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Study on the microstructure, mechanical properties and corrosion behaviour

of S355JR/316L dissimilar welded joint prepared by gas tungsten arc welding
multi-pass welding process

Article in Science and Technology of Welding & Joining · April 2016

DOI: 10.1080/13621718.2015.1122152

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 Science and Technology of Welding and Joining

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Study on the microstructure, mechanical

properties and corrosion behaviour of S355JR/316L
dissimilar welded joint prepared by gas tungsten
arc welding multi-pass welding process

B.-S. Huang, J. Yang, D.-H. Lu & W.-J. Bin

To cite this article: B.-S. Huang, J. Yang, D.-H. Lu & W.-J. Bin (2016) Study on the microstructure,
mechanical properties and corrosion behaviour of S355JR/316L dissimilar welded joint prepared
by gas tungsten arc welding multi-pass welding process, Science and Technology of Welding and
Joining, 21:5, 381-388, DOI: 10.1080/13621718.2015.1122152

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 Study on the microstructure, mechanical
properties and corrosion behaviour of S355JR/
316L dissimilar welded joint prepared by gas
tungsten arc welding multi-pass welding
process
B.-S. Huang1, J. Yang1∗ , D.-H. Lu2 and W.-J. Bin3
In this study, the joints of dissimilar materials between S355JR carbon steel and 316L stainless
Downloaded by [Dalian University of Technology] at 19:12 20 November 2017

steel were welded by gas tungsten arc welding (GTAW) multi-pass welding process.
Characterisations of microstructure, mechanical properties and corrosion behaviours of
dissimilar joint were investigated. The experimental results reveal that the microstructure of weld
metal (WM) is austenite and vermiform δ-ferrite, and they cross-distribute in the weld seam.
Moreover, there is a decarburisation layer on the interface of S355JR/WM, but the detrimental
phase σ and M23C6 (chromium carbide) are not observed in the WM through X-ray diffraction.
The fracture of the S355JR/316L welded joints always occurs in the S355JR heat affected zone
during tensile test. Mechanical properties of the welded joints prepared by GTAW can meet the
requirements of engineering application. The electrochemical corrosion test is also indicates that
the corrosion resistance of WM decreases compared with the 316L base material. The corrosion
products of S355JR/316L dissimilar welded joints in 3.5 wt-% NaCl aqueous solution mainly are
α-Fe and FeOOH.
Keywords: Carbon steel, Austenitic stainless steel, Dissimilar welding, Microstructure, Mechanical properties, Corrosion mechanism

Introduction is employed in most of the structure of oil extraction

and transportation that will improve the production
With the increasing demand in recent decades for energy cost. Based on the various components operate at differ-
of the whole world, the exploitation of oil and natural gas ent service conditions in the petrochemical industry, com-
is growing. The complex oil and gas fields which is rich in ponents operating at corrosive environment are made of
any kind of corrosive mediums have appeared one after stainless steels and those operating at normal circum-
another, which lead to the corrosion problem of equip- stances are made of ordinary steels, respectively. Thus,
ment being more serious during the drilling operation dissimilar joints are inevitable for connecting the com-
and long-distance transport by pipeline.1,2 Therefore, ponents with different materials.6
how to safely and effectively carry out the exploitation At present, dissimilar steel welding components are
and transportation of corrosive oil and gas becomes the extensively employed in the steam lines of power plants,
primary problem. AISI 316 type is a typical austenitic nuclear power plants, petrochemical plants, oil–gas pipe-
stainless steel, and modified 316 steel is also known as lines and so on, because of the effective and economical
316L steel. It is widely used in chemical, petrochemical, utilisation of the different mechanical properties of
power engineering and aerospace industry as structure every steel.7–15 Especially, the dissimilar welded joints
material for its good resistance to high-temperature between austenitic stainless steel and carbon steel in var-
creep and corrosion.3–5 However, if 316L stainless steel ious structures are widely applied, such as pressure vessels,
offshore, spacecraft, etc.12 Among them, S355JR and
316L steels are the typical representatives of carbon steels
1
School of Materials Science and Engineering, Southwest Petroleum and austenitic stainless steels, respectively. The joints of
University, Chengdu 610500, China
2
S355JR and 316L dissimilar steel not only meet the
Third Engineering Branch, China Petroleum Pipeline Bureau, Zhengzhou
450000, China
requirements of the service environment mentioned in
3
Petroleum and Petrochemical equipment four plant, Daqing Oilfield the previous but also reduce the production cost. How-
Construction Group Building Materials Company, Daqing 163000, China ever, it is well known that the welding of dissimilar
∗
Corresponding author, email [email protected] materials is much more complicated than that of welding

