000 0.890 0.335 0.437 0.6748 1
4. 0.660 0.713 0.500 0.333 0.333 0.4787 4
5. 0.710 0.781 1.000 0.387 0.377 0.6061 3
6. 0.405 0.498 0.801 0.333 0.333 0.4506 9
7. 0.624 0.562 0.584 0.358 0.335 0.4683 6
8. 0.523 0.416 0.535 0.358 0.508 0.4622 7
9. 0.520 0.434 0.447 0.381 0.550 0.4662 8

Table 3.4 Main effects of GRG table. Figure 3.3 Main effects of GRG response.

Welding Current Voltage Travel speed

Level
(Amps) (V) (mm/s)
1 0.6145 0.5384 0.5270
2 0.5118 0.5230 0.4818
3 0.4656 0.5306 0.5831
Delta 0.1489 0.0154 0.1013
Rank 1 3 2

Table 3.5. Analysis of Variance

Source DF Adj SS Adj MS P-value Contribution

Current (Amps) 2 0.034837 0.017418 0.334 51.17%
Voltage (V) 2 0.000357 0.000178 0.984 0.52%
Travel speed 2 0.015446 0.007723 0.530 22.69%
(mm/s)
Error 2 0.017447 0.008724
Total 8 0.068086

Based on the value of rank shown in figure 4.11,
combination effect on the output of cumulative
result can be concluded from the response table that
control parameters affecting the response variables
follows the order in ascending order, welding
current < welding speed < welding voltage. From
the Table 4.12 (ANOVA for GRG), it is observed
that welding current is the dominant factor on the
response variable with a contribution of 51.17%
followed by travel speed and welding voltage.

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3.3 Thermal result

The thermal history along the welding direction

shows the temperature distribution graph increases
as the heat input increases from 6.32x107 W/m2 to
9.75x107 W/m2 with a varied range of temperature
minimum of 633.35 0C to a maximum of 10190C. Figure 3.4 Temperature distribution graphs with constant welding
for different process parameters. As the heat source current.

applies, the temperature of the plate falls as the 3.4 C. R effect on microstructural of weldment
welding speed increases. The cooling rate (C.R) of
the different weld sample is calculated in phase
transformation range of temperature distribution
800°C to 500°C, this temperature range is useful to
phase transformation. The centerline cooling rate
for thin materials in a two-dimensional case was
considered based on the thin plate study given
[25,26]. For an increased heat input (welding
Figure 3.5 WZ microstructural image result in a low heat input
current, travel speed and welding voltage)
range.
calculated cooling rate (table 3.6) of the weldment
reduced from 6.08°C/sec to 2.54°C/sec.

Figure 3.6 WZ microstructural image result in a medium heat

input range.

Figure 3.7 WZ microstructural image result in a high heat input

range.
9
For the first three weld samples of uniform welding Table 3.6 Calculated cooling rate of weld sample

current 100Amp in figure 3.5, the temperature of W. S Peak Temperature (℃) Cooling rate (℃/s)
0
the weld sample is decreased from 718.39 C to 1 718.39 5.46

633.35 C and the C.R is increased from 5.46℃/s to

0 2 680.76 5.71
3 633.35 6.08
6.08℃/s from the left to the right. According to the
4 769.35 4.36
C.R of the thermal cycle and microstructural image
5 720.34 4.62
result obtained, the grain size of welded samples 6 919.93 3.16
figure a and b have scattered and coarser ferrite 7 795.51 3.72
grain sizes, corresponding result of hardness of the 8 1019.0 2.54

weldment is decreased with an increase result of 9 967.31 2.67

yield stress, and tensile stress. The grain obtained

in figure-c with a higher C.R and lower temperature
are much finer as compared with figure a and b. The
maximum results of yield stress, tensile stress, and
3.5 Effect of weld parameter in transversal
directions
The heat generated during welding brings an

% elongation obtained at lower temperature and at important temperature gradient in and around the

higher C.R whereas a lower hardness result is welded area. Its property and microstructure are

obtained. Further increased in medium and high affected by the thermal cycle. The mechanical

heat input range results in a higher temperature and properties of the welded metal and the HAZ are

a decreased in C.R, figure 3.6 and 3.7. This closely related to their microstructures, which are

variation results a coarse grain formation and dependent on the thermal history (cycles). Process

scattered ferrite distribution as can be seen in figure parameter effect on thermal cycle, microstructural

g and i. Temperature range of 800–1250◦C, which evolution and residual stress in transversal direction

is accompanied by the decrease in dislocation was investigated. Figure 3.8, for constant welding

density and dissolution of ferrite, causes the current and for an increased welding speed the

decrease in strength [29]. Due to high displacement temperature of WZ and HAZ increases for

density in austenitic grains and coarse ferrite, decreased heat input. These thermal results

mechanical properties of yield stress, ultimate increment, increased the cooling rate of WZ and

tensile strength and ductility of high heat input HAZ. Corresponding obtained microstructural

range is decreased comparing to medium heat input image result indicates; grains formation and

range. [27-30]. distribution vary. As welding speed increases

formation of equiaxed ferrite was obtained and the
δ-ferrite content in the transverse direction was
decreased in WS3. Microstructural change along
the transversal direction clearly shows with the

