Influence of submerged arc welding process parameters and metallurgical behaviour in a thick carbon steel section for boiler application

Abstract

AbstractThe aim of the research is to investigate the weldability of thick sections of carbon steel using submerged arc welding with varying process parameters. The experimental design for joining thick carbon steel involves manipulating input weld process parameters such as current (A), voltage (V), weld speed (mm/h), and weld electrode diameter (mm). The quality of the weld material is assessed based on transformations in microstructure, weld hardness measured by Brinell hardness number, and tensile strength (MPa). It is crucial to note that the grain structure and metallurgical behavior of other hard materials may differ significantly. The presence of carbon in the ferrite phase has led to the formation of bainite, martensite, and composites of martensite and austenite within the weld zone, as confirmed by high‐resolution microscopy. The weldment‘s hardness has increased from 242.5 HV 30 in the base metal to 316.4 HV 30 in the weldment due to metallurgical alterations in the microstructure. Weld energy input emerges as the primary factor influencing weld quality. With increasing weld current and voltage, there is a corresponding increase in the joined metal, resulting in improved characteristics in the weld structure, particularly at maximal energy input and welding speed. In the context of boiler applications, understanding the weldability of thick carbon steel sections is paramount for ensuring structural integrity and longevity under high‐temperature and high‐pressure conditions. The optimized welding parameters identified in this study can contribute to enhancing the reliability and performance of boilers, thereby promoting safety and efficiency in industrial settings.