Science and Technology of Welding and Joining

ISSN: (Print) (Online) Journal homepage: https://www.tandfonline.com/loi/ystw20

Microstructure and mechanical properties

of stainless steel clad plate welding joints by
different welding processes

W. X. Yu , B. X. Liu , C. X. Chen , M. Y. Liu , X. Zhang , W. Fang , P. G. Ji , J. N. He

& F. X. Yin

To cite this article: W. X. Yu , B. X. Liu , C. X. Chen , M. Y. Liu , X. Zhang , W. Fang , P. G. Ji ,

J. N. He & F. X. Yin (2020): Microstructure and mechanical properties of stainless steel clad plate
welding joints by different welding processes, Science and Technology of Welding and Joining,
DOI: 10.1080/13621718.2020.1774995

To link to this article: https://doi.org/10.1080/13621718.2020.1774995

Published online: 15 Jun 2020.

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SCIENCE AND TECHNOLOGY OF WELDING AND JOINING
https://doi.org/10.1080/13621718.2020.1774995

Microstructure and mechanical properties of stainless steel clad plate welding

joints by different welding processes

W. X. Yu, B. X. Liu, C. X. Chen, M. Y. Liu, X. Zhang, W. Fang, P. G. Ji , J. N. He and F. X. Yin

School of Materials Science and Engineering, Research Institute for Energy Equipment Materials, Tianjin Key Laboratory
of Materials Laminating Fabrication and Interfacial Controlling Technology, Hebei University of Technology, Tianjin, People’s
Republic of China

ABSTRACT ARTICLE HISTORY

This work aims to study the microstructure and mechanical properties of stainless steel/carbon Received 8 January 2020
steel clad plate joints with three welding types: welding without transition layer, welding with Revised 13 May 2020
transition layer using tungsten inert gas arc welding and shielded metal arc welding, respectively. Accepted 17 May 2020
Both of transition layer-weld metals contain ferrite + austenite phases obtained by different KEYWORDS
solidification modes. The brittle martensite zone is formed in the stainless steel weld metal with- Stainless steel clad plate;
out the transition layer because of the excessive diffusion of Cr, Ni elements. The clad plate welding joints;
joints with transition layer welded by shielded metal arc welding achieved the best welding microstructure; mechanical
quality without excessive alloy element dilution or formation of brittle phase, which reveals a properties; alloying element
perfect welding joint without obvious hardness gradient and obtains outstanding mechanical dilution; dissimilar metal
properties. welding; martensite phase

Introduction Ni) diffusion from stainless steel weld metal (SSWM)

Stainless steel clad plate consisting of carbon steel sub- to carbon steel weld metal (CSWM) causes the exces-
strate and stainless steel cladding has widespread met sive dilution of alloy elements as well as the disappear-
the increasing demand for industrial applications, espe- ance of δ-ferrite in the SSWM zone near the welding
cially due to its excellent weldability, high corrosion interface, which degrades the mechanical properties
resistance and superior mechanical properties [1–4]. and corrosion resistance of weld joints [14]. In addi-
Meanwhile, it saves the expensive strategic Cr and Ni tion, the following reacted hard and brittle phases are
elements and reduces the fabrication cost, offering a harmful to the mechanical and physical properties of
wide range of development prospects [5,6]. Welding the welding joint. For example, Hajiannia et al. [15]
of stainless steel clad plate is an indispensable process and Venkateswara et al. [16] found that the excessive
to fabricate separators, pressure vessels, pulp digesters, alloying element diffusion resulted in the formation of
heat exchanger shells and tube plates in gas, petro- Cr3 C7 and Cr23 C6 carbides at the welding interface,
chemical industry and other fields [7–11]. Moreover, leading to the severe intergranular Cr-depletion and
stainless steel clad plate often forms defects and cracks intergranular cracks. Moreover, the high welding heat
during the manufacturing or service process, which input always introduces the formation of a large amount
should be repaired by multiple welding to guarantee the of hard martensite phase on the weld metal (close
integrity, safety and lifetime of the equipment [7,12]. to the fusion line), resulting in severe microstructure
However, the welding of stainless steel clad plate is and hardness gradients. This phenomenon may lead to
much more complicated in operation technology and crack initiation and in-service failure [17]. Therefore,
bonding behaviour than traditional materials, which is stabilising the Cr and Ni elements, generating a cer-
attributed to the large differences in chemical compo- tain amount of δ-ferrite phases, as well as avoiding the
sition, microstructure, mechanical and physical prop- formation of local martensite hardening zone, are ben-
erties between the substrate and the cladding metals eficial to the welding quality. In the present work, in
[13]. Thus, the weld joint between carbon steel and order to solve these difficulties, the microstructures and
stainless steel behaves plenty of welding defects during mechanical properties of SUS304/Q345 clad plate weld
the welding process. The excessive alloy elements (Cr, joints using three welding processes were studied, and