10
 decrease of heat input and with an increase of
temperature, grain formation of ferrite was better
and fine grain was obtained. The finite element
analysis result of residual stress distributions
shows, tensile and compressive types of stresses are
seen in the weld zone and heat-affected zone; this
is ascribed to various temperature profiles. It can be
seen that for unform welding current and for
variable welding speed, compressive stress was
increased for an increased travel speed. Obtained
result shows, the weld zone, and HAZ residual
stress increased from -48.9 MPa to -74.8 MPa and
-72.1MPa to -85 MPa respectively. Whereas WZ
and HAZ tensile stress obtained result shows a
little. Compressive stresses improve the strength of
the material, and better balanced compressive
transversal residual stress was obtained in weld
sample 3 [31, 32].

Figure 3.8 Shows cropped microstructural image, thermal cycle & stress distribution graph of WS1, WS2 & WS3.

W. S Weld zone and Heat affected zone Thermal and stress graph along transversal direction
800 711.11 3.E+08
700 2.00E+08
634.5
2.E+08
600 556.3 1.46E+08

Stress (MPa)
500 2.E+08
Temprature 0C

400 1.24E+08
1.E+08
1 300 149.98
7.21E+07

200 5.E+07 4.89E+07

76.138 3.73E+06
100
0.E+00
W.C=100Amps, T. S=3.33mm/s, Q=66.6x106W/mm2 0 -0.15 -0.1 -0.05 0 0.05 0.1 0.15
0 0.05 0.1 0.15
Distance from the weld line center/m Distance from the weld line center/m

3.E+08
800 721.86
700 665.94 2.E+08 1.94E+08
Stress (MPa)

600
582.61 2.E+08 1.46E+08
Temprature 0C

500
1.20E+08
400
1.E+08
2 300 169.5 7.82E+07
5.E+07 3.91E+07
200
77.257 3.74E+06
100
0.E+00
0 -0.2 -0.1 0 0.1 0.2
W.C=100Amps, T. S=3.57mm/s, Q=65.1x106W/mm2 0 0.05 0.1 0.15
Distance from the weld line center/m Distance from the weld line center/m

800 3.E+08
730.26
674.08 2.E+08 1.95E+08
600
600.21 1.43E+08
Stress (MPa)

2.E+08 1.18E+08
Temprature 0C

400
225.91
3 200
1.E+08 8.89E+07
57.809 7.48E+07
5.E+07
0 4.53E+06
0.E+00
0 0.05 0.1 0.15
6
W.C=100Amps, T. S=3.85mm/s, Q=63.2x10 W/mm2 -0.2 -0.1 0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m

11
 The thermal result obtained indicates that with the
increases of heat input (72.6 to 87.4 W/m2), thermal
behavior is increased and the compressive residual
stress is decreased as shown in figure 3.9. Effect of
welding current, results a higher temperature result
HAZ compared to the low heat input range. The
corresponding tensile residual stress in the fusion
zone was decreased for an increased temperature,
but HAZ tensile residual stress result has little
difference.

Figure 3.9 Shows cropped microstructural image, thermal cycle & stress distribution graph of WS4, WS5 & WS6 .

W. S Weld zone and Heat affected zone Thermal and stress graph along transversal direction
1000 3.E+08
796.87
800 2.E+08 1.99E+08
709.39

Stress (MPa)
600 2.E+08 1.30E+08

Temprature 0C
620.61 9.69E+07
4 400 1.E+08
156.35 8.08E+07
200 5.E+07 3.13E+07
75.751
0 0.E+00 4.88E+06
W.C=120Amps, T. S=3.57mm/s, Q=74.6x106W/mm2 0 0.05 0.1 0.15 -0.2 -0.1 0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m
1000 3.E+08
808.13
800 2.01E+08
713.61 2.E+08

Stress (MPa)
600 1.22E+08
Temprature 0C

617.66 2.E+08
9.65E+07
5 400 1.E+08
138.55 8.67E+07
200 65.098 5.E+07 3.84E+07
0 5.80E+06
0.E+00
0 0.05 0.1 0.15 -0.2 -0.1 0 0.1 0.2
W.C=120Amps, T. S=3.85mm/s, Q=72.6x106W/mm2 Distance from the weld line center/m Distance from the weld line center/m
1000
862.43 3.E+08
800 2.E+08 2.00E+08
738.08
Stress (MPa)
1.13E+08
Temprature 0C