© 2016 Institute of Materials, Minerals and Mining

Published by Taylor & Francis on behalf of the Institute
DOI 10.1080/13621718.2015.1122152 Science and Technology of Welding and Joining 2016 VOL 21 NO 5 381
 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

Table 1 Chemical composition of welding wires and base metals (wt-%)

Materials C Si Mn S P Ni Cr Mo Cu Fe

S355JR 0.185 0.270 1.540 0.030 0.030 … … … … Bal.

316L 0.020 0.960 1.860 0.023 0.027 12.340 16.770 2.290 … Bal.
ER309L 0.026 0.38 2.11 0.008 0.017 12.50 23.50 0.20 0.07 Bal.

1 Geometry and weld sequence of the employed dissimilar welded joint

similar ones in welding mechanism and operation tech- Materials and experimental procedure
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nology, because of the significant discrepancies existing

among in the physical properties, chemical composition, Experimental materials and welding process
mechanical properties and microstructure of the base The base materials used in this research are S355JR UNI
materials. Moreover, these differences also make great EN 10025 low carbon steel and AISI 316L austenitic
effect on the physical and chemical properties of dissimi- stainless steel, with the dimension of 200 mm × 100
lar joints. During the welding process, the weld joints mm × 12 mm, respectively. The filler materials are
between carbon steel and stainless steel exhibit a number ER309L with the diameter of 2.4 mm, and their chemical
of limitations: (a) losing of carbon by migration and dif- compositions are listed in Table 1. The welded joint was
fusion of carbon in S355JR heat affected zone (HAZ) and prepared by gas tungsten arc welding (GTAW) with 7-
subsequent formation of harmful phase or secondary pass welding process. Figure 1 shows the geometrical
phase in weld metal (WM), (b) dilution of alloying shape and dimensions of the employed dissimilar joint,
elements in the WM zone and (c) grain growth takes single-V groove with 75° is used, and the sequence of
place in HAZ, which leads to the significant deterioration welding pass and the dimensional details of the groove
in mechanical properties and corrosion resistance of weld are also shown in Fig. 1. During the experiments, the
seam. inter-pass temperature is approximately 50°C. The weld-
In order to solve these problems, several studies on dis- ing conditions for each pass are given in Table 2.
similar joints between carbon steel and stainless steel have Before welding, the oxide on the upper surface and
been carried out.7,8,16–19 Wu et al.7 investigated that the lower surface was removed with the 800Cw waterproof
microstructure, mechanical properties and corrosion abrasive paper, and surface impurities and contamination
behaviour of dissimilar welded joints between ferritic were eliminated through chemical method with acetone.
stainless steel and low carbon steel prepared by laser During the welding process, a pure argon shielding gas
beam with the welding speed of 12 and 24 mm s–1, was employed to avoid the oxidation of WM surface
respectively, are different. As the welding speed increases, and the flow rate is 12 L min–1.
HAZ of carbon steel becomes narrower and higher hard-
ness of weld seam close to ferritic stainless steel side is
obtained. Torkamany et al.16 studied the metallurgical Microstructure observation
and mechanical characterisation of dissimilar spot weld In order to observe and analyse the microstructure fea-
between low carbon and austenitic stainless steel. Poura- tures under the optical microscope, SEM, energy-disper-
liakbar et al.17 investigated the microstructure and mech- sive spectroscopy (EDS) and X-ray diffraction (XRD).
anical properties of CK45 carbon steel and 304 stainless Specimens were cut down perpendicular to the weld
steel dissimilar joints, and they also investigated the seam, and then the conventional metallographic methods
effects of different post-weld heat treatment (PWHT) on were used with final 5000Cw waterproof abrasive paper
dissimilar joint. Their results show that the structure of milling and 12000Cw polishing. Due to the difference of
WM is completely austenitic, and the carbides M23C6 is corrosion resistance, two etchants were selected to reveal
observed in the WM. Simultaneous, both grain growth the microstructure of dissimilar welded joint. The
and carbides precipitation occur during PWHT. S355JR carbon steel was etched by the solution of 4%
Until now, as for the S355JR/316L dissimilar welded Nital, while 316L stainless steel and WM were etched
joints, few of literatures discussed it. Therefore, it is very using aqua regia (volume ratio, HCl–HNO3 = 3:1).
important to reduce the risk of oil and gas transportation
and extend the service life of the pipeline. In the present
Table 2 Welding parameters of GTAW for each pass
study, welding experiments and series of tests were per-
formed in order to investigate the microstructural evol- Weld Welding Welding Travelling speed
ution, mechanical properties, composition distribution pass current, I (A) voltage (V) (mm s–1)
near the fusion zone and corrosion behaviour of dissimilar
joints. 7 110–120 12–14 2.0

