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<p>This study examines the microstructural evolution, mechanical properties, fatigue performance, and corrosion resistance of Monel 400 weldments created using automated DC pulsed MIG welding. Electron backscatter diffraction (EBSD) demonstrated grain coarsening in the fusion zone and dendritic formations in the weld zone, affecting hardness and fatigue characteristics. The weld metal demonstrated superior microhardness (154 HV) and flexural strength (391&#xa0;MPa) relative to the base metal. Fatigue tests revealed the weld metal’s exceptional performance, with an endurance limit of 158.4&#xa0;MPa after 2 × 10<sup>6</sup> cycles, about 25% greater than that of the base metal (128.4&#xa0;MPa). Corrosion experiments revealed a somewhat higher weight loss in weldments compared to the base metal. The data validate that microstructural refinement in the weld zone improves the fatigue resistance of welded Monel 400, albeit with slightly diminished corrosion resistance.</p>

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Microstructure Evaluation and Fatigue Properties of Automated DC Pulsed MIG Welding of Monel 400

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • B. K. Parrthipan,
  • P. Narayanasamy,
  • R. Rajaprasanna,
  • T. Ramkumar,
  • N. Lenin

摘要

This study examines the microstructural evolution, mechanical properties, fatigue performance, and corrosion resistance of Monel 400 weldments created using automated DC pulsed MIG welding. Electron backscatter diffraction (EBSD) demonstrated grain coarsening in the fusion zone and dendritic formations in the weld zone, affecting hardness and fatigue characteristics. The weld metal demonstrated superior microhardness (154 HV) and flexural strength (391 MPa) relative to the base metal. Fatigue tests revealed the weld metal’s exceptional performance, with an endurance limit of 158.4 MPa after 2 × 106 cycles, about 25% greater than that of the base metal (128.4 MPa). Corrosion experiments revealed a somewhat higher weight loss in weldments compared to the base metal. The data validate that microstructural refinement in the weld zone improves the fatigue resistance of welded Monel 400, albeit with slightly diminished corrosion resistance.