Abstract
In this work, two graded transition interlayers were designed using a CALPHAD-based ICME framework (CALPHAD: Calculation of Phase Diagrams; ICME: Integrated Computational Materials Engineering) for joining Inconel 740H superalloy with P91 steel. Successful builds with the designed interlayers (content of P91 steel are 60 and 85 wt.%) sandwiched between the constituent materials were fabricated using wire-arc additive manufacturing. 60% P91 interlayer exhibited an FCC structure with low hardness, while the 85% P91 interlayer had a martensitic structure with high hardness. A two-step post-heat treatment consisting of homogenization at 1150°C and aging at 760°C was designed. 60% P91 interlayer showed no improvement in hardness after aging. It agrees with the CALPHAD modeling that predicts a lack of effective strengthening precipitates at 760°C, whereas the hardness of 85% P91 increased significantly after aging for 8 h due to the precipitation of the M23C6 phase. Mechanical tests equipped with digital image correlation were performed to determine the location of the failure and tensile properties. As-built and heat treated 60% P91 build failed in the graded alloy block, whereas the as-built 85% P91 alloy failed at the 85% P91/740H interface, and the aged alloy failed in the pure P91 region. This proves that post-heat treated 85% P91 is much stronger than pure P91, and the alloy design strategy used in this work proves successful for developing interlayers for dissimilar joining.
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The authors gratefully acknowledge the financial support from the National Energy Technology Laboratory, Department of Energy, United States under the award number DE‐FE0031637.
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Sridar, S., Wang, X., Shabani, M., Klecka, M.A., Xiong, W. (2023). Design of Graded Transition Interlayer for Joining Inconel 740H Superalloy with P91 Steel Using Wire-Arc Additive Manufacturing. In: Ott, E.A., et al. Proceedings of the 10th International Symposium on Superalloy 718 and Derivatives. TMS 2023. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-031-27447-3_45
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