CONTACT B. X. Liu [email protected], C. X. Chen [email protected], J. N. He [email protected] School of Materials Science and
Engineering, Research Institute for Energy Equipment Materials, Tianjin Key Laboratory of Materials Laminating Fabrication and Interfacial Controlling
Technology, Hebei University of Technology, Tianjin 300130, People’s Republic of China

© 2020 Institute of Materials, Minerals and Mining. Published by Taylor & Francis on behalf of the Institute.
2 W. X. YU ET AL.

Figure 1. The schematic diagrams of stainless steel clad plates welding joints and corresponding welding sequence. (a) NT sample;
(b) T-TIG sample and (c) T-SMAW sample.

Table 1. The chemical composition of raw metals and weld metals (wt-%).
Classification Element C Cr Ni Si Mn Mo S P
Carbon steel substrate Q235 0.22 – – 0.3 0.8 – 0.05 0.045
Stainless steel cladding SUS304 0.044 18.26 8.21 0.5 1.16 – 0.003 0.029
CSWM ER50-6 0.073 0.019 0.015 0.89 1.48 0.006 0.009 0.011
TWM(TIG) ER309Lwire 0.025 23.50 13.76 0.50 2.15 0.010 0.006 0.015
TWM(SMAW) ER309L rod 0.028 23.50 12.6 0.63 0.80 0.25 0.004 0.027
SSWM ER308 0.020 20.26 10.02 0.63 1.82 0.01 0.009 0.021

the optimum welding process of clad plate welding joint Table 2. The welding parameters of weld metals with different
to ensure high welding quality was analysed. welding processes.
Welding
Welding Filler Welding Arc wire Welding
Experimental procedures methods metal current voltage diameter speed
MAG ER50-6 100–200 A 15–17 V 1.2 mm 1.5 mm s−1
The stainless steel clad plate containing SUS304 stain- TIG ER309L 100–140 A 20–24 V 2.5 mm 1.5 mm s−1
less steel cladding and Q235 carbon steel substrate SMAW E309L 60–80 A 20–24 V 2.5 mm 3 mm s−1
SMAW E308 70–90 A 20–24 V 2.5 mm 2.5 mm s−1
was fabricated by vacuum hot rolling. The carbon
steel plates with the dimension of 200 × 240 × 60 mm
and 304 stainless steel plates with the dimension of
160 × 200 × 12 mm were prepared, and the surface
rusts of steels were polished by abrasive papers. After ER309L welding rod, respectively. The specific chem-
heated at 1200°C for 40 min, the stainless clad plate ical compositions of raw metals and weld metals are
was hot-rolled to a final thickness of 7.2 mm with a listed in Table 1. Three kinds of SUS304/Q345 clad plate
total reduction of 90%, and the detailed procedures welding joints are designed as illustrated in Figure 1.
have been reported in our previous works [18]. The Figure 1(a) shows the sample without a transition layer
hot-rolled stainless steel clad plate was initially cut (named as NT sample). Figure 1(b, C) shows sam-
into pieces with a size of 240 mm(length) × 150 mm ples with transition layers welded by TIG welding and
(width) × 7.2 mm (thickness), and then the ladder- SMAW welding, respectively (entitled as T-TIG sam-
shaped V-groove with the angle of 60° in these plates ple and T-SMAW sample, respectively). The welding
were prepared for welding as shown in Figure 1. sequences were ordered as numbers ‘1–3’, ‘1–5’, ‘1–4’
The carbon steel substrate was welded by metal in Figure 1(a–c), as follows: first, carbon steel sub-
active gas (MAG) arc welding using ER50-6 carbon strate welding, then transition layer welding (if any) and
steel wire. The stainless steel cladding was welded by finally stainless steel cladding welding. This is a com-
shielded metal arc welding (SMAW) using ER308 stain- mon stainless steel clad plate welding sequence [13,19],
less steel wire with the chemical composition similar which can prevent a large amount of SSWM alloys from
to the cladding metal. The filler materials of transi- melting into the CSWM and achieve an optimal corro-
tion layers were welded by tungsten inert gas (TIG) arc sion resistance of SSWM. The corresponding welding
welding and SMAW using ER309L welding wire and process parameters are listed in Table 2.
 SCIENCE AND TECHNOLOGY OF WELDING AND JOINING 3

