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Inconel 600镍基合金PAW + TIG接头微观组织及力学性能

乔小丽, 曹帅, 武靖伟, 张建晓, 黄健康, 樊丁

乔小丽, 曹帅, 武靖伟, 张建晓, 黄健康, 樊丁. Inconel 600镍基合金PAW + TIG接头微观组织及力学性能[J]. 焊接学报, 2024, 45(6): 105-112. DOI: 10.12073/j.hjxb.20231225002
引用本文: 乔小丽, 曹帅, 武靖伟, 张建晓, 黄健康, 樊丁. Inconel 600镍基合金PAW + TIG接头微观组织及力学性能[J]. 焊接学报, 2024, 45(6): 105-112. DOI: 10.12073/j.hjxb.20231225002
QIAO Xiaoli, CAO Shuai, WU Jingwei, ZHANG Jianxiao, HUANG Jiankang, FAN Ding. Microstructure and mechanical properties of Inconel 600 nickel-based alloy PAW + TIG joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(6): 105-112. DOI: 10.12073/j.hjxb.20231225002
Citation: QIAO Xiaoli, CAO Shuai, WU Jingwei, ZHANG Jianxiao, HUANG Jiankang, FAN Ding. Microstructure and mechanical properties of Inconel 600 nickel-based alloy PAW + TIG joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(6): 105-112. DOI: 10.12073/j.hjxb.20231225002

Inconel 600镍基合金PAW + TIG接头微观组织及力学性能

基金项目: 甘肃省科技重大专项资助项目(22ZD6GA008);甘肃省科技重点研发计划(20YF3GA041)
详细信息
    作者简介:

    乔小丽,硕士,高级工程师;主要从事压力容器设计、制造及管理工作;Email: qiaoxiaoli@lshec.com

    通讯作者:

    黄健康,博士,教授;Email: sr2810@163.com

  • 中图分类号: TG 442

Microstructure and mechanical properties of Inconel 600 nickel-based alloy PAW + TIG joints

  • 摘要:

    针对Inconel 600镍基合金在石化装备行业的应用焊接问题,选择合适的焊接工艺是其所面临的一项挑战. 采用PAW + TIG工艺流程对厚度为6 mm的Inconel 600镍基合金进行焊接,应用光学显微镜、扫描电镜和拉伸试验机等对Inconel 600镍基合金PAW + TIG接头的微观组织及其性能进行研究. 微观组织分析结果表明,接头焊缝表面成形光滑平齐,半椭圆状的鱼鳞纹均匀分布,接头母材区域和热影响区的组织均为细小的等轴晶奥氏体,其中热影响区晶粒的尺寸大于母材区,焊缝区域的组织为树枝晶;接头的抗拉强度达到589 MPa,接头断裂类型为韧性断裂,焊接接头具有良好的塑性和抗弯曲性能;焊缝处电化学腐蚀测试结果表明,在焊接热影响区域局部腐蚀敏感性增加,说明焊接接头的耐腐蚀性降低;对焊缝退火处理并进行性能测试的结果表明,退火后焊接接头析出针状第二相,其在晶界和孪晶界处形成了一定的强化效应,能够抑制晶粒长大并影响材料的整体性能. 综合分析焊接接头微观组织及其性能表明,采用PAW + TIG的接头热稳定性较好,能够满足其在高温条件下的工作要求.

    Abstract:

    Addressing the welding challenges of Inconel 600 nickel-based alloy in the petrochemical equipment industry, selecting an appropriate welding process is challenging. A 6 mm thick Inconel 600 nickel-based alloy is welded using the PAW + TIG process. The microstructure and mechanical properties of the Inconel 600 nickel-based alloy PAW + TIG joints are studied using optical microscopy, scanning electron microscopy, and tensile testing machine. Microstructure analysis shows that the joint weld surface is smooth and even, with a semi-elliptical fish scale pattern uniformly distributed. Both the base material area and the heat-affected zone exhibit fine equiaxed austenite crystals, with the grain size in the heat-affected zone being larger than in the base material area. The weld zone has a dendritic structure. The tensile strength of the joint reaches 589 MPa, and the fracture type is ductile, indicating good plasticity and bending resistance of the welded joint. Electrochemical corrosion tests at the weld indicate increased localized corrosion sensitivity in the heat-affected zone, suggesting reduced corrosion resistance of the welded joint. Post-weld annealing and performance testing shows that annealing precipitated needle-like second phases, forming a certain strengthening effect at grain boundaries and twin boundaries, which can inhibit grain growth and affect the overall performance of the material. A comprehensive analysis of the microstructure and performance of the welded joints shows that the PAW + TIG joints have good thermal stability, meeting the requirements for high-temperature operation.

