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Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Weldability of AISI 430/AISI 1030 Steel Couples


via the Synergic Controlled Pulsed (GMAW-P) and
Manual Gas Metal Arc (GMAW) Welding Techniques
Tanju Teker & Turhan Kurun
To cite this article: Tanju Teker & Turhan Kurun (2011) Weldability of AISI 430/AISI 1030
Steel Couples via the Synergic Controlled Pulsed (GMAW-P) and Manual Gas Metal Arc
(GMAW) Welding Techniques, Materials and Manufacturing Processes, 26:7, 926-932, DOI:
10.1080/10426914.2011.551909
To link to this article: http://dx.doi.org/10.1080/10426914.2011.551909

Published online: 27 Jun 2011.

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Date: 21 July 2016, At: 17:14

Materials and Manufacturing Processes, 26: 926932, 2011


Copyright Taylor & Francis Group, LLC
ISSN: 1042-6914 print/1532-2475 online
DOI: 10.1080/10426914.2011.551909

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Weldability of AISI 430/AISI 1030 Steel Couples


via the Synergic Controlled Pulsed (GMAW-P) and
Manual Gas Metal Arc (GMAW) Welding Techniques
Tanju Teker1 and Turhan Kursun2
2

1
Frat University, Technical Education Faculty, Elazg , Turkey
Cumhuriyet University, Sivas Vocational High School, Sivas, Turkey

In this study, ferritic stainless steel (AISI 430)/medium-carbon steel (AISI 1030) couples, having two different properties of 10 mm thick, were
welded by using the synergic controlled pulsed (GMAW-P) and manual gas metal arc welding (GMAW) techniques. Constant wire feed speed,
voltage, welding speed, and gas ow rates (3.2 m/min, 22.5 V, 4 mm/s, 16 L/min) were used in these techniques. The interface appearances of
the welded samples were examined by optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectrometry (EDS),
and X-Ray diffraction (XRD). In order to determine mechanical properties of samples, the tensile and microhardness tests were conducted. The
GMAW-P joints of AISI 430/AISI 1030 steel couples showed superior tensile strength, less grain growth, and narrower heat affected zone (HAZ)
when compared with GMAW joints, and this was mainly due to lower heat input, ner fusion zone grain, and higher fusion hardness.
Keywords GMAW-P; Mechanical; Welding.

automotive industry, food industry, architecture, kitchen


equipment, wash boiler, and drying chamber. FSS contain
16%30% Cr. This ratio depends on alloy elements.
The heat of welding leads to grain coarsening and
carbide precipitation in the heat-affected zone (HAZ) above
950 C. The grain coarsening and carbide precipitation
affect mechanical properties in a bad way of joint in
the weld metal of FSS. As they solidify directly from
the liquid to the ferrite phase without any intermediate
phase transformation. In general, the ductility of FSS
welds is reported to be low due to large grain size
of the fusion zone. A general premise to increase the
fracture toughness of engineering steel is to ensure that the
steel is characterized by ne-scale microstructure that is
favorable and contains minimum harmful effects that can
be induced by grain boundary precipitation or segregation
of detrimental elements or inclusions, to name a few. Grain
size reduction in weld zones confers the advantage of
an improvement in mechanical properties. Because grain
renement has an advantage of markedly increasing strength
as well as improving toughness of materials. It is therefore
recommended that these alloys are welded with a low heat
input [48].
AISI 1030 steel contains about 0.30% carbon and
a relatively low percentage of manganese has good
weldability. Medium-carbon steels are used extensively in
machinery and tools. Often these steels are selected for their
wear resistance rather than high strength, and their parts
frequently must be heat treated to meet in-service strength
requirements [9].
In conclusion, joining of FSS is faced with the problem
of coarse grains in the fusion zone and, consequently,
low toughness and ductility due to the absence of phase
transformation during which grain renement can occur.

Introduction
The joining of dissimilar metals is generally more
challenging than that of similar metals because of difference
in the physical, mechanical, and metallurgical properties
of the parent metals to be joined. In order to take
full advantage of properties of different metals it is
necessary to produce high quality joints between them. The
most widely used metal underpinning modern industry is
carbon steel. Stainless steels designed to increase corrosion
resistance (excellent stress corrosion cracking resistance
and good resistance to pitting and crevice corrosion
in chloride environments) and oxidation resistances are
extensively used in the manufacture of thermal nuclear
power plants, chemical plants, etc. An extremely important
and unavoidable practical requirement in modern steel
construction technology is to be able to perform dissimilar
welding of stainless steel to carbon steel. In this case, it is
necessary to join AISI 430 to AISI 1030 [13].
Ferritic stainless steels (FSS) are iron-chromium carbon
alloys with sufcient chromium or chromium plus another
ferrite stabilizer, such as aluminum, niobium, molybdenum,
or titanium, to inhibit the formation of austenite on heating.
The pressure vessel and piping applications of FSS are
listed under the American Society of Mechanical Engineers
(ASME) codes. FSS are used commonly due to their
good corrosion resistance, easy formation property, and
signicant economic advantage with regard to austenitic
in many environments. Furthermore they are used in

