metals

Article
Welding Residual Stress Analysis and Fatigue
Strength Assessment of Multi-Pass Dissimilar
Material Welded Joint between Alloy 617 and
12Cr Steel
Hafiz Waqar Ahmad * ID
, Jeong Ho Hwang, Ju Hwa Lee and Dong Ho Bae *
Graduate School of Mechanical Engineering, Sungkyunkwan University, Suwon 440-746, Korea;
reflika@skku.edu (J.H.H.); juhwa0207@skku.edu (J.H.L.)
* Correspondence: waqar543@skku.edu (H.W.A.); bae@yurim.skku.ac.kr (D.H.B.); Tel.: +82-31-290-7443 (D.H.B.)

Received: 30 November 2017; Accepted: 27 December 2017; Published: 31 December 2017

Abstract: The reliability of welded structure can be evaluated through welding residual stress
analysis and fatigue strength assessment. In this study, welding residual stresses of multi-pass
dissimilar material welded joint between alloy 617 and 12Cr steel were analyzed numerically and
experimentally. Fatigue strength was then assessed in the air. Based on results of welding residual
stress analysis and fatigue strength assessment, a fatigue design method considering welding residual
stress was investigated. Welding residual stresses at the weld of dissimilar welded joints distributed
complicatedly on longitudinal and transverse directions, showing differences but a very similar
distribution tendency between numerical and experimental results. Numerical and experimental
peak values of welding residual stresses at HAZ of the weld on the 12Cr steel side were predicted to
be 333 MPa and 282 MPa HAZ, respectively. The fatigue limit of dissimilar material welded joint
between alloy 617 and 12Cr steel was assessed to be 306.8 MPa, which was 40% of tensile strength
(767 MPa) of dissimilar material welded joint. However, the stress range including welding residual
stress was assessed to be 206.9 MPa, which was 14% lower than that calculated by including the effect
of residual stresses.

Keywords: dissimilar material welding; welding residual stress; finite element method; fatigue
strength; modified Goodman equation; fatigue design; alloy 617; 12Cr steel

1. Introduction
It is well-known that the most effective methodology for green power plant systems is to increase
the generative efficiency of steam power plants [1]. The core technology for increasing the generative
efficiency is to improve the performance of steam turbines. A basic method for improving the
performance of thermal power plants is to elevate steam temperature [2]. Therefore, it is necessary
to develop suitable materials for extreme environment of power plants. So far, Ni alloys have been
candidates as available materials for high temperature steam power plants due to their incredible
mechanical properties [3,4]. However, in order to apply Ni alloys (alloy 617 in this paper) to steam
turbine materials such as turbine rotor and blades, it is necessary to do dissimilar material welding
with the 12Cr steel alloy that is currently used as material for turbine rotor and blades. However,
since Inconel alloy 617 and 12Cr steel alloy have different chemical compositions and mechanical
properties, reliable welding technology needs to be developed to manufacture hybrid structures that
can withstand extreme environmental conditions [4,5]. There are many suitable processes for the
joining of dissimilar material as comprehensively summarized by Martinsen et al. [6]. These dissimilar
material welded structures often experience variable loadings, ranging from cyclic to completely
random fluctuation during their practical working.

Metals 2018, 8, 21; doi:10.3390/met8010021 www.mdpi.com/journal/metals

Metals 2018, 8, 21 2 of 11

Therefore, engineering designers should sufficiently understand the welding metallurgical

phenomena, as well as the mechanical properties of the weld, including the mechanism of welding
residual stresses generated during the welding process. In particular, as the generation of welding
residual stresses is formidable, as well as being the crack driving force of the welded structures, it is
very important to understand and assess welding residual stresses in the design process of welded
structures. Basically, as welding residual stresses are generated due to repetitive nonlinear thermal
loading cycles by the welding heat input, assessing the distribution of these stresses may be too complex
to be predicted accurately [7,8]. Residual stresses have a substantial effect on engineering properties
of material and welded structures, particularly fatigue strength, corrosion resistance, dimensional
stability, and distortion [9]. Many researchers have practiced various methods to measure residual
stresses using experimental and numerical methods [10–12]. In recent years, as high computational
power is available, many researchers have acknowledged the reliability of using the finite element
method for this purpose [13,14].
In the present study, the hole-drilling method and the finite element method were used to measure
welding residual stresses.
Fatigue is considered the most common cause of failure in welded structures [15]. Dissimilar
material welded joints are very sensitive to fatigue stress [16]. Therefore, fatigue testing with varying
limits of high stresses can provide very useful information to assess the quality of welded joints [15].
Bae et al. have proposed a σa-r stress range including welding residual stresses by using a modified
Goodman equation [17]. Their results showed that fatigue strength, including welding residual stresses,
was lower than fatigue strength without considering residual stresses. The objective of the present
study was to analyze the welding residual stresses of the multi-pass dissimilar material welded joint
between alloy 617 and 12Cr steel, numerically and experimentally. Fatigue strength was then assessed
in the air.