  • 随着石油和精细化工行业的快速发展,在各类具有严峻腐蚀特性的环境中,如何选择合适的设备材料成为产品制造中的一项重大挑战[1-3]. Inconel 600是一种Ni-Cr-Fe固溶强化合金,国内牌号为N06600,在700 ℃以下具有优良的耐热性和高塑性,其特点是熔点高、耐热、耐腐蚀、强度高,具有良好的抗氧化性能、力学性能和加工性能,因为其良好的耐高温腐蚀性和抗氧化性能,所以常用于制造化工设备和石油化工装备[4-6].

    镍基合金传统的焊接方法有埋弧焊、钨极氩弧焊、焊条电弧焊等[7-9]. TIG对镍基合金焊接应用最为广泛[10],焊接接头组织及性能与工艺参数密切相关. 杨子威等人[11]采用等离子和TIG分别对Inconel 600进行焊接,研究不同焊接方法对其显微组织和力学性能的影响,结果表明焊缝显微硬度均低于母材,TIG接头的硬度低于等离子焊接接头. PAW是在钨极氩弧焊的基础上通过压缩电弧的方法来获得的一种高效焊接方法[12]. TIG自由的电弧具有良好的覆盖能力,添加适当的填充金属,可达到正面成形美观的效果,但焊接时需开坡口,且很难实现单面焊双面成形[13]. PAW + TIG可同时发挥两种焊接方法的优势,将电弧易控制、焊缝成形美观、焊缝质量高、焊接变形小和探伤合格率高等优点体现出来,从而提高生产效率[14]. 文中采用PAW + TIG方法对Inconel 600镍基合金进行焊接,考察了焊缝的微观组织及力学性能,从而为Inconel 600镍基合金的实际生产应用提供有力的理论支撑和参考依据.

    试验选用规格为600 mm × 65 mm × 6 mm的Inconel 600钢板作为试验母材,选用直径为1.0 mm的ERNiCr-3作为TIG填充材料,母材及焊丝的化学成分如表1所示,母材抗拉强度为585 MPa,屈服强度为35 MPa,断后伸长率为20%. 试验所选用的焊接设备为专用PAW + TIG焊机,其焊接示意图如图1(a)所示,Inconel 600板材选用如图1(b)所示焊接坡口, 等离子弧焊枪喷嘴应选择铜制三孔扩散式喷嘴. PAW和TIG焊枪均选择直径为3.2 mm的铈钨极,选用直流正接. PAW + TIG组合焊接时,以PAW打底,填丝TIG紧随其后盖面,依次盖面3次,填充示意图如图1(b)所示.

    表  1  Inconel 600及焊丝ERNiCr-3化学成分(质量分数,%)
    Table  1.  Chemical composition of the Inconel 600 and ERNiCr-3 metal wire
    材料NiCrFeCuMnCSiSPAlTi
    Inconel 60073.4115.987.830.501.000.1500.500.0150.0150.300.3
    ERNiCr-374.7519.581.750.013.220.0210.280.0050.0040.080.3
    下载: 导出CSV 
    | 显示表格
    图  1  Inconel 600 PAW + TIG接头填充示意图
    Figure  1.  Schematic diagram and welding test diagram of Inconel 600 PAW + TIG jionts. (a) PAW + TIG diagram; (b) groove form

    在焊接过程中焊枪固定不动,起弧后焊枪随着焊接平台移动完成焊接,待试板冷却后拍照记录焊缝表面成形,取样、打磨和腐蚀并观察焊缝形貌和焊缝组织,按照 GB/T 228—2002《金属材料室温冲击试验方法》[15]制备焊接接头拉伸试样. 焊接基本工艺参数如表2所示,焊接速度为240 ~ 250 mm/min,保护气采用95%Ar + 5%H2,流速为8 ~ 12 L/min,保护罩Ar气流量为10 ~ 15 L/min.