Received March 8, 2010; Accepted December 31, 2010


Address correspondence to Turhan Kursun, Cumhuriyet University,
Sivas Vocational High School, Sivas, Turkey; E-mail: tkursun@
cumhuriyet.edu.tr

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WELDABILITY OF AISI 430/AISI 1030 STEEL COUPLES

927

It is therefore recommended that these metals are welded


with a low heat input. For this reason, one of the main
requirements for the welding procedure designed in this
work was to choose the most suitable welding technique [1].
Fusion welding is an ideal and economical means of
achieving good productivity. Fusion welding through gas
metal arc welding (GMAW) is achieved by coalescence
of metals by melting continuously fed current-carrying
wire. Its wide popularity is due to practical advantages
offered like continuously fed electrode, ux free operation,
relatively low operator skills required, and ease of
automation. GMAW can weld wide range of metals and
welding in any positions possible. GMAW is also widely
used by the sheet metal industry, due to its high efciency
and suitability in automated processes. GMAW is used on
all thicknesses of steels, aluminum, nickel, stainless steels,
etc. The GMAW is suitable both for steel and unalloyed,
low-alloy, and high-alloy based materials. On the other
hand, the process of GMAW is used for welding aluminum
and copper materials. But the quality of weld obtained
from GMAW depends on various welding parameters
like voltage, current, etc. Various welding parameters
inuence transfer mode in GMAW that inuences weld
quality. Hence, in a welding system, principal sources of
disturbances are welding parameters, which need constant
control and adjustment to achieve best quality. At relatively
low currents, GMAW operates in the globular metal transfer
mode. It is characterized by periodic formation of big
droplets at the end of electrodes, which detach due to
gravitational force into the weld pool. This metal transfer
mode suffers from lack of control over molten droplets
and arc instability due to formation of big droplets. At
higher currents, the process transits to spray mode. This
mode offers high deposition rate but due to tapering of
electrode smaller diameter drops are formed. Continuous
metal deposition, in form of drops, produces smooth bead
and stiffer arc. Drawbacks of this metal transfer mode
are: Minimum current for spray modes being too high for
some materials, large heat input to work piece, wide bead,
and only down hand positional capability. In recent years,
extensive research has been performed on pulsed current
welding technique. Synergic controlled pulsed welding
(GMAW-P) is being increasingly used for joining wide
variety of ferrous and non-ferrous materials in industries due
to its inherent advantages, such as deep penetration, smooth
weld bead, high welding speed, large metal deposition
rate, lower spatter, lower distortion, and lesser probability
of porosity fusion defects. For GMAW-P, it is generally
not easy and time consuming to establish usable working
pulse condition by trial and error when adjusting pulse
parameters. For achieving controlled transfer during pulse
welding, it is essential that wire feed rate is balanced by burn
rate. This means achieving one drop per pulse condition
all the time, which involves constant control of all the
pulse parameters. Synergic control is dened as any system
by which pulse parameters (or wire feed speed) can be
manipulated to achieve equilibrium over a wide range of
wire feed speeds (or mean current levels). This mode of
metal transfer overcomes the drawbacks of globular mode
while achieving the benets of spray transfer. This mode
is characterized by pulsing of current between low-level

background current and high-level peak current in such a


way that mean current is always below the threshold level
of spray transfer. The purpose of background current is to
maintain arc where the peak currents are long enough to
make sure detachment of the molten droplet [1012].
In this study, two welding processes, namely, GMAW
and GMAW-P, were employed in joining of AISI 430/AISI
1030 steel couples.
Experimental procedure
Ten-millimeter thick AISI 430/AISI 1030 steel couples
were used as test materials. The chemical compositions and
the mechanical properties of the welded materials are given
in Tables 1 and 2. Welding was performed with a GMA
mechanized unit (MIGATRONIK, KME 400 type), using
a 1 mm diameter AISI 316L welding wire. The mixture of
Ar + 2% O2 gas was used as shielding gas. Prior to welding,
the plates were thoroughly cleaned to remove the oxide
layer and any dirt or grease adherent to the V-groove (60
groove angle) surface. An arc voltage of 22.5 V, a welding
speed of 4 mm/s, a wire feeding speed of 3.2 m/min, and
a constant gas ow rate of 16 L/min were selected. The
welding was carried out by lling the weld groove in multipasses (2 passes) at the top and single pass at the bottom of
each of them (Fig. 1).
After welding, cross-sectional samples were cut to
analyze their microstructures and microhardness values.