2. Materials and Methods

Materials used for dissimilar material welding included alloy 617 and 12Cr steel alloy. Alloy 617
has good resistance against high temperature and corrosion as it consists of Cr, Mo, and Co as major
compositions, while 12Cr steel is being currently used as a material of turbine rotor and blade of steam
power plant. Filler material used in this study was Thyssen 617. Its chemical composition is similar to
alloy 617. Mechanical properties and chemical compositions of alloy 617, 12Cr steel, and Thyssen 617
are illustrated in Tables 1 and 2. Multi-pass direct current straight polarity (DCSP) tungsten inert gas
(TIG) welding was carried out for multi-pass dissimilar material welding.

Table 1. Mechanical properties of alloy 617, 12Cr steel, and dissimilar material weld.

Yield Strenght Tensile Strenght Reduction in Melting Point

Base Material Elongation
(MPa) (MPA) Area (%) (◦ C)
Alloy 617 322 732 62 56 1330
12Cr 551 758 18 50 1375
Dissimilar material
490 767 48 - -
welded joint

Table 2. Chemical composition of alloy 617, Thyssen 617, and 12Cr steel.

Chemical Composition (Weight %)

Base/Filler Metal
Ni Cr Co Mo Al C Fe Si Ti Cu Mn S
Alloy 617 44.3 22 12.5 9.0 1.2 0.07 1.5 0.5 0.3 0.2 0.5 0.008
12Cr 0.43 11.6 - 0.04 - 0.13 Bal. 0.4 - 0.1 0.58 -
Thyssen 617 45.7 21.5 11.0 9.0 1.0 0.05 1.0 0.1 1 - - -
Metals 2018, 8, 21 3 of 11

Metals 2018, 8, 21 3 of 12

Real time monitoring system was used to control welding conditions (electrode shape, electrode to
Real time monitoring system was used to control welding conditions (electrode shape, electrode
workpiece distance, welding wave form, and welding heat input). Preliminary welding was performed
to workpiece distance, welding wave form, and welding heat input). Preliminary welding was
under various welding parameters (i.e., current, voltage, welding speed, shield gas compositions, and
performed under various welding parameters (i.e., current, voltage, welding speed, shield gas
flow rates) to determine optimum dissimilar material welding conditions. Obtained optimum welding
compositions, and flow rates) to determine optimum dissimilar material welding conditions.
conditions for dissimilar material are listed in Table 3 [18].
Obtained optimum welding conditions for dissimilar material are listed in Table 3 [18].
Table 3. Optimum welding conditions.
Table 3. Optimum welding conditions.
Pass PassShield Gas Gas Voltage
Shield (V)(V)
Voltage Current
Current (A)
(A) WeldingSpeed
Welding Speed(cm/min)
(cm/min) Heat
Heat Input
input (kJ/mm)
(kJ/mm)
1 1Argon-2.5% H2 H2
Argon-2.5% 10 10 150
150 1010 0.9 0.9
2 2Argon-2.5% H2 H2
Argon-2.5% 13 13 150
150 1010 1.171.17
3 3Argon-2.5% H2 H2
Argon-2.5% 16 16 150
150 1010 1.441.44
4 Argon-2.5% H2 16 150 10 1.44
4 Argon-2.5% H2 16 150 10 1.44
5 Argon-2.5% H2 16 150 10 1.44
5 Argon-2.5% H2 16 150 10 1.44
6 Argon-2.5% H2 16 150 10 1.44
7 6Argon-2.5%
Argon-2.5%
H2 H2 16 16 150
150 1010 1.441.44
7 Argon-2.5% H2 16 150 10 1.44

Since
Since the
the out of plane
out of plane thermal
thermaldistortion
distortionisisformidably
formidablycaused
causedbyby welding
welding heatheat input
input during
during the
the multi-pass welding process, welding jigs were used to fix both ends of base metals
multi-pass welding process, welding jigs were used to fix both ends of base metals to prevent out-of- to prevent
out-of-plane
plane thermal thermal distortion.
distortion. Multi-pass
Multi-pass welding welding directions
directions werewere parallel
parallel to the
to the rolling
rolling direction.
direction. U-
U-groove shape was machined for narrow-gap welding [19]. U-groove is economical,
groove shape was machined for narrow-gap welding [19]. U-groove is economical, as it requires less as it requires
less
fillerfiller metal,
metal, which
which results
results in distortion
in less less distortion and residual
and residual stress-related
stress-related problemsproblems [20]. Figure
[20]. Figure 1 shows1
shows a welding specimen with U-groove and narrow gap. In the multi-pass welding
a welding specimen with U-groove and narrow gap. In the multi-pass welding process, the specimen process, the
specimen was cooled down to 70
be °C
under ◦ C in the interval of every welding process. After finishing
70 interval
was cooled down to be under in the of every welding process. After finishing each pass
each pass welding,
welding, the ultrasonic
the ultrasonic testing
testing was was carried
carried out following
out following ASTM ASTM
E164-13 E164-13 standard
standard to inspect
to inspect weld
weld defects of multi-pass
defects of multi-pass welds. welds.

Figure1.1. Specimen
Figure Specimenwith
withU-groove
U-groove(Unit:
(Unit:mm).
mm).