    表  2  基本工艺参数
    Table  2.  Basic welding process parameters
    层数焊接方法送丝速度
    vf/(cm·min−1)
    焊接电流
    I/A
    电弧电压
    U/V
    1PAW210~25027~29
    3TIG22230~26015~17
    下载: 导出CSV 
    | 显示表格

    Inconel 600镍基合金PAW + TIG焊接接头形貌如图2所示,由图2(a)可知,焊缝呈银白色,焊缝表面成形均匀、光滑,鱼鳞纹均匀分布,未出现明显的夹渣、咬边和未熔合等宏观缺陷. 接头横截面形貌如图2(b)所示,接头呈上大下小的形貌,PAW焊缝和TIG焊缝两部分,且具有清晰的分界线.

    图  2  Inconel 600 PAW + TIG接头形貌
    Figure  2.  Morphology of the Inconel 600 PAW + TIG joint. (a) macroscopic morphology; (b) cross-sectional morphology

    Inconel 600镍基合金PAW + TIG接头微观组织如图3所示,熔合线附近无明显的孔洞和裂纹等缺陷,两者完全熔合. 母材和热影响区的组织为奥氏体,与母材相比,热影响区晶粒的尺寸较大. 焊缝区域的组织为树枝晶,垂直于熔合线生长. Inconel 600镍基合金PAW + TIG接头熔合线EDS线扫描如图4所示,焊缝到母材方向Ni元素含量明显增加、Fe元素含量减少、C元素和Cr元素含量几乎保持不变. 焊缝部位的Ni元素和Fe元素含量之比为3∶1,故判断焊接接头的物相主要为Ni3Fe相. 如图5所示为焊接接头XRD图谱,分析结果表明接头物相主要为FeNi3相,经退火热处理后出现第二相,为γ-(Fe,Ni)化合物,结合图3中SEM可知焊缝处Fe元素、Ni元素形成了固溶体相,并且焊接接头熔合线XRD分析结果与EDS线扫描结果一致.

    图  3  Inconel 600 镍基合金PAW + TIG接头微观组织
    Figure  3.  Cross section of the Inconel 600 PA + TIG joint
    图  4  Inconel 600 PAW + TIG接头元素线扫描分析
    Figure  4.  EDS liner scan of the Inconel 600 PAW + TIG joint. (a) EDS liner scan direction; (b) EDS liner scan 1; (b) EDS liner scan 2
    图  5  Inconel 600 PAW + TIG接头XRD分析
    Figure  5.  XRD analysis of Inconel 600 PAW + TIG joints

    采用维氏显微硬度仪对热处理前后的Inconel 600镍基合金PAW + TIG接头分别进行硬度测量,硬度分布如图6所示,焊接接头硬度分布规律基本一致,焊缝区域硬度最低,热影响区硬度次之,母材硬度最高. 随着焊接热输入的增加,界面的未熔合缺陷在逐渐减少,晶粒的尺寸逐渐增大. 随着晶粒的细化,硬度随之升高. 由于热影响区的晶粒尺寸较母材小,焊缝区域晶粒尺寸较热影响小,故接头的显微硬度分布呈现出该趋势.

    图  6  焊接接头显微硬度分布规律
    Figure  6.  Microhardness distribution of the welded joints

    对焊后试样在700 ℃下保温8 h进行退火试验,通过高温保温退火,有助于晶粒再结晶,使晶粒尺寸重新分布,提高晶界的稳定性,改善材料的力学性能和耐腐蚀性. 图7可以看出两个焊接试样均断裂在Inconel 600镍基合金母材. 通过扫描电镜对Inconel 600镍基合金PAW + TIG接头拉伸断口进行观察. 在图8(b)的局部放大图中可以看出断口由少量韧窝和未熔合孔洞组成,结合文献[16]分析可知接头的断裂形式为韧性断裂. 对退火前后两个试样力学性能进行对比,图9(a)所示为拉伸工程应力—应变曲线,焊接接头的屈服强度为305 MPa,抗拉强度为589 MPa,从图9(b)中可以看出退火后的焊接接头抗拉强度和屈服强度都有所增加,抗拉强度和屈服强度分别达到了632 MPa和311 MPa,较未进行退火的焊接接头抗拉强度提高了7.3%,但是退火试验后的焊接接头断后伸长率有所下降,说明高温退火试验使得焊接接头的塑性降低. 如图10所示,Inconel 600镍基合金PAW + TIG面弯和背弯试样经180°弯曲后,正面和侧面均未发现裂纹、气孔及夹渣等缺陷,Inconel 600镍基合金 PAW + TIG接头的塑性较好.