Table 1.The chemical compositions of the welded materials.


Chemical Composition (%)
Samples

Fe

AISI1030
AISI 430
AISI316L

Balance
Balance
Balance

Cr

Ni

Si

Mo

Mn

16.02
18

0.267
0.048
0.03

0.22
12

0.177
0.44
0.7

0.016
2.5

0.053
0.002

1.13
0.610
0.8

Table 2.The mechanical properties of the welded materials.


Samples

AISI 430
AISI 1030

Tensile strength (N/mm2 )

% Elongation (mm)

Hardness (HV)

485
463.7

25
31.2

82
133

Figure 1.The macro-appearance of welded AISI 430/AISI 1030 steel


couples.

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T. TEKER AND T. KURSUN

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Figure 2.Tensile test specimen [11].

All weld samples were polished using a grit sequence


of 200, 400, 600, 800, 1000, and 1200. These samples
were further polished using cloth and polishing solution
of 3 m diamond paste. AISI 430 side of samples were
etched by electrolytic etching method with 30% HCl +

Figure 3.Microstructure of the S1 sample: (a) side of AISI 1030; (b) weld
metal; and (c) side of AISI 430 and transition zone.

10% HNO3 + 30% pure water and 12 V in 25 s. AISI 1030


side of samples were etched by chemical etching method
with 2% HNO3 + 98% pure alcohol in 23 s. The interface
appearances of the etched samples were then examined by
optical microscopy (OM) and scanning electron microscopy
(SEM), with attachment of energy dispersive spectrometry
(EDS).
In this study, LEO, EVO 40XVP model SEM was used.
At the same time, the breaking off surfaces of tensile
specimens was examined by SEM. EDS analysis was done
by BRUKER 125 eV type device to pick up the elementary
contents of phases which were formed at the interface
appearance of the welded samples. SHIMADZU XRD-6000
type X-ray analysis device was used to pick up the phases
and compounds which occurred at the welded samples.
The mechanical properties of the weldments were
evaluated by means of tensile, microhardness tests. Standard

Figure 4.Microstructure of the S2 sample: (a) side of AISI 1030; (b) weld
metal; and (c) side of AISI 430 and transition zone.

929

tensile specimens were prepared according to the EN100021:1996 (Fig. 2). The specimens were removed from the
materials in such a way that the weld was located in the
center of each specimen, and the samples were machined
transverse to the welding direction. The tensile tests were
carried on a HOUNSFIELD (50000 N) tensile test machine
at a cross head speed of 2 mm/min. The microhardness
of weld metal and the HAZ were measured with a Leica
MHF-10 microhardness test machine at different points by
Vickers microhardness method. A 200 g load was used in
the measurement.

Result and discussion


Metallographic Examination
The dissimilar AISI 430/AISI1030 metal combination
was welded by GMAW (S1) and GMAW-P (S2) techniques.
S1 and S2 joints exhibited uniform bead appearance and
generally narrow HAZ. HAZ measured 7 mm for S1 and

Figure 5.SEM microstructure of the S1 sample: (a) side of AISI 1030;


(b) weld metal; and (c) side of AISI 430 and transition zone (color gure
available online).

Figure 6.SEM microstructure of the S2 sample: (a) side of AISI 1030;


(b) weld metal; and (c) side of AISI 430 and transition zone (color gure
available online).

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WELDABILITY OF AISI 430/AISI 1030 STEEL COUPLES

930

T. TEKER AND T. KURSUN

microstructure of these combinations consists of many


acicular ferrite islets just near the weld metal and many
widmanstatten ferrite in the grain-growth zone, starting from
grain boundary at the AISI 1030 side of S1 and S2 samples.
There are also intensive Crx Cy yields in grain inner and grain
boundary at grain-growth zone at the AISI 430 side of S1 and
S2 samples. Solidication was formed as dendritic according

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5 mm for S2 samples. S2 joints of AISI 430/AISI 1030 steel


couples showed narrower HAZ when compared with S1
joints, and this mainly was due to lower heat input.
Observation by optical indicated that both GMAW (S1)
and GMAW-P (S2) produced fusion zones with marked grain
growth microstructure as shown Figs. 3 and 4, respectively.
But grain growth was more pronounced for GMAW. The

Figure 7.EDS analysis of S2 sample (color gure available online).

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WELDABILITY OF AISI 430/AISI 1030 STEEL COUPLES

Figure 8.XRD analysis of S2 sample.