Figure 2. The schematic diagrams of testing specimens. (a) Tensile sample and (b) impact sample.

The microstructure characterisation was observed cells and the zone near the CSWM contains colum-
and analysed by optical microscope (OM), ultra- nar ferrites along the solidification direction. However,
depth three-dimensional microscope, scanning elec- the TLWM of the T-SMAW sample consists only of
tron microscope (SEM) and transmission electron columnar ferrites as shown in Figure 5(b, C). The dif-
microscope (TEM). The penetrant inspections (PT) ferent TLWM microstructures of T-TIG and T-SMAW
were carried out after welding to inspect the continu- samples are attributed to the different chemical com-
ities and qualities of the entire welding joints. Vickers positions, cooling rates and solidification modes of the
microhardness measurements were performed using a two welding joints. It is worth noting that the SSWM
100 g load for 15 s and a 100 mm spacing, the testing bottom of the NT sample contains a certain amount
data were taken approximately at the centre of the weld of lath martensite (enlarged image of Figure 3(a)). It is
cross-section (per sample). In addition, tensile testing because that welding the SSWM and CSWM of the NT
was carried out on the bone-type tensile specimens sample directly causes the excessive diffusion of Cr and
with a gauge length of 75 mm and a width of 10 mm Ni elements from SSWM into CSWM [20]. However,
as illustrated in Figure 2(a), and the tensile tests were the Cr and Ni contents at the SSWM bottom of T-TIG
conducted with a crosshead speed of 2 mm min−1 at and T-SMAW samples are stable due to the protection
room temperature. The Charpy V-notch impact sam- of TLWM. Hence, there is no brittle martensite formed
ples with a dimension of 7.2 × 10 × 55 mm were tested in the SSWM.
at different temperatures of −40°C, −20°C, 0°C and Figure 6 shows the EPMA mapping distribution of
25°C, and the specimens were carried out along three Cr, Ni elements for NT welding joints. The SSWM
different notch directions, whose notches were located near the interface behaves a band-like element concen-
at SSWM (I1), CSWM (I2) and divider (I3) directions, tration distribution, which indicates a severe dilution
respectively, as shown in Figure 2(b). behaviour of alloying elements during the welding pro-
cess. The SSWMs of the T-TIG and T-SMAW welding
joints are not excessively diluted by CSWMs due to the
Results protection of transition layer, which is beneficial to the
formation of enough δ-ferrite, thereby stabilising Cr
Microstructure observation element and improving the corrosion resistance [21].
Figures 3–5 show the optical microstructures of three
welding joints in different areas of SSWM, CSWM,
Mechanical properties
transition layer-weld metals (TLWMs) and the corre-
sponding heat-affected zone (HAZ). All the welding Figure 7 shows the microhardness distribution of three
zones and corresponding interfaces were well bonded, welding joints. For NT and T-TIG welding joints, the
and the cracks, pores, unfused zone, incomplete weld- microhardness of both SSWM and CSWM away from
ment and slag inclusions were not found in the whole the interface reaches approximately 250 HV. However,
area, which are in agreement with the result of pen- the hardness value of SSWM of NT welding joints near
etrant inspections (PT) of the entire welding joints. the interface reaches 524 HV, which may be attributed
All the SSWMs contain austenite matrix and dendritic to the formation of martensite zone. The average
δ-ferrite phases, while the CSWMs mainly consist of TLWM hardness value of T-TIG welding joints is sig-
grain-boundary ferrite (GBF), ferrite-side-plate (FSP) nificantly higher than that of the SSWM. This may be
and acicular ferrite (AF). The -HAZ of NT sample con- attributed to that the high heat input causes a large
tains GBFs and FSPs, while the HAZs of the other amount of C element to diffuse from carbon steel sub-
two welding joints are mainly composed of AF and strate into TLWM, leading to the formation of hard Cr
nibble-like or equiaxed ferrites. The TLWM of the carbides [16], while the hardness value of the T-SMAW
T-TIG sample consists of three zones: the central area welding joint is basically maintained in the range from
is composed of intercellular ferrite formed at a faster 210 to 240 Hv.
cooling rate; the region near the SSWM consists of fer- Figure 8(a) and Table 3 show the tensile prop-
rite particles located at the three-point intersection and erties of raw metals, stainless steel clad plate and
4 W. X. YU ET AL.

