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2000-01-0314
P. Pdarr
Ugine Savoie Imphy
A. Bruyre
Sprint Mtal
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ISSN 0148-7191
Copyright 2000 Society of Automotive Engineers, Inc.
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2000-01-0314
P. Pdarr
Ugine Savoie Imphy
A. Bruyre
Sprint Mtal
Copyright 2000 Society of Automotive Engineers, Inc.
ABSTRACT
INTRODUCTION
The increasingly widespread use of ferritic stainless
steels (AISI 409, 439, 436 and 441) for automotive
exhaust systems has led USI (Ugine Savoie Imphy, a
subsidiary of Usinor) to develop a new ferritic stainless
steel welding wire adapted to this application, designated
430LNb. Until now, the welding wires most commonly
used in Europe are the 308LSi and 307Si austenitic
stainless steels, capable of welding both carbon steels
and austenitic and ferritic stainless grades. However, in
the USA, 409Cb wire has been employed for many years
for welding low Cr ferritic sheets.
The present paper shows that the new wire has weldability and service properties equal to, and in some cases
better than, those of the 308LSi and 307Si austenitic
grades. Weldability was evaluated by joining ferritic stainless steel sheets corresponding to AISI grades 409, 436
and 441. The functional properties were determined by
measuring the corrosion and oxidation resistance,
together with the mechanical and thermal fatigue
strengths. This was done with the aid of specially developed tests, which are briefly described below.
1
MAIN SECTION
1.5 mm
EXPERIMENTAL PROCEDURE
Materials The 430LNb wire was used to weld AISI 409,
441 and 436 sheets and was compared with 308LSi and
307Si filler materials. A comparison in terms of weldability was also made with a 409Cb wire, used to weld AISI
409. The chemical analyses of the wires and sheets evaluated are given in Table 1 below.
Figure 1.
Si
Mn
Ni
Cr
Mo
409
.007 .5
.004 .021 .2
.1
11.2 .01
436
.040 .4
.004 .022 .5
.1
441
.014 .5
.003 .020 .5
.2
Wires
307Si
Si
.077 .7
Mn
Ni
8.3
Ti
Nb
.010
17.2 1.20 -
.54
.024
17.5 .02
.55
.018
Cr
.18
.15
Mo
18.9 .12
Ti
-
Nb
-
.056
308LSi
.014 .9
.045
409Nb
.056 1.3
.2
12.2 .06
.36
.93
.037
430LNb
.017 .4
.002 .018 .3
.3
18.0 .04
.01
.32
.017
Welding procedure In order to enable mechanical testing of the welds, gapless MIG butt welding was performed. The welding parameters were adapted to comply
with standard exhaust system welding procedures:
Furnace
Beakers, acid
nickel-base superalloy, designed to both clamp the specimen ends and to guide them to within 1.5 mm of the edge
of the seam (Figure 3b), in order to avoid buckling during
tension-compression loading (R = max/min = - 1). In
the case of tests on unwelded sheet, the same type of
specimen was used, conserving a free zone 3 mm long
(twice the sheet thickness) between the guided parts.
Guided parts
(0.08 mm clearance on either side of the sheet)
Clamped parts
Clamped parts
.
thickness = 1.5
weld seam
45.5
w
(weld seam width)
1.5
15
124 + w
(a)
HAZ
FZ
Thermocouple
Figure 4.
(b)
Figure 3.
with austenitic filler metals, there is a sharp discontinuity in hardness between the fusion zone and the
ferritic base metal (cf. example hardness profiles for
409/409 and 441/441 assemblies in Figure 5b) ; this
is due to extensive martensite formation in the
melted zone, especially in the 409/409 assembly.
Heating was performed in a radiation furnace. The temperature was controlled by a thermocouple attached by
refractory string to the free part of the specimen, the
string also protecting this zone from direct radiation. The
tests were performed on a 100 kN servohydraulic
machine, at a frequency of 20 Hz, at temperatures from
300 to 950C, to a maximum of about 2.105 cycles.
with ferritic filler metals, especially 430LNb, the hardness of the fusion zone is the same as that of the
base metal.