Figure 9.Microhardness graphics of S1-S2 samples.

to the microstructure of weld metal. SEM micrographs of


AISI 430/AISI 1030 steel couples in weld metal are shown
in Figs. 5 and 6. According to Fig. 7, there are chromium and
carbon diffusions from the AISI 430 side to the AISI 1030
side. Austenite, Cr23 C6 , and Cr7 C3 yields were determined in
the XRD analysis of S2 sample (Fig. 8).
Hardness Measurement
Hardness measurements were performed on fusion zones
of S1 and S2 weldments. Figure 9 presents hardness proles
across S1 and S2 weldments. As seen from Fig. 9, the
hardness of weld metal is higher than HAZ and base metal
for S1 and S2 weldments. This could be due to the transition
chromium atoms which were diffused from AISI 430 side
to AISI 1030 side. The maximum hardness of weld metals
was measured approximately 298 HV for S1 and 394 HV for
S2 weldment. Results showed that hardness of weldments
which was obtained from GMAW (S1) and GMAW-P (S2)
were different. It was noticed that, hardness of the S2 weld
metals HAZ was found higher than S1 weld metal and HAZ.
Especially the weld metal hardness of S2 joint 96 HV was
lower than S1 joint. This mainly was due to lower heat input
and ner fusion zone grain, because S2 weldment has ne
rened grains and a little bit martensite structure. The higher
hardness values in weld metal and HAZ could be due to
the chromium-carbide phases and quick cooling. This can
mainly be attributed to the formation of martensite structure.
Tensile Properties
The percentage of elongation and tensile strength of
welded joints of GMAW (S1) and GMAW-P (S2) were
evaluated. In each condition, three specimens were tested,
and average of three values is presented in results. The S2
joints of AISI 430/AISI 1030 steel couples showed superior
tensile strength as well as elongation when compared
with S1 joints. The elongation of S1 and S2 joints are,
respectively, 3.306% and 9.667%. However, the elongation
of S2 joints is (9.667%) higher than S1 joints, both of S1
and S2 weldments did not show ductile fracture behavior.
The tensile strength of S1 and S2 joints are, respectively,
268 N/mm2 and 554 N/mm2 . During the tensile testing, all
test samples were fractured from AISI 1030 side. This could
be due to the martensite transformation and grain growth in
AISI 1030 side, because ductility and toughness decrease

with the increase of austenite content and quick cooling.


The highest tensile strength was evaluated from S2 samples.
As a result, S2 joints of AISI 430/AISI 1030 steel couples
showed superior tensile strength when compared to S1
joints, and this was mainly due to the lower heat input, ller
metal, ner fusion zone grain, and higher fusion hardness.
There seems to be a connection between fusion hardness
and tensile strength. The joining of dissimilar materials is
generally more challenging that of similar materials because
of differences in the physical, chemical, and mechanical
properties of the base metals. These differences may also
complicate the selection of ller metals compatible to base
metals. The main reasons for the enhancement in the tensile
strength at S2 samples are welding method (GMAW-P)
and AISI 316L austenitic welding ller metal. GMAW-P
supplies lower heat input and less carbide precipitation.
AISI 316 L austenitic welding ller metal has ferrite content
and approximately 600 N/mm2 tensile strength.
SEM Fractography of Tensile Test Specimens
Fracture surfaces of tensile tested specimens of S1 and
S2 joints were examined, using SEM to reveal the fracture
surface morphology. However, dimple size is much ner
in S1 joints compared to S2 joints; it is clear that the
fractured surfaces of S1 and S2 joints generally displayed
heterogeneous distribution and brittle breaking mechanism.
But S2 joints exhibit predominantly ductile features, while
the fusion welds exhibit cleavage fracture. The cleavage
fracture size is smaller in the low heat input.
Conclusions
The following conclusions have been drawn concerning
weldability of AISI 430/AISI 1030 steel couples via the
GMAW-P and GMAW techniques:
1. GMAW-P joints of AISI 430/AISI 1030 steel couples
exhibit narrower HAZ and less grain growth compared
to GMAW joints.
2. GMAW-P technique achieves reduced heat input in
welding of AISI 430/AISI 1030 steel couples.
3. GMAW-P joints of AISI 430/AISI 1030 steel couples
exhibit superior tensile strength and hardness compared
to GMAW joints.

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T. TEKER AND T. KURSUN

4. Excessive grain growth is avoided by using GMAWP technique in welding of AISI 430/AISI 1030 steel
couples.
5. Joining of 10 mm thick AISI 430/AISI 1030 steel couples
is accomplished by GMAW-P technique.

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