    图  7  Inconel 600 镍基合金PA + TIG接头拉伸试样
    Figure  7.  Macromorphology of Inconel 600 tensile samples of the Inconel 600 PA + TIG joints
    图  8  Inconel 600 镍基合金PA + TIG接头断口形貌
    Figure  8.  Tensile fracture morphologies of Inconel 600 tensile samples. (a) fracture morphology; (b) a partial enlargement of Fig.8(a)
    图  9  热处理前后接头工程应力—应变曲线与力学性能对比
    Figure  9.  Comparison of stress-strain curves and mechanical properties of the welded joints before and after heat treatment. (a) engineering stress-strain curves; (b) comparison of mechanical properties
    图  10  接头弯曲宏观形貌
    Figure  10.  Macro morphology of the welded joints bend samples

    图11给出了焊缝和母材的位置的电化学腐蚀极化曲线. 通过Tafel外推法拟合曲线,得到了腐蚀电位(Ecorr)、腐蚀电流密度(icorr),计算结果列于表3中. 焊缝区域和母材区域自腐蚀电流密度分别为0.7316 µA/cm20.7399 µA/cm2,焊缝区域自腐蚀电流密度较小,因此认为焊缝处腐蚀速率较母材区域小.焊缝与母材处自腐蚀电位分别为−0.7867 V和−0.3346 V,母材处自腐蚀电位明显高于焊缝处,因此焊缝处更趋向发生电化学反应.

    图  11  焊缝与母材位置极化曲线
    Figure  11.  Polarization curves of weld seam and base metal
    表  3  Tafel拟合的自腐蚀电流密度与自腐蚀电位
    Table  3.  Self corrosion current density and self corrosion potential fitted by Tafel
    位置自腐蚀电流密度
    icorr/(µA·cm−2)
    腐蚀电位
    Ecorr /V
    母材0.73990.334 6
    焊缝0.73160.786 7
    下载: 导出CSV 
    | 显示表格

    图12为Nyquist图与Bode图,图12(a)所示为Nyquist图,显示不完全电容回路,通常由于较大电容回路的样品具有较低的溶解速率和较高的耐腐蚀性,因此母材区域溶解速率较低且耐腐蚀性较好. Bode图如图12(b)所示,阻抗Z的模值在低频范围内表示极化电阻,在低频时相位角较大,这可归因于保护膜的形成,因此可见母材区域易于形成保护膜,降低其腐蚀发生的倾向,导致其腐蚀电位较低.

    图  12  Nyquist图与Bode图
    Figure  12.  Nyquist curves and Bode diagram. (a) Nyquist curves; (b) Bode digram

    图13为母材与焊缝位置经电化学腐蚀后的形貌,可以明显发现母材位置点蚀坑较小,焊缝处明显有较大点蚀坑且相互连接. Cl提供电子给金属表面,促使合金溶解. 局部产生的酸性环境进一步加速金属的腐蚀,导致表面出现小孔洞或凹坑. 这是由于在焊接过程中,在快速冷却的焊接热影响区域,形成析出相以及晶粒边界变化,导致局部腐蚀敏感性增加,从而降低了焊接接头的耐腐蚀性.

    图  13  母材与焊缝位置电化学腐蚀形貌
    Figure  13.  Electrochemical corrosion morphology of base metal and weld seam positions. (a) base material position; (b) weld position

    为研究Inconel 600镍基合金 PAW + TIG接头的耐蚀性,以确保焊接接头在特殊的环境中达到设备的使用要求,因此在100%射线检验合格的焊接接头中部分别取样选择ASTM A262-15[17]中的Practice E和ASTM G28-22[18]中的Method A进行腐蚀试验. ASTM A262-15[17]为奥氏体不锈钢抗晶间腐蚀的试验方法,Practice E为铜-硫酸铜-16%硫酸试验用于检测晶间腐蚀敏感性,ASTM G28-22[18]为富镍铬合金抗晶间腐蚀的试验方法,Method A为硫酸铁-硫酸试验. 采用扫描电镜对焊接接头的晶间腐蚀进行SEM形貌进行观察,如图14所示,可以看出整个接头腐蚀形貌仅存在凹凸不平的相,在晶界