Development of Stellite 1 hardfacing procedure for crack-free SS 304 stainless steel orifice plate
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ORIGINAL ARTICLE
Development of Stellite 1 hardfacing procedure for crack-free SS 304 stainless steel orifice plate V. Tamizhinian 1 & P. Chandramohan 2 Received: 26 December 2019 / Accepted: 25 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper studies establishing an effective deposition technique of cobalt-based Stellite1 on austenitic stainless steel (SS 304) orifice plate component, used in offshore application. Stellite1 hardfacing was done using gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW) techniques, which resulted in intergranular and longitudinal cracks. In finite element analysis (FEA), a three-dimensional solid model was generated and simulated for spot heat welding using ANSYS software. After simulation for heat distribution with and without weld bordering, crack-free hardfacing of Stellite1 was carried out and validated experimentally using FCAW technique. A control on substrate preheating, thermal insulation, job clamping and cooling time reduced the intersecting cracks. Metallurgical analysis using Optical microscopy, SEM, EDS and XRD along with hardness measurements was done to investigate the mechanisms causing failure. Crack area measurements were done in gradient edge detection technique using MATLAB software and quantified. Keywords Orifice plate . Stellite . Hardfacing . Intergranular crack . Cladding
1 Introduction Dissimilar metal welding are being carried out using few familiar techniques such as flux core arc welding (FCAW), gas tungsten arc welding (GTAW), plasma transfer arc welding (PTAW), friction stir welding (FSW), resistant spot welding (RSW), manual metal arc (MMA) and laser cladding (LC) [1, 2]. Few dissimilar metals welded using these techniques are Monel-SS316, CuCrZr -SS304, Al6063-SS304, Ti-6Al-4 VSS316L, carbon steel SS and cobalt alloy (Stellite) SS [3, 4]. Mahmud Sarkari Khorrami et al. carried out dissimilar welding of plain carbon steel and AISI 430 ferritic SS using GTAW process. An increase in strength, ductility and hardness was reported due to grain growth, intergranular martensite and carbide formation [5]. Dissimilar welding of carbon steel CK45and AISI304 stainless steel (SS) was performed using GTAW followed with different post weld heat
* P. Chandramohan [email protected] 1
Department of Mechanical Engineering, Ambal Professional Group of Institution, Palladam, India
2
Department of Mechanical Engineering, Sri Ramakrishna Engineering College, Coimbatore, India
treatments (PWHT). An improvement in mechanical properties was observed due to grain growth and carbide precipitation after PWHT. Furthermore, lower Cr/Ni ratio did not favour sigma phase formation in both the as-weld and PWHTed specimens [6]. Hardfacing is a dissimilar welding process in which a hard metal is laid over a soft substrate metal. Hard-faced components have longer service life and its usage in the industrial applications reduce the downtime of the plant [7]. Stellite is a hard-facing alloy used in offshore applications due t
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