Figure 3. Optical microstructures of the whole welding joints without transition layers. (a) Interface between SSWM and CSWM and
(b) interface between CSWM and HAZ.

Figure 4. Optical microstructures of the whole welding joints of T-TIG sample. (a) Cross-sectional OM images; (b) interface between
SSWM and TLWM; (c) TLWM; (d) interface between TLWM and CSWM and (e) interface between CSWM and HAZ.

stainless steel clad plate welding joints. These data temperatures of 0°C and 25°C, the impact tough-
indicate that the tensile strength and elongation of ness of samples complies with the following order:
T-TIG and T-SMAW samples beyond that of raw car- I2 sample > I1sample > I3 sample. It is worth noting
bon steel plate. The carbon steel plate and stainless steel that at the testing temperatures ranging from 0°C to
clad plate have a yielding platform, which is not formed −40°C, impact toughness of all the samples decreases
in other samples, and the same phenomenon appeared sharply with the decreasing temperature, and the frac-
in Ref. [22]. In addition, the fracture positions of all the ture modes transform from ductile fracture to brittle
tensile specimens (as shown in Figure 8(b)) are located fracture as shown in Figure 9, indicating that a sig-
at the raw base clad plate rather than welding positions, nificant ductile–brittle transition in this temperature
which indicates that the welding joints achieved equiv- range. Moreover, the impact toughness of the I2 sample
alent strength matching and good mechanical proper- decreases faster than the other two samples from 0°C
ties balance. Figure 8(c) shows the impact toughness to −20°C, indicating that the I2 sample has higher low-
vs. testing temperature relationship of T-SMAW sam- temperature sensitivity and ductile–brittle transition
ples notched along different directions, and the impact temperature to impact toughness.
toughness of all the samples decreases with the decreas- Figure 9 shows the impact fracture characteristics of
ing testing temperature. At 25°C, the impact toughness T-SMAW welding joints along I3 direction at different
of I1, I2 and I3 samples reached the maximum value temperatures of −40°C and 25°C, respectively. The
of 190, 215 and 171 J cm−2 , respectively. At the testing obvious larger fibrous zone and shear lips are presented
 SCIENCE AND TECHNOLOGY OF WELDING AND JOINING 5

Figure 5. Optical microstructures of the whole welding joints of T-SAMW sample. (a) Cross-sectional OM images; (b) interface
between SSWM and TLWM; (c) interface between TLWM and CSWM and (d) interface between CSWM and HAZ.