FZ
BM
HAZ
HAZ
Base
metal
AISI 409
400
308LSI
Hardness HV100g
350
4370M
300
430LNb
250
AISI 409
AISI 436
AISI 441
Filler metal
Ericksen %
BM
Ericksen %
BM
Ericksen %
BM
Punch side
top
rear
top
rear
top
rear
307Si
68.5
70.8
66
63
86.6
86.6
308LSi
77.6
78.8
76
77
90.4
87.3
409Cb
86.5
84
430LNb
98
96
93
93
96
94.5
409Cb
200
150
100
Corrosion resistance
50
0
1
10
11
Intergranular corrosion resistance None of the assemblies tested (AISI 409, 441 and 436, with 430LNb, 308LSi
and 307Si filler metals) showed any sign of intergranular
corrosion.
AISI 441
400
Hardness HV100g
350
308LSI
300
4370M
250
430LNb
200
150
100
50
0
1
10
11
308LSi
Figure 6.
307Si
430LNb
and 950C). For both sheet alloys and for all test temperatures, the stress for a life of 200000 cycles (Nf = 200000)
can be seen to vary very little with the type of filler metal
employed.
500
UTS
300C
450
400
400
350
300
stress (MPa)
200
AISI 436
AISI 441
AISI 441
160
430LNb
308LSi
307Si
50
307Si
100
50
430LNb
308LSi
150
100
AISI 441
AISI 441
150
AISI 436
200
Nf = 200000
250
AISI 436
Nf = 200000
0.2%YS
250
0.2%YS
350
300
stress (MPa)
UTS
500
300C
450
AISI 436
750C
850C
950C
UTS
90
Nf = 200000
Nf = 200000
80
60
40
0.2%YS
UTS
100
100
0.2%YS
UTS
stress (MPa)
120
0.2%YS
140
Nf = 200000
430LNb
308LSi
307Si
AISI 441
AISI 441
AISI 441
430LNb
308LSi
307Si
AISI 441
AISI 441
AISI 441
430LNb
308LSi
307Si
AISI 441
AISI 441
AISI 441
20
409
50
441
436
40
30
0
308LSi
307Si
430LNb
Welding wires
750C
850C
950C
140
Nf = 200000
80
60
Nf = 200000
40
In the case of 441 and 436 assemblies, the fatigue thermal life of the specimen welded with 430LNb wire is
always included in the range of lives of specimen welded
using 308LSi and 307Si (see figure 8) . Metallographic
observations evidence two type of thermal fatigue crack
propagation in specimen : in Heat Affected Zone (HAZ)
or Base Metal (BM) or at interface between HAZ and
Fusion Zone (FZ), as shown in Table 3 and Figure 9.
20
430LNb
308LSi
307Si
AISI 436
AISI 436
AISI 436
430LNb
308LSi
307Si
AISI 436
AISI 436
AISI 436
430LNb
308LSi
307Si
AISI 436
AISI 436
AISI 436
AISI 436
Figure 7.
Nf = 200000
0.2%YS
UTS
0.2%YS
UTS
Figure 8.
0.2%YS
UTS
stress (MPa)
60
10
160
100
Base metals
70
20
AISI441
120
80
308LSi
307Si
430LNb
indicates a crack at interface between Heated Affected Zone and Fusion Zone ;
indicates a crack in Heated Affected Zone or Base Metal.
(a)
(a)
(b)
Figure 3.
(b)
Figure 10. Fillet welds on Faurecia catalysts : (a) straight
weld on an AISI 409 racetrack type catalytic
converter can; (b) circular weld on an
AISI 441 cylindrical catalytic converter can.
CONCLUSIONS
CONTACT
1. N. Renaudot, Research Metallurgist, Usinor Recherches, Centre de Recherches, 73403 Ugine cedex
(France), fax : 33 4 79 89 35 00
2. P.O. Santacreu, Research Metallurgist, Usinor
Recherches, Centre de Recherches, 73403 Ugine
cedex (France), tel: 33 4 79 89 35 43, fax: 33 4 79 89
35 00.
REFERENCES
1. T.M. DEVINE and J. DRUMMOND : An Accelerated
Intergranular Corrosion Test for Detecting Sensitization in Low Chromium Ferritic Stainless Steel, in
Corrosion NACE, 38 (6), 1982