382 Science and Technology of Welding and Joining 2016 VOL 21 NO 5

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

2 Schematic of the microhardness specimen

Mechanical properties testing of 100 gf and duration time of 15 s. The schematic dia-
The tensile tests were carried out using WDW-1000 with gram of the microhardness specimen is shown in Fig. 2.
the specimens of 5 mm × 10 mm × 120 mm at room temp-
erature. The impact tests were performed by using Electrochemical testing
ZBC2302-D at room temperature with the specimens of The electrochemical corrosion test was carried out by
10 mm × 10 mm × 55 mm. The room temperature tensile using PGSTAS 302N in a conventional three-electrode
and impact tests of the joints were carried out according cell. Corrosion samples from the joints and base materials
to the international standards ISO 6892.1-200920 and
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were cut down with the dimensions of 10 mm × 10 mm ×

ISO 148.1-2010,21 respectively. Microhardness values of 3 mm. The samples were packaged in epoxy resin and just
the joints were measured using HVS-1000 with a load exposed the area of 1 cm2. The working surface was

3 Microstructure of base materials and S355JR/316L dissimilar welded joints: a S355JR; b WM-S355JR junction; c WM; d WM/
316L junction and e 316L

Science and Technology of Welding and Joining 2016 VOL 21 NO 5 383

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

observed by using SEM, as is shown in Fig. 4. SEM

results show that carbon migration closed to the fusion
boundary did occur in S355JR HAZ. EDS was also uti-
lised to explain the carbon migration presented above
and the dilution of alloying elements in the weld zone.
Figure 5 shows the variations of different elements and
the positions of line scanning across the S355JR/WM
interface. From Fig. 5b, the variations of C concentration
decrease in S355JR near the fusion line and increase in
WM closed to fusion boundary. It obviously has a decar-
burised layer and carburised layer. This is due to that the
diffusion of carbon from S355JR to WM during welding,
which is consistent with that of Refs.7,22 Besides, the high
content of Cr in weld seam may promote the diffusion of
carbon from S355JR to the WM.18 From Fig. 5c–d, the
variations in Cr, Mn and Ni content increase across the
4 Microstructure of S355JR/WM interface of dissimilar S355JR/WM interface. However, the Mo content changes
welded joint not significantly.
In general, the multi-pass welding process was per-
formed in the medium or thick plate welding, which is
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burnished with abrasive paper and degreased with prone to form detrimental phase or secondary phase in
acetone. The experiments were carried out in solution of WM, such as σ phase(Fe–Cr compound), M23C6 (chro-
3.5 wt-% NaCl at room temperature with the scan rate mium carbide), ect.17,23 Wherefore, XRD analysis was
of 30 mV min–1. carried out on the WM, and the results are shown in
Fig. 6. From this pattern, it can be observed that there
Results and discussion are α phase, γ phase, Cr2Ni3 and FeNi3 in the WM, but
σ phase and M23C6 (chromium carbide) do not exist,
Microstructure analysis which indicates that the quality of WM is excellent. It is
Figure 3 shows the microstructure of S355JR base benefit to ensure the mechanical properties and corrosion
materials, 316L base materials and the S355JR/316L dis- resistance of dissimilar welded joints and prolong service
similar joints. It can be seen that the microstructure in life of dissimilar welded component.
S355JR steel is composed of ferrite and pearlite (Fig.
3a) and in 316L steel it is clumpy austenite (Fig. 3e). How- Mechanical properties analysis
ever, the microstructure in WM is austenite and vermi-
Tensile properties
form δ-ferrite as shown in Fig. 3c. What is more, it can
see that the microstructure in S355JR HAZ is composed The tensile test results of S355/316L dissimilar welded