Figure 6. The EPMA mapping distribution of Cr, Ni elements for NT welding joints.

in the fracture surface of impact sample tested at 25°C. Discussions

The fibrous zone represents a typical plastic fracture
Figure 10 shows TEM microstructures of filler metals
mode characterised by many fine and deep dimples.
about welding joints. Herein, the SSWM microstruc-
The impact fracture characteristic of the partial CSWM
ture near the interface (dotted line in Figure 3(a)) of
contains cleavage-like planes, small tearing ridges and
NT sample consists of lath martensite with a width of
microvoids, indicating a typical quasi-cleavage fracture
0.25 μm as shown in Figure 10(a). The formation of
mechanism. However, the fracture surface of the impact
martensite is due to the excessive diffusion of alloy ele-
sample tested at −40°C appears larger flat plane, as well
ments (such as Cr, Ni) from SSWM to CSWM. For the
as smaller fibrous zone and shear lips. The dimples of
T-TIG sample, the central area of TLWM mainly con-
SSWM become shallower and larger, and the CSWM
tains intercellular ferrites with a width of 2.5 μm, which
zone presents a typical brittle fracture characterised by
are uniformly distributed in the austenite matrix (as
river-like cleavage fracture. Hence, the fracture mode
shown in Figure 4(c)). However, the intercellular ferrite
transforms from ductile fracture and quasi-cleavage
is not formed in T-SMAW sample because of different
fracture to brittle cleavage fracture with the decrease of
chemical compositions, cooling rates and solidification
testing temperature.
modes.
6 W. X. YU ET AL.

Figure 7. Microhardness distribution of three welding joints (a) NT; (b) T-TIG and (c) T-SMAW.

Figure 8. The tensile and impact properties of samples. (a) Stress–strain curves, (b) macro pictures of tensile samples and (c) impact
toughness vs. testing temperature curves of the T-SMAW sample along different notch directions.

The different SSWM and TLWM microstructures of Table 3. The tensile properties of the raw carbon steel, raw
welding samples mainly depend on chromium equiv- stainless steel, stainless steel clad plate and stainless steel clad
alent/nickel equivalent (Creq /Nieq ) value factors and plate welding joints.
cooling rate, and the corresponding Creq and Nieq of Samples Tensile strength/MPa Elongation/%
weld metals can be calculated using Schaeffler equa- Stainless steel 590 47.4
Carbon steel 398 16.8
tions [23]: Clad plate 438 31.4
T-TIG 446 17.8
Nieq = Ni + 0.5Mn + 30C/% (1) T-SMAW 451 17.9

Creq = Cr + 1.5Si + Mo + 0.5Nb/% (2)

The Creq and Nieq of the weld metals are listed Creq /Nieq values of SSWM and the TLWM are located
in Table 4. When Creq /Nieq < 1.37, austenite is in the two-phase region (austenite + ferrite), and the
taken as the initial solidified phase correspond- δ-ferrite content is approximately in the range from 5
ing to A mode; when 1.37 ≤ Creq /Nieq ≤ 1.48, the to 12%. These welding joints present high intergranu-
room temperature microstructure is mainly com- lar corrosion resistance and hot crack resistance. This is
posed of austenite + martensite + ferrite (AF mode); because a certain amount of ferrite inhibits the growth
when 1.48 ≤ Creq /Nieq ≤ 2, the room tempera- of austenite dendrites and promotes the formation of
ture microstructure contains austenite + ferrite, corre- ideal ferrite/austenite interfaces [26]. However, high
sponding to FA mode; when Creq /Nieq > 2, only fer- δ-ferrite content is easy to induce the formation of σ
rite exists at room temperature (F Mode) [24,25]. The brittle hard phase at high temperature, deteriorating
 SCIENCE AND TECHNOLOGY OF WELDING AND JOINING 7

Figure 9. The impact fracture characteristics of T-SMAW welding joints along I3 direction at 25°C ((a–c) and −40°C (d–f)). (a), (d) The
whole welding joints; (b), (e) SSWM and (c), (f) CSWM.