600 2.E+08
634.6 9.70E+07
6 400
200.56
1.E+08 8.63E+07
5.E+07 5.28E+07
200 68.403
6.01E+06
0 0.E+00
W.C=120Amps, T. S=3.33mm/s, Q=87.4x106W/mm2 0 0.05 0.1 0.15 -0.2 -0.1 0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m

distribution for lower welding speed, the thermal
behavior of the weld zone and heat-affected zone
temperature increased as compared to the low heat
input range. Due to thermal effect coarse grain
formation, and large distribution ferrite is obtained
in the middle heat input range. the austenite grain
size was slightly increased, and the δ-ferrite content
in the transverse direction was increased. For an
increased temperature, the compressive residual
stress was decreased from -74.8 MPa to -52.8 MPa
in WZ and increased from -85 MPa to -86.7 MPa in
An increased more welding current (140Amp); the
outcome of simulated thermal effect increased, and
WZ residual stress decreased in figure 3.10. An
increasing heat/temperature results in a decrement
of cooling rate having coarse grain formation and
scattered ferrite distribution. The tensile and
compressive stresses distribution graph behavior
was different compared to the low and middle heat
input range. Due to the incremental in thermal
stress in the weld zone, residual stress distribution
was more tensile behavior in weld samples 8 and 9.

12
 The tensile residual stress is located in the weld
zone near the weld joint transition ranges 99.3 to
115MPa whereas residual compressive stresses
present 14.9 to 33.2 MPa. Corresponding tensile
and compressive residual stress of HAZ reaches the
maximum range of 196 to 202 MPa and 94.7 to 104
MPa respectively. Heat affected zone indicates that
the thermal effect on tensile stress has little change
but the compressive stress was increased in this
zone. Volume expansion during the cooling-
induced transition from austenite to ferrite is the
primary cause of these compressive residual stress,
which superimpose with transformation residual
stresses [32, 34].

Figure 3.10. Shows cropped microstructural image, thermal cycle & stress distribution graph of WS7, WS8 & WS9.

W. S Weld zone and Heat affected zone Thermal and stress graph along transversal direction
1000 3.E+08
870.57
1.98E+08
800 2.E+08
772.74

Stress (MPa)
1.15E+08
Temprature 0C

600 673.4 2.E+08

9.68E+07

7 400 1.E+08
156.31 3.32E+07
5.E+07
200 72.27
W.C=140Amps, T. S=3.85mm/s, Q=80.8x106W/mm2 0
0.E+00
0 0.05 0.1 0.15 -0.2 -0.1 0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m

1000 3.E+08
926.73 1.96E+08
800 2.E+08
870.48
Stress (MPa) 2.E+08
Temprature 0C

600 692.54 9.75E+07

8 400 1.E+08
163.51
200 5.E+07 1.49E+07
76.636
8.15E+06
0 0.E+00
W.C=100Amps, T. S=3.33mm/s, Q=97.5x106W/mm2 -0.2 -0.1 0 0.1 0.2
0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m
3.E+08
1000
940.37 2.02E+08
2.E+08
800
926.52
Temprature 0c

Stress MPa

600 2.E+08 9.72E+07 9.93E+07

689.45
1.04E+08
9 400 206.87 1.E+08

200 66.146 3.22E+07

5.E+07
6
W.C=140Amps, T. S=3.57mm/s, Q=95.3x10 W/mm2 9.94E+06
0
0 0.05 0.1 0.15 0.E+00
-0.2 -0.1 0 0.1 0.2
Distance from the weld line center/m Distance from the weld line center/m

13
Conclusion the tensile stress weakened. An increased
transverse stress of HAZ was observed.
• Welding current and welding speed variation
• Prominent microstructural variance in the FZ,
results in a decrease of tensile result of yield
HAZ and BM was obtained from the
stress, ultimate tensile strength, and ductility of
microstructural mage. The microstructure
weld sample as a factor of thermal changes.
evolution was closely related with the calculated
• Increasing the welding heat input, the
thermal cycles.
solidification mode transferred from AF mode to
FA mode, and the morphology of different types
Acknowledgment
of δ-ferrites. The δ-ferrite content indicated the
I would like to thank Dr. Samuel. T, Dr. Mulugeta.
highest tendency of all conditions through the
H and Dr. Getasew. A for their expertise and
welding sample 3 attributed to fine grain with
assistance throughout all aspects of my study and
fine structure and higher tensile test result with
for their help in writing the manuscript.
a lower hardness.
• With an increased temperature, the typical
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