of polygonal ferrite, pearlite and a small amount of bai- joint and base materials on both sides at room tempera-
nite (Fig. 3b), and there is an obvious white region in ture are presented in Table 3. It is clear that the average
S355JR HAZ near the weld seam (decarburisation tensile strength of weld joints is 533.4 MPa. Moreover,
layer), which is due to the decomposition of pearlite the average yield strength of weld joints is 390 MPa, it
during the course of welding.18 Furthermore, grain is higher than that of base materials. Because of the
grows to a certain extent on the right side of S355JR cross-distributed of ferrite and austenite in weld seam, it
near the fusion line, while a fine grained region away results in an increasing of the grain boundary and pinning
from fusion line in the HAZ is observed. Because the of dislocation. In addition, fore-pass can provide a pre-
grains close to the fusion line experienced a higher temp- heating treatment to the rear-pass in the multi-pass
erature than those far away. The grains away from the welds. Similarly, the action of rear-pass equals to that of
fusion line were recrystallised and refined.7 The micro- post-heating and the fore-pass. So, it has a positive effect
structure of dissimilar joints WM/316L junction is on improving the strength of WM. Furthermore, it can be
shown in Fig. 3d. As it can be seen, the microstructure seen that the fracture position of all the welded joints
in 316L HAZ is also the clumpy austenite, and compared specimens is located at the HAZ of S355JR steel side,
with Fig. 3e, the grain size changes a little. In addition, it which indicates that the region is still the weakest of the
can be noted that a complex fusion zone with the width of whole welded joint.
about 70 μm width forms on the WM/316L interface. The
fusion zone consists of fine ferrite distributing on the aus- Impact toughness
tenite matrix. Microstructure and mechanical properties Charpy impact tests of S355JR/316L dissimilar joints
are totally different from the WM. The existence of this impact specimens are carried out at room temperature
zone can attribute to the discrepancies of physical proper- according to the international standards ISO 148.1-
ties, chemical composition and mechanical properties 2009. The impact strength values of base materials,
between 316L and the filler materials. In addition, the HAZ of S355JR and 316L, fusion line of welded joints
molten metal lacking of liquidity on the edge of molten and WM are listed in Table 4. Table 4 is the average of
pool near 316L, cause its mechanical agitation weaken the three values. The results show that the average impact
and the liquid residence time shorten, which also leads strength of 316L base material is the highest while the
to the fusion zone forms in the vicinity of fusion line. average impact strength of the WM is the lowest. It can
In order to study the phenomenon of carbon migration be seen that the average impact strength of WM is 98.3
further, microstructure of S355JR/WM interface is J cm–2. Generally, the average impact strength of every

384 Science and Technology of Welding and Joining 2016 VOL 21 NO 5

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour
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5 Schematic diagram of EDS line scanning of S355JR/WM interface and alloying elements distribution chart: a schematic of line
scanning; b carbon; c chromium; d manganese; e nickel and f molybdenum

part on the weld joint should be higher than 53 J cm–2 at impact toughness of dissimilar joints in this experiment
room temperature according to ASTM standard. So the is satisfactory. Moreover, the average impact toughness
of S355JR HAZ and 316L HAZ is lower than that of
their base materials, respectively. Based on the classic
Hall–Petch relationship and previously microstructure
analyses, during the welding process, the grain size in
the HAZs of S355JR and 316L have growth. Meanwhile,
during the austenite–ferrite transformation process, the
mixture of high carbon martensite and residual austenite

