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<p>This study examines underwater wet automated metal arc welding of AISI 304 stainless steel in a butt configuration using a flux-coated electrode (3.15&#xa0;mm × 350&#xa0;mm) and welding parameters of 145 A, 23&#xa0;V, and 2.5&#xa0;mm/sec feed rate. Microstructural analysis revealed refined weld zones with columnar grains and coarse heat-affected zones. Rapid cooling enhanced grain refinement, resulting in a peak hardness of 438 Hv in the weld zone, especially at the weld bottom due to lower heat input. Tensile testing of underwater weld (UWW) recorded an ultimate tensile strength (UTS) of 412 Mpa, Yield strength 225 Mpa, Elongation 37% and 63% joint efficiency Fractography showed mixed fracture behavior with ductile dimples and brittle cracks linked to incomplete fusion. Wear analysis demonstrated improved resistance, with a wear rate of 2.016 × 10⁻<sup>17</sup>&#xa0;m<sup>3</sup>/Nm under a 140 N load. 3D profilometry indicated reduced surface roughness (0.67&#xa0;µm) and wear depth (5.24&#xa0;µm) compared to the base SS304 specimen (1.09&#xa0;µm and 9.48&#xa0;µm, respectively). These findings highlight the method’s potential to enhance marine structural integrity while emphasizing the need for defect minimization and further optimization.</p>

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Tribo-Mechanical Assessment of Austenitic SS304 Welds Fabricated by Underwater Wet Automated Metal Arc Welding

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Mohd Ashraf Hajam,
  • Dinesh Kumar Rajendran

摘要

This study examines underwater wet automated metal arc welding of AISI 304 stainless steel in a butt configuration using a flux-coated electrode (3.15 mm × 350 mm) and welding parameters of 145 A, 23 V, and 2.5 mm/sec feed rate. Microstructural analysis revealed refined weld zones with columnar grains and coarse heat-affected zones. Rapid cooling enhanced grain refinement, resulting in a peak hardness of 438 Hv in the weld zone, especially at the weld bottom due to lower heat input. Tensile testing of underwater weld (UWW) recorded an ultimate tensile strength (UTS) of 412 Mpa, Yield strength 225 Mpa, Elongation 37% and 63% joint efficiency Fractography showed mixed fracture behavior with ductile dimples and brittle cracks linked to incomplete fusion. Wear analysis demonstrated improved resistance, with a wear rate of 2.016 × 10⁻17 m3/Nm under a 140 N load. 3D profilometry indicated reduced surface roughness (0.67 µm) and wear depth (5.24 µm) compared to the base SS304 specimen (1.09 µm and 9.48 µm, respectively). These findings highlight the method’s potential to enhance marine structural integrity while emphasizing the need for defect minimization and further optimization.