3. Residual Stress Analysis of Multi-Pass Dissimilar Material Welded Joint between Alloy 617
3. Residual Stress Analysis of Multi-Pass Dissimilar Material Welded Joint between Alloy 617
and12Cr
and 12CrSteel
Steel

3.1. Numerical
3.1. Numerical Analysis
Analysis of
of Welding
WeldingResidual
ResidualStresses
Stresses
AAseven-pass
seven-passdissimilar
dissimilar material
material welded
welded plateplate
modelmodel
shown shown in Figure
in Figure 2 was
2 was used usedanalysis.
in this in this
analysis.
Its Its thickness,
thickness, width, andwidth, and weld
weld length werelength wereand
12.7, 300, 12.7,
300300,
mm,and 300 mm, respectively.
respectively. Three-dimensionalThree-
dimensional
finite elementfinite element
models models
were used for were used forand
both thermal bothmechanical
thermal and mechanical
analyses with aanalyses withmodel.
heat source a heat
source model. In this study, ramp heat source model was used. For welding,
In this study, ramp heat source model was used. For welding, 8-node brick solid elements of type 8-node brick solid
elements
DC3D8 of type
were DC3D8
used. Weld were
beadsused.
of theWeld
model beads of the model
represented represented
the weld the weld bead
bead determined fromdetermined
the actual
fromcondition.
weld the actualFiner
weldmeshes
condition.
wereFiner meshes
generated in were generated
weld metal regionsin weld metal
to handle regions
the greatertononlinearity
handle the
greater
and nonlinearity
to obtain accurateand to obtain
results. The accurate results.
total number The total and
of elements number
nodes of were
elements andand
221,760 nodes were
474,012,
221,760 and 474,012,
respectively. Hyper-mesh ® (10.0, Altair,
respectively. Hyper-mesh ® (10.0, Altair, Troy, MI, USA, 2008) was used for mesh
Troy, MI, USA, 2008) was used for mesh generation. ABAQUS
generation.
(6.10, ABAQUS
Dassault (6.10,Johnston,
Systemes, Dassault RI,
Systemes, Johnston,
USA, 2010) was RI, USA, 2010)
employed was employed
for transient for transient
temperature and
temperaturewelding
subsequent and subsequent welding
residual stress residual stress analysis.
analysis.
Metals 2018, 8, 21 4 of 11
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8, 21
21 44 of
of 12
12

Figure 2.
Figure 2. Finite
Finite element
element mesh
mesh of
of 3-D
3-D model.
model.
Figure 2. Finite element mesh of 3-D model.
3.1.1. Numerical
3.1.1. Numerical Analysis
Analysis Procedure
Procedure
3.1.1. Numerical Analysis Procedure
Uncoupled thermo-mechanical
Uncoupled thermo-mechanical analysis analysis waswas performed
performed in in this
this study
study as as shown
shown in in Figure
Figure 33 [21].
[21].
Uncoupled thermo-mechanical
Temperature distribution
distribution at at the
the weld analysis
weld was was
was analyzed performed
analyzed firstfirst by in this
by thermal study
thermal analysis. as shown
analysis. It It was in
was thenFigure
then usedused[21].
3 as
Temperature as
Temperature
input data fordistribution
stress at
analysis. the
Some weld was
assumptions analyzed
were first
taken by thermal
into account analysis.
in the It was
process then
of used
thermal-
input data for stress analysis. Some assumptions were taken into account in the process of thermal-
as input data
mechanical for stress
analysis. When analysis.
performing Some theassumptions
thermal analysis, werethe
analysis, taken
initialinto account inofthe
temperature baseprocess
and weld of
weld
mechanical analysis. When performing the thermal the initial temperature of base and
thermal-mechanical
metal was
was assumed
assumed to analysis.
to be
be aa room When
room temperature performing
temperature (25 (25 °C).the
°C). The thermal analysis,
The conductivity
conductivity and the initial
and specific
specific heat temperature
heat in in the
the molten of
molten
metal
base
pool and
were weld metaltowas
assumed be assumed Radiation
constant. to be a room and temperature
forced (25 ◦ C).due
convection Thetoconductivity
shielding gasandflow specific
were
pool were assumed to be constant. Radiation and forced convection due to shielding gas flow were
heat in the
neglected. Since molten
Since the pool were
the temperature
temperature is assumed
is very to
very high be
high in constant.
in the
the molten Radiation
molten pool, and
pool, radiation forced
radiation and convection
convection due
and convection can
neglected. can
to shielding
influence gas flow
microstructures were neglected.
and cooling Since
rates the
in temperature
weld metal. is
Heat very high
losses or in the
gains molten
from pool,
phase
influence microstructures and cooling rates in weld metal. Heat losses or gains from phase
radiation
transformationand convection
were neglected. can influence
neglected. The volume
volume microstructures
change effect
effect dueandtocooling
due rates in weldwas
phase transformation
transformation metal. Heat
neglected
transformation were The change to phase was neglected
losses
in the or gains
the stress from
stress analysis. phase
analysis. Apart transformation
Apart from from these were
these assumptionsneglected.
assumptions mentioned The volume
mentioned above, change
above, in effect due
in thermal-mechanical
thermal-mechanicalto phase
in
transformation
analyses for was neglected
dissimilar in thewelded
material stress analysis.
model, Apart from these
influences of assumptions
transient mentionedfield
temperature above, in
and
analyses for dissimilar material welded model, influences of transient temperature field and
thermal-mechanical
temperature-dependent analyses for dissimilar
physical properties material welded model,
were considered
considered influences
as input
input data for of transient
for accurate temperature
and reliable
reliable
temperature-dependent physical properties were as data accurate and
field and
assessment oftemperature-dependent
of thermal
thermal analysis.
analysis. When physical
When performingproperties
performing the were
the stressconsidered
stress analysis, as input
analysis, mechanical data
mechanical and for accurate
and physical
physical
assessment
and reliableofassessment
properties yield of thermal
stress, elastic analysis.
and plastic When performing
modules, and the stress
thermal analysis, coefficient
expansion mechanicalwere and
properties of yield stress, elastic and plastic modules, and thermal expansion coefficient were
physical
considered properties
to be of yield stress,
be temperature
temperature elastic andHowever,
dependent. plastic modules, and thermal
mechanical expansion
properties were coefficient
assumed to were
to be
considered to dependent. However, mechanical properties were assumed be
considered
constant to
above be temperature
the melting dependent.
point. The However,
temperature mechanical
dependency properties
of were
Poisson’s assumed
ratio to
was be constant
neglected.
constant above the melting point. The temperature dependency of Poisson’s ratio was neglected.
above
Physicaltheand
melting point. The
mechanical temperature
properties dependency
of Alloy
Alloy 617 andandof Poisson’ssteelratio
12Cr steel are was
givenneglected.
in Figures
Figures Physical andand
Physical and mechanical properties of 617 12Cr are given in 44 and 5,
5,
mechanical properties
respectively [22,23].
[22,23]. of Alloy 617 and 12Cr steel are given in Figures 4 and 5, respectively [22,23].
respectively