Table 3 Tensile properties of base materials and S355JR/

316L dissimilar joint at room temperature

Tensile Yield
strength, strength, Elongation, Fracture
Samples Rm (MPa) Re (MPa) δ (%) position

S355JR 490.7 355 22.3 …

316L 585.6 255 40.2 …
DWJ 533.4 390 25.6 HAZ of
S355JR
side
6 XRD pattern of S355JR/316L dissimilar joint WM Note: Where DWJ is the S355JR/316L dissimilar welded joint.

Science and Technology of Welding and Joining 2016 VOL 21 NO 5 385

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

Table 4 Charpy impact test results of different zones of S355JR/316L dissimilar welded joint at room temperature

V type notch position S355JR BM S355JR HAZ S355JR FL WM 316L FL 316L HAZ 316L BM

αk (J cm–2) 144.1 134.6 130.5 98.3 156.7 162.8 191.5

Note: Where FL is the fusion line of welded joint.

may be formed in the HAZ, namely, granular bainite, carbon migration from the S355JR side to WM during
which can significantly reduce the toughness of the steel. welding forms a decarburised layer mentioned above
Thus, the toughness of the HAZs obviously decreases. and then the grain growth of HAZ during welding. The
Compared with the base materials and the HAZs, the grain growth of HAZ causes the softening of microstruc-
impact toughness of WM is still the lowest. The possible ture, which also leads to the sharp drop of hardness in the
reason is that the diffusion of carbon and alloying vicinity of the fusion line on the S355JR side and 316L
elements to lower the impact toughness of WM. The side. As stated in the earlier, the mechanical properties
non-uniform distribution of microstructure and the of S355JR/316L dissimilar welded joints can meet the
harder microstructure of upper bainite and widmanstat- requirements of engineering application.
ten ferrite formed in WM can also lower the impact
toughness of WM.

Corrosion
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Microhardness In this section, the electrochemical corrosion behaviour of

Figure 7 shows the microhardness of dissimilar welded WM and 316L base material was studied. The used sol-
joints. Generally, microhardness usually implies a resist- ution is 3.5 wt-% NaCl aqueous, namely, simulated sea-
ance to plastic deformation. In the as-welded condition, water environment. Test samples were sealed with epoxy
the microhardness distribution is roughly symmetrical, resin, leaving about 10 mm × 10 mm test area. Figure 8
and the average microhardness of WM is 257.06 HV. shows the potentiodynamic polarisation of WM and
This figure shows that the trend of microhardness 316L base material. The self-corrosion potential and cor-
decreases as the distance between edge and the weld rosion current density are presented in Table 5. From
seam centre increases. Obviously, the microhardness of this figure, 316L base material shows passivity to a certain
the WM is higher than that of the S355JR base material extent, whereas dissimilar welded joints have typical
and the HAZ of S355JR, which attributes to the differ- characteristics of active dissolution in 3.5% NaCl aqueous
ences in chemical composition and properties. Simul- solution. In general, the higher the corrosion current den-
taneously, the microhardness of the WM is higher than sity and the smaller the self-corrosion potential is, the
that of the 316L base material and the HAZ of 316L, weaker the corrosion resistance of the metallic materials
because of the fast heating and cooling rate of the WM is. So, both Fig. 8 and Table 5 show that 316L base material
during the welding process. Then, it leads to the formation has a higher self-corrosion potential of –438 mV and lower
of martensite-like and the increase of grain size in HAZ corrosion current density of 0.3018 × 10–5 A cm–2.
for the thermal circle. Similar results are reported in Whereas, dissimilar welded joint has a lower self-corrosion
Refs.7,13 It can be noted that the maximum hardness is potential of –518 mV and higher corrosion current density
approximately 268 HV at the fusion line of S355JR side. of 0.8123 × 10–5 A cm–2. Therefore, corrosion resistance
The reason is probably the inhomogeneous distribution of 316L base material is better than that of WM in 3.5%
of microstructure and chemical composition and there is NaCl aqueous solution. This is due to the dilution and
a carburised layer in the vicinity of the fusion line of loss of alloying elements in the course of welding, and gal-
S355JR side. It can also be seen that point A is the mini- vanic interaction with S355JR and 316L.
mum hardness in the S355JR side HAZ. Because the