Figure 10. The TEM microstructure of filler metals about NT welding joints. (a) Dotted line of SSWM, (b) EDS analysis in martensite,
(c) TLWM microstructure of T-SMAW welding joints and (d) corresponding diffraction pattern of (c).

the corrosion resistance and mechanical properties of Table 4. The Cr, Ni equivalent value of weld metals of T-TIG and
welding joints [27]. The T-TIG and T-SMAW welding T-SMAW samples.
joints present higher mechanical properties than that Type ER308 ER309L wire ER309L rod
of NT sample, which may be attributed to the protec- Creq 22.14 24.26 24.70
tion of TLWM with higher Cr and Ni element contents, Nieq 13.59 15.585 13.84
Creq /Nieq 1.63 1.56 1.78
obstructing the dilution effect of SSWM.
Figure 11 shows the cooling rate-chemical com-
position map and solidification microstructures with rate-chemical composition map by squares. The room
four principal modes [28,29], and three solidification temperature microstructures of all the SSWMs were
modes of weld metals were marked in the cooling mainly developed from AF solidification mode, and
8 W. X. YU ET AL.

Figure 11. Cooling rate-chemical composition map [26,29] and microstructures of the four principal solidification modes. (a) Cooling
rate- chemical composition map; (b) interface between CSWM and TLWM(SMAW); (c) CSWM and TLWM(TIG); (d) CSWM; (e) interface
between CSWM and TLWM(TIG); (f) TLWM(TIG) central area and (g) TLWM(TIG) area near SSWM.

the δ-ferrite was restricted to the cellular wall. Herein, (1) The microstructures of all SSWMs contain austen-
the phase transformation sequence of alloying element ite matrix and dendritic δ-ferrite phases, corre-
depleted zone is as follows: L → L+γ → L+γ +δ → sponding to primary austenite with second-phase
δ+γ . Moreover, the TLWM microstructure of the ferrite solidification mode. The microstructures
SMAW sample behaves in a FA solidification mode, of TLWMs welded by SMAW or TIG arc weld-
which shows a typical cellular-like subgrain growing ing contain ferrite + austenite phase, but differ
characterisation along the solidification direction. This in the solidification mode. The former is only
solidification sequence is as follows: L → L+δ → L+γ + formed through primary ferrite with second-phase
δ → δ+γ . In addition, the whole TLWM microstruc- austenite mode, while the latter follows three solid-
ture of the TIG sample follows the A + AF solidification ification modes: single-phase austenite, primary
modes → FA solidification mode → A solidification austenite with second-phase ferrite and primary
mode, and the solidified single-phase austenite corre- ferrite with second-phase austenite.
sponds to A mode as follows: L → L+γ → γ . The inter- (2) The sample with the transition layer welded by
face between SSWM and TLWM of the T-TIG sample SMAW has no obvious hardness gradient com-
consists of single austenite formed through A mode, pared to other two samples. The SSWM without
and ferrite + austenite phase formed through AF mode. transition layer behaves excessive diffusion of Cr,
However, the interface between SSWM and TLWM Ni elements and the formation of brittle martensite
of the SMAW sample consists of ferrite and austenite, zone, which can deteriorate corrosion resistance
which follows FA mode or AF mode. Therefore, the and mechanical properties of welding samples.
uniform microstructure transformation of the SMAW (3) The tensile strengths of clad plates with transi-
sample results in high impact toughness. tion layer welded by TIG arc welding and SMAW,
respectively, are both generally equivalent to that
of raw stainless steel clad plate. The impact frac-
ture mode transforms from ductile fracture to brit-
Conclusions tle cleavage fracture as the temperature decreases
The stainless steel/carbon steel clad plates were suc- from −40°C to 25°C.
cessfully welded by MAG arc welding, TIG arc weld- (4) The stainless steel clad plate welding joint with a
ing and SMAW, respectively. The microstructure and high welding quality can be obtained by adding
mechanical properties of welding samples were inves- a transition layer using the SMAW method. The
tigated in detail. The main results are summarised as excessive alloy element dilution or brittle phase
follows: is absent in the SSWM. It has a perfect interface
 SCIENCE AND TECHNOLOGY OF WELDING AND JOINING 9

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