Figure 3.
Figure 3. Numerical
Numerical analysis
Numerical analysis procedure
analysis procedure for the
procedure for the uncoupled
uncoupled thermo-mechanical
thermo-mechanical analysis
analysis [21].
[21].
Metals 2018, 8, 21 5 of 11
Metals 2018, 8, 21 5 of 12
Metals 2018, 8, 21 5 of 12

Metals 2018, 8, 21 5 of 12

Figure 4. Physical and mechanical properties of Alloy 617.

Figure Physical
4. 4.
Figure Physicaland
andmechanical propertiesofofAlloy
mechanical properties Alloy617.
617.

Figure 4. Physical and mechanical properties of Alloy 617.

Figure 5. Physical and mechanical properties of 12Cr steel.

Figure 5. Physical and mechanical properties of 12Cr steel.
Figure 5. Physical and mechanical properties of 12Cr steel.
The element rebirth technique [24] was applied to simulate the multi-pass weld metal deposition
TheWith
effect. element thisrebirth Figure
technique, 5. Physical
technique
elements and
[24] was mechanical
applied
simulating to properties
simulate
each weld theof 12Cr
pass steel.grouped
multi-pass
were weld metal deposition
at the model
The
effect. element
generation
With stage.rebirth
this technique
During
technique, [24]these
analysis,
elements was applied
element to
simulating simulate
groups
each that the
weld multi-pass
presented
pass were weld weld metal
passes
grouped the deposition
at were first
model
effect. WithThe
removed
generation element
this
and thenrebirth
technique,
stage. technique
elements
reactivated
During analysis, [24] waselement
at a simulating
specified
these applied
each to
moment tosimulate
weld pass
simulate
groups thatthe
were multi-pass
grouped
a presented
given weld metal
at the
deposition
weld deposition
model
sequence
passes ofgeneration
wereweld
first
stage. effect.
During
passes.
removed With
When
and this
analysis, technique,
a group
then these
of weld
reactivated elements
element
elements
at simulating
groups
were
a specified that each
presented
activated,
moment weld
weld
specific
to simulate pass
initial
a givenwere
passes grouped
were
temperatures at imposed
firstwere
deposition the of
removed
sequence model
and at then
weld
generation
all nodes stage. During
associated with analysis,
the weld these element groups that presented weld passes were first
elements.
reactivated
passes. Whenat a specified
a group ofmoment to simulate
weld elements a given specific
were activated, deposition
initialsequence
temperaturesof weld
werepasses.
imposedWhenat
removed and then reactivated at a specified moment to simulate a given deposition sequence of weld
all nodes
a group associated
of weld elementswithwere
the weld elements.
activated, specific initial temperatures were imposed at all nodes
passes. When
3.1.2. Heat a group
Source Model of weld elements were
for Numerical activated, specific initial temperatures were imposed at
Analysis
associated
all with
nodes the weldwith
associated elements.
the weld elements.
3.1.2. Heat
In this Source
study,Model for Numerical
the heat input model Analysis
using ramp function as shown in Figure 6 based on the
3.1.2. 3.1.2.
Heat
concept Source
InHeatof
this Source Model
Pavelic’s
study, Model for
disc
the heat Numerical
model
forinputwas Analysis
employed
using[25,26].
modelAnalysis
Numerical ramp function as shown in Figure 6 based on the
concept
In this of Pavelic’s disc modelmodel
was employed [25,26].
In study, the heat
this study, the input usingusing
heat input model ramp function
ramp as shown
function in Figure
as shown 6 based
in Figure on the
6 based concept
on the
of Pavelic’s disc model was employed [25,26].
concept of Pavelic’s disc model was employed [25,26].