8 Polarisation curves of WM and 316L base materials in

7 Microhardness of S355JR/316L dissimilar joints 3.5% NaCl aqueous solution

386 Science and Technology of Welding and Joining 2016 VOL 21 NO 5

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

Table 5 The corrosion current density and corrosion

potential of S355JR/316L dissimilar joint WM and 316L base
materials in 3.5% NaCl aqueous solution

Corrosion current Corrosion potential,

Samples density, Icorr (A cm–2) Ecorr (mV)

S355JR/ 0.8123×10-5 −518

316L WM
316L BM 0.3018×10-5 −438

11 XRD pattern of dissimilar joint WMs after electrochemical

corrosion test
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and NaCl. Generally, Fe + 3O(OH) is a kind of

FeOOH. In the presence of two kinds of stable crystal
forms, the goethite (α-FeOOH) and the lepidocrocite
(γ-FeOOH). In the corrosion products of Fe, FeO has
the highest Gibbs free energy which belong to the thermo-
dynamics unstable phase and will preferentially form
9 SEM morphologies of corrosion product film of WM after during the corrosion process. According to the above
electrochemical corrosion test state and analysis, it can be known that the Fe matrix is
oxidised to Fe2+ and then generates an instable FeO
In order to further understand the corrosion mechan- and Fe(OH)2 in NaCl aqueous solution. As the corrosion
ism of WM in the NaCl solution, the microstructure of continued, Fe2+ further oxidised to Fe3+ and forms
corrosion product film of WM is observed. The SEM γ-FeOOH and α-FeOOH. Due to the α-FeOOH have a
morphologies of corrosion product film are shown in good continuity, compactness and non-conductivity, it
Fig. 9. Meanwhile, EDS was also utilised to analyse the can ensure that the corrosion process is carried out on
corrosion product film components, and the correspond- the matrix and corrosion product interface and avoid
ing results are presented in Fig. 10. From Fig. 9, it can the re-etching of metal matrix.
be seen that the surface of the specimen is completely cov-
ered by the corrosion product film. Cracks and white par-
ticles are observed on the product film. Initial estimates Conclusions
the white particles are NaCl, while the crack is spreading (i) The microstructure of WM consists of austenite and
from the centre to the periphery. EDS results indicate that vermiform δ-ferrite, and the microstructure in
the corrosion product film contains C, O, Al, Si, S, Cl and S355JR HAZ is composed of polygonal ferrite, pear-
Fe elements. Elements Fe and O are on the top of the list. lite and a small amount of bainite. Decarburisation
So, the corrosion product film may be Fe2O3 or Fe3O4 or layer is observed at the interface of S355JR/WM.
the mixture of them, namely FexOy. A complex fusion zone is formed at the junction of
Nevertheless, EDS is not accurate for the measurement 316L HAZ/WM with the width about 70 μm. The
of light elements, such as hydrogen, carbon and so on. fusion zone is made of fine ferrite distributed on
XRD analysis was performed on the corrosion product the austenite matrix. There are α phase, γ phase,
film, and the spectra results are shown in Fig. 11. From Cr2Ni3 and FeNi3 in WMs, while σ phase and
this figure, it can be confirmed that the phases are primar- M23C6 (chromium carbide) are not observed in the
ily α-Fe with the corrosion products of S, Fe + 3O(OH) current case.

10 EDS analysis of corrosion product film components: a spot scanning position and b energy spectrum analysis results

Science and Technology of Welding and Joining 2016 VOL 21 NO 5 387

 Huang et al. Study on the microstructure, mechanical properties and corrosion behaviour

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388 Science and Technology of Welding and Joining 2016 VOL 21 NO 5

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