Effects of Filler Metals on Heat-Affected Zone Cracking in IN-939 Superalloy Gas-Tungsten-Arc Welds

Filler metals play an important role in reducing the weld cracking in nickel-based superalloys. In order to improve the welding conditions of IN939 superalloy, a wide range of solid solutions and age-hardenable filler metals were investigated in this study. Five solid solutions (HAYNES 230, IN625, IN617, HASTELLOY X, HAYNES 25) and two precipitation-strengthened alloys (IN718, HAYNES C-263) were used as filler metal to weld IN939 superalloy via gas-tungsten-arc welding. Microstructural studies were performed using optical microscopy and field-emission scanning electron microscopy. The results revealed that IN939 alloy is susceptible to liquation cracking in the heat-affected zone. In addition, the primary γ′ particles had grown into “ogdoadically diced cubes” of about of 2 μm in side length. The microstructure of the weld pool made with various filler metals was observed to be made up of fine spherical γ′ particles with a diameter of about 0.2 μm. The study of mechanical properties and thermodynamic behavior of the weld showed that the filler metals with lower concentrations of (Al + Ti + Nb + Ta + Mo + W) than the base metal can effectively attenuate the PWHT cracking. We found that optimal IN939 alloy weld performance can be achieved using HAYNES C-263 as filler metal, followed by IN617 and then IN625.