Figure 6. Heat input model with ramp function.

Figure 6. Heat input model with ramp function.

The ramp source heat input model for simulation was used for analysis. Heat flux is expressed
Figure
in the following equation. Figure6. 6.Heat
Heatinput
input model withramp
model with rampfunction.
function.
The ramp source heat input model for simulation was used for analysis. Heat flux is expressed
in theThe
following equation.
ramp source heat input model for simulation was used for analysis. Heat flux is expressed
The ramp source heat input model for simulation was used for analysis. Heat flux is expressed in
in the following equation.
the following equation.
Metals 2018, 8, 21 6 of 11

2
q( x ) = q(0)e−Cx (1)

q(0): maximum heat flux at the center of heating spot

x: distance from the center of heating spot
C: heat flux concentration coefficient
Metals 2018, 8, 21 6 of 12
In this case, the total amount of heat input is indicated as the combination of surface heat input
and body heat input as shown in Equation (2):( ) = (0) (1)
q(0): maximum heat flux at the center of heating spot
x: distance from the center of heating spot Q = Qs + Qb (2)
C: heat flux concentration coefficient
where
In this case, the total amount of heat input is indicated as the combination of surface heat input
and body heat input as shown in Equation (2):
Q: total heat input
QS : surface heat input = + (2)
Qb : body heat input
where
Q: total heat input
The energy input per unit length (H, J/mm) can be shown as Equation (3):
QS: surface heat input
Qb: body heat input 1
H = Q× (3)
The energy input per unit length (H, J/mm) can be vshown as Equation (3):
1
v: welding speed (mm/s) = × (3)
Body heat flux (qb , W/mm3 ) and surface heat flux (qs , W/mm2 ) are indicated in Equations (4)
v: welding speed (mm/s)
and (5): Body heat flux ( , W/mm3) and surface heat flux ( , W/mm2) are indicated in Equations (4) and
Q
(5): qb = b (4)
Ve
r= (4)
Q s 3 −3 x 2
qs = e b (5)
bL π
3
=
where b and L are geometrical parameters of weld bead [25]. (5)

where b andAnalysis
3.2. Experimental L are geometrical
of Weldingparameters
ResidualofAnalysis
weld bead [25].

Experimental analysis
3.2. Experimental was
Analysis performed
of Welding to Analysis
Residual calculate welding residual stresses and evaluate results
of numerical analysis. In
Experimental this study,
analysis a hole drilling
was performed method
to calculate weldingwas usedstresses
residual according to ASTM
and evaluate E837 [27].
results
RS-200 of
milling guide equipment shown in Figure 7a and strain rosette (Micro measurement
numerical analysis. In this study, a hole drilling method was used according to ASTM E837 [27]. Co.,
EA-06-062RE-120
RS-200 millingtype, Kyunggi,
guide equipmentKorea)
shown were used
in Figure to measure
7a and residual
strain rosette (Microstresses. We analyzed
measurement Co., EA- three
06-062RE-120
points (5, 20 and 35 mm)type, Kyunggi,
apart fromKorea) were center,
the weld used to respectively,
measure residual stresses.
on both Weasanalyzed
sides shown in three
Figure 7b.
points (5, 20 and 35 mm) apart from the weld center, respectively, on both sides as shown in Figure
Surfaces of these specimens fabricated by the actual dissimilar material welding between alloy 617
7b. Surfaces of these specimens fabricated by the actual dissimilar material welding between alloy
and 12Cr steel were carefully polished to reduce surface roughness error.
617 and 12Cr steel were carefully polished to reduce surface roughness error.

Figure 7. (a) RS-200 milling guide, (b) position of hole drilling.

Figure 7. (a) RS-200 milling guide, (b) position of hole drilling.
Metals 2018, 8, 21 7 of 11
Metals 2018, 8, 21 7 of 12

