Studies on Similar and Dissimilar Metal EBW Joints of Fe-31Ni-5Co and Co-20Cr-15W-10Ni Alloys

Superinvar Fe-31Ni-5Co alloy (SI) and Co-20Cr-15W-10Ni superalloy (SA) are used in space applications. Similar metal (SI-SI and SA-SA) joints as well as dissimilar metal (SA-SI) joints of these alloys have been made using electron beam welding (EBW) technique. Extensive characterization of these weldments has been carried out using optical and electron microscopy, microhardness measurements and tensile testing at ambient and cryogenic temperatures. It has been observed that weld efficiency is 100% for similar metal joints, whereas it is governed by base metal properties of the alloy having lower strength for dissimilar metal joint. Weld efficiency of SA-SI/EBW joint is comparable with base metal of lower strength indicating no detrimental formation of intermetallic/brittle phase. Microhardness of the SA-SI/EBW joint is found to be representative of the respective base metal properties with no sudden variation across the SA/SI interface in the weldment indicating good dilution in the weld. This has been confirmed through energy-dispersive spectrum using x-rays (EDX) showing the presence of Fe near the superalloy weldment interface and the presence of Cr and W near the superinvar weldment interface. Increase in strength and decrease in ductility of base metals are observed for all types of joints when tested at cryogenic temperature (77 K) vis-à-vis at ambient temperature. Fracture features of the failed surface of SA-SI/EBW joint are found to be similar to that of the SI-SI/EBW joint. Microhardness, mechanical properties and fracture analysis confirm that failure of dissimilar metal joint takes place toward lower strength base metal, i.e., superinvar.