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<p>Dissimilar weld joints (DWJ) between Grade 91 (modified 9Cr-1Mo) steel and 316LN stainless steel are essential in thermal and nuclear power plants. The joint between these two materials is typically produced using Tungsten Inert Gas welding (TIG), which can cause high tensile residual stresses. Though possessing good strength, the welds of Grade 91 steel are generally subjected to Type-IV failures along the heat-affected zone (HAZ) formed. The cause of such failures could be due to the presence of residual stress. This study focuses on the residual stress developed in a DWJ made by multi-pass welding between Grade 91 and 316LN steels, with Inconel 82 (ERNiCr-3) as the filler material. The welding process is simulated using a 2D finite element model, considering the effects of temperature-dependent material properties, phase transformation of Grade 91, strain hardening, and annealing effect of 316LN. The residual stresses obtained from weld joint simulations are compared with those measured using the x-ray diffraction technique. The through-thickness residual stress is compared with the hole drilling technique. The results revealed that high tensile residual stress exists at the boundary of the HAZ in Grade 91 and is wider at the 316LN side. The predicted FEM simulation results show that the phase transformation has a significant influence in the residual stress formation at the HAZ of Grade 91. The through-thickness measurement also indicates the presence of high tensile stress along the thickness of the plate.</p>

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Experimental and Numerical Analysis of Residual Stress in Dissimilar Weld Joints Between Grade 91 and 316LN Steels Using Inconel 82 Filler

  • 期刊论文

  • 发表日期：

    2025年9月4日

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  • Anoop A. Pillai,
  • H. C. Dey,
  • S. Arun Kumar,
  • K. P. Vineesh,
  • U. B. Jayadeep,
  • M. M. Mahapatra

摘要

Dissimilar weld joints (DWJ) between Grade 91 (modified 9Cr-1Mo) steel and 316LN stainless steel are essential in thermal and nuclear power plants. The joint between these two materials is typically produced using Tungsten Inert Gas welding (TIG), which can cause high tensile residual stresses. Though possessing good strength, the welds of Grade 91 steel are generally subjected to Type-IV failures along the heat-affected zone (HAZ) formed. The cause of such failures could be due to the presence of residual stress. This study focuses on the residual stress developed in a DWJ made by multi-pass welding between Grade 91 and 316LN steels, with Inconel 82 (ERNiCr-3) as the filler material. The welding process is simulated using a 2D finite element model, considering the effects of temperature-dependent material properties, phase transformation of Grade 91, strain hardening, and annealing effect of 316LN. The residual stresses obtained from weld joint simulations are compared with those measured using the x-ray diffraction technique. The through-thickness residual stress is compared with the hole drilling technique. The results revealed that high tensile residual stress exists at the boundary of the HAZ in Grade 91 and is wider at the 316LN side. The predicted FEM simulation results show that the phase transformation has a significant influence in the residual stress formation at the HAZ of Grade 91. The through-thickness measurement also indicates the presence of high tensile stress along the thickness of the plate.