3.3. Results and Discussion

The fundamental goal of this study was to develop a reliable FEA model capable of predicting
thermal history and residual stresses stresses ofof dissimilar
dissimilar material
material weld
weld withwith higher
higher accuracy.
accuracy. Figure 8
shows comparative results obtained from the FEA developed in this study study and experimental analysis.
and experimental analysis.
resultsshowed
Both results showed quantitatively
quantitatively differences.
differences. However,
However, qualitatively,
qualitatively, they similar
they showed showedtendency.
similar
tendency. Quantitative
Quantitative differencedifference
was due wasto thedue to the
fact thatfact that temperature-dependent
temperature-dependent physical
physical properties
properties were
were not taken into account or neglected by some assumptions. Welding
not taken into account or neglected by some assumptions. Welding residual stresses were predicted residual stresses were
predicted
highly highly
at HAZ onatboth
HAZ on both
sides of thesides
weld.of Residual
the weld.stresses
Residual at stresses
the HAZaton thethe
HAZ
sideonof the
12Crside of alloy
steel 12Cr
steel alloy
were higherwere
thanhigher
thosethan those
of the alloyof617
theside.
alloyThis
617 side.
is dueThis is due
to the facttothat
the Alloy
fact that
617Alloy 617 hasthermal
has higher higher
thermal expansion
expansion coefficient
coefficient than 12Cr than 12Cr
steel, steel,thermal
while while thermal conductivity
conductivity of alloyof alloy
617 617 isthan
is lower lower than
that of
that of
12Cr 12Cr steel.
steel.
In longitudinal direction (along the welding direction), numerical peak stress value on the 12Cr
steel alloy side was predicted to be be 333
333 MPa.
MPa. However, the experimental result showed a value of
around 282
around 282MPa.
MPa.InIntransverse
transverse direction
direction (perpendicular
(perpendicular to welding
to the the welding direction),
direction), numerical
numerical peak
peak stress
stress value on the 12Cr steel alloy side was predicted to be around
value on the 12Cr steel alloy side was predicted to be around 306 MPa. However, the experimental306 MPa. However, the
experimental
result showedresult
a value showed a value
of around 268 of around 268 MPa.
MPa.

Figure 8. Comparison
Figure 8. Comparison of
of FE analysis results
FE analysis results with
with experimental
experimental measurements.
measurements.

4. Fatigue Strength Assessment of Multi-Pass Dissimilar Material Welded Joint

4. Fatigue Strength Assessment of Multi-Pass Dissimilar Material Welded Joint

4.1. Specimen
4.1. and Test
Specimen and Test Procedure
Procedure
Tensile and
Tensile and fatigue
fatiguetest
testspecimens
specimensofofthe dissimilar
the material
dissimilar welded
material joint
welded between
joint Alloy
between 617 and
Alloy 617
12Cr steel alloy were fabricated from seven-pass welded plate in accordance with
and 12Cr steel alloy were fabricated from seven-pass welded plate in accordance with ASTM-E8 ASTM-E8 standard
[28]. Figure
standard 9 shows
[28]. Figuretest specimen
9 shows test configuration. Gauge length
specimen configuration. of the
Gauge specimen
length of theincluded
specimenbase metals
included
(Alloy
base 617 and
metals 12Cr617
(Alloy steel),
and their
12Cr HAZ,
steel),and
theirweld
HAZ, metal.
and Tensile and fatigue
weld metal. Tensilestrengths
and fatigueof dissimilar
strengths
material welded joint were evaluated by using a material testing system (INSTRON
of dissimilar material welded joint were evaluated by using a material testing system (INSTRON 8801, LLC, Seoul
Korea,LLC,
8801, 100 kN).
SeoulLoading speed
Korea, 100 forLoading
kN). tensile test wasfor
speed controlled by displacement
tensile test was controlled ofby1 mm/min. Fatigue
displacement of
tests were started from σ max = 690 MPa, corresponding to 90% of the static tensile strength (767 MPa)
1 mm/min. Fatigue tests were started from σmax = 690 MPa, corresponding to 90% of the static
of a multi-pass
tensile dissimilar
strength (767 MPa) of material weld dissimilar
a multi-pass between Alloy 617 weld
material and 12Cr steel.
between Tests
Alloy were
617 andperformed
12Cr steel.
usingwere
Tests a 10% load decreasing
performed using a 10%method
loaduntil 10 cycles
6
decreasing as illustrated
method in Table
until 106 cycles 4. The fatigue
as illustrated load
in Table 4.
frequency was 10 Hz in sine wave. Load ratio (R = Pmin/Pmax) was 0.1. The load range was constant.
Metals 2018, 8, 21 8 of 11

The fatigue load frequency was 10 Hz in sine wave. Load ratio (R = Pmin /Pmax ) was 0.1. The load
range was8,constant.
Metals 2018, 21 8 of 12

Figure 9. Configuration of test specimen (ASTM E8M,

E8M, unit:
unit: mm).

Table 4.
Table 4. Fatigue test
test conditions.
conditions.

Load Conditions
σmax (MPa) 0.9σu = 690.3 0.8σu = 613.6
Load Conditions
0.7σu = 536.9 0.6σu = 460.2 0.5σu = 383.5 0.4σu = 306.8
σmax (MPa) 0.9σu = 690.3 0.8σu = 613.6
Stress Ratio 0.7σu = 536.9
R = 0.10.6σu = 460.2 0.5σu = 383.5 0.4σu = 306.8
FrEquation 10 Hz
Stress Ratio R = 0.1
FrEquation 10 Hz
4.2. Calculation of Stress Range Considering Welding Residual Stresses
For the appraisal
4.2. Calculation of Stress of stress
Range range, a Welding
Considering technique was published
Residual Stresses by Bae et al. that incorporated
welding residual stresses [17]. They used modified Goodman equation to calculate stress range by
Forwelding
taking the appraisal
residualofstresses
stress range, a technique
into account was published by Bae et al. that incorporated
. Maximum stress (σmax) values were taken from Table
welding residual stresses [17]. They used modified
4. Minimum stress (σmin) was calculated using Equation Goodman
(6): equation to calculate stress range by
taking welding residual stresses into account. Maximum stress (σmax ) values were taken from Table 4.
σ
Minimum stress (σmin ) was calculated using Equation R= (6): (6)
σ
σ
Equation (7) represents the Goodman Requation = min used to measure the stress range without (6)
σmax
considering welding residual stresses
Equation (7) represents the Goodmanσ equation
σ used to measure the stress range without
+ =1 (7)
considering welding residual stresses
σa σmean
where + =1 (7)
Se Su
where σ (stress amplitude) = ;
σmax − σmin
σa (stress amplitude) = ;
and 2
and
σσmax ++σσ
σσmean (mean
(meanstress
stress)
) == min
22
S
See:: fatigue
fatigue strength
strength
S : ultimate strength
Suu: ultimate strength
The
The proposed
proposedmodified
modifiedGoodman
Goodmanequation taking
equation into
taking account
into thethe
account welding residual
welding stresses
residual can
stresses
be
canrepresented as Equation
be represented (8): (8):
as Equation
σa−r (σmean + σr )
σ + (σ +σ ) =1 (8)
Se + Su =1 (8)
where σa-r is the stress taking into account the welding residual stresses. It can be calculated by using
where σa-r(9):
Equation is the stress taking into account the welding residual stresses. It can be calculated by using
 
Equation (9): (σmean + σr )
σa−r = Se 1 − (9)
(σ Su + σ )
σ = 1− (9)
4.3. Results and Discussion
Figureand
4.3. Results 10 shows the relationship between the stress (σ) and the fatigue life (Nf) of a dissimilar
Discussion
material multi-pass welded joint between alloy 617 and 12Cr steel. Fatigue tested specimens mostly
Figure 10 shows the relationship between the stress (σ) and the fatigue life (Nf) of a dissimilar
material multi-pass welded joint between alloy 617 and 12Cr steel. Fatigue tested specimens mostly
failed at HAZ of 12Cr steel alloy as shown in Figure 11, even though welding residual stresses were
reduced during machining for specimen fabrication. This might be due to higher welding residual
Metals 2018, 8, 21 9 of 11

failed2018,
Metals at HAZ
8, 21 of 12Cr steel alloy as shown in Figure 11, even though welding residual stresses 9 of 12
Metals 2018,
were 8, 21 during machining for specimen fabrication. This might be due to higher welding
reduced 9 of 12
residual
stress stress distribution
distribution as compared
as compared to those
to those of alloy
of alloy 617,617,
andand
thethe metallurgicalmicrostructure
metallurgical microstructure and
stress distribution as compared to those of alloy 617, and the metallurgical microstructure and
composition changes during multi-pass welding heat cycle [18].
composition changes during multi-pass welding heat cycle [18].

Figure
Figure 10.
10. S-N
S-N curve
curve for
for fatigue
fatigue test
test result.
result.
Figure 10. S-N curve for fatigue test result.

Figure 11. The

The fatigue
fatigue tested specimen (failed at HAZ of 12Cr steel alloy).
Figure 11. The fatigue tested specimen (failed at HAZ of 12Cr steel alloy).
From
From Figure 10, the low
low fatigue limit that was
was the stress
stress value did did not failfail until 10 1066 cycles of a
From Figure
Figure 10,
10, the
the low fatigue
fatigue limit
limit that
that was the the stress value
value did not not fail until
until 106 cycles
cycles ofof aa
dissimilar
dissimilar material multi-pass welded joint between Alloy 617 and 12Cr steel alloy, σ L, were assessed
dissimilar material
material multi-pass
multi-pass welded welded joint joint between
between AlloyAlloy 617
617 and
and 12Cr
12Cr steel
steel alloy,
alloy, σσLL,, were
were assessed
assessed
to
to be around
be around306.8 306.8MPa.
MPa. ThisThis
was was 40% 40%
of of static
the the static
tensiletensile
strengthstrength
(767 (767ofMPa)
MPa) the of the dissimilar
dissimilar material.
to be around 306.8 MPa. This was 40% of the static tensile strength (767 MPa) of the dissimilar
material.
Since Since
welding welding residual stresses commonly become crack driving factors in the welded
material. Sinceresidual
welding stresses
residual commonly
stresses become
commonly crack drivingcrack
become factors in the factors
driving weldedin structure,
the welded it is
structure,
very it
important is very
to important
take into to take
account into account
welding welding
residual residual
stresses for stresses
safe designfor safe
of design
welded of welded
structures.
structure, it is very important to take into account welding residual stresses for safe design of welded
structures.
However, However, as above,
mentioned sinceabove, since welding residual
werestresses
relievedwere relieved during
structures.asHowever,
mentioned as mentioned welding
above, residual
since weldingstresses
residual stresses during
were fabrication
relieved during of
fabrication
fatigue of fatigue
specimen, it specimen,
is difficult ittoisassess
difficult
the toeffect
assessofthe effect ofresidual
welding weldingstress
residualon stress
fatigue onstrength
fatigue
fabrication of fatigue specimen, it is difficult to assess the effect of welding residual stress on fatigue
strength
from from12.
Figure Figure
In this12. In this study,
study, stress stress
rangerange including
including welding welding residual
residual stresses
stresses waswas calculated
calculated by
strength from Figure 12. In this study, stress range including welding residual stresses was calculated
by modified
modified Goodman
Goodman equation
equation represented
represented by
by EquationEquation (9).
(9). Figure Figure 12
12 shows shows
comparisoncomparison of stress
of stressofranges
by modified Goodman equation represented by Equation (9). Figure 12 shows comparison stress
ranges
includingincluding and not including the welding residual stress. Stress ranges (σa) that do not include
ranges including and not including the welding residual stress. Stress ranges (σa) that do include
and not including the welding residual stress. Stress ranges (σ a ) that do not not include the
the welding
welding residual
residual stressesstresses
are 14%are higher
14% higher
than than that
those those that include
include the theofeffect
effect weldingof welding
residual residual
stresses.
the welding residual stresses are 14% higher than those that include the effect of welding residual
stresses.
The The low
low stress stress
range limitrange limit not including
not including the residual thestresses
residual stresses
was was 276.1
276.1 MPa. The low MPa. Therange
stress low stress
limit
stresses. The low stress range limit not including the residual stresses was 276.1 MPa. The low stress
range limit
including theincluding
welding the welding
residual stress residual
was stress
predicted was
to bepredicted
206.9 MPa. to be
This 206.9
means MPa.
that This
welding means that
residual
range limit including the welding residual stress was predicted to be 206.9 MPa. This means that
welding
stresses residual stresses should be taken into account for fatigue design of the welded structure.
weldingshould
residual bestresses
taken into account
should for fatigue
be taken design for
into account of the welded
fatigue structure.
design of the welded structure.
Metals 2018, 8, 21 10 of 11
Metals 2018, 8, 21 10 of 12

Figure 12.
Figure Comparison of
12. Comparison ∆σ-Nf relations.
of Δσ-Nf relations.

5.
5. Conclusions
Conclusions
In
In this study,
study,weweinvestigated
investigatedresidual
residual stresses
stresses of of multi-pass
multi-pass dissimilar
dissimilar material
material welded
welded joint joint
both
both experimentally
experimentally and byand by numerical
numerical simulation.
simulation. FatigueFatigue life assessment
life assessment of the dissimilar
of the dissimilar materialmaterial
welded
welded
joint was joint
alsowas also out.
carried carried
Ourout. Our conclusions
conclusions are summarized
are summarized in the following:
in the following:
(1)
(1) Welding
Weldingresidual
residual stresses
stresses at
at the
the weld
weld of
of dissimilar
dissimilar welded
welded joint
joint distributed
distributed complicatedly
complicatedly on on
longitudinal and transverse directions. Results of numerical and experimental analysis
longitudinal and transverse directions. Results of numerical and experimental analysis showed a showed
agood
goodagreement
agreementqualitatively.
qualitatively.
(2)
(2) Numerical and experimentalpeak
Numerical and experimental peakvalues
valuesofofwelding
weldingresidual
residual stresses
stresses at
at HAZ
HAZ ofof the
the weld
weld on
on the
the
12Cr steel side were predicted to be 333 and 282 MPa HAZ, respectively.
12Cr steel side were predicted to be 333 and 282 MPa HAZ, respectively.
(3)
(3) The
Thelow
lowfatigue
fatiguelimit
limitof
ofdissimilar
dissimilarmaterial
materialwelded
weldedjoint
jointwas
was assessed
assessedtoto be
be 306.8
306.8 MPa,
MPa, which
which
was 40% of tensile strength (767 MPa).
was 40% of tensile strength (767 MPa).
(4) Stress range values without including welding residual stresses were 14% higher than those
(4) Stress range values without including welding residual stresses were 14% higher than those
calculated by including the effect of residual stresses.
calculated by including the effect of residual stresses.
Acknowledgments: This work was supported by the Reliability Evaluation Lab of the Mechanical Engineering
Acknowledgments:
Department, This work
Sungkyunkwan was supported
University, byKorea.
Suwon, the Reliability Evaluation Lab of the Mechanical Engineering
Department, Sungkyunkwan University, Suwon, Korea.
Author Contributions: H.W.A. conceived and designed the experiments; H.W.A. and J.H.H. performed the
Author Contributions: H.W.A. conceived and designed the experiments; H.W.A. and J.H.H. performed the
experiments and analyzed the data under the supervision of D.H.B. All experiments were performed in
experiments and analyzed the data under the supervision of D.H.B. All experiments were performed in
Sungkyunkwan
Sungkyunkwan University,
University, Korea;
Korea; H.W.A. wrote the
H.W.A. wrote the paper.
paper.

Conflicts
Conflicts of Interest: The authors have no conflict of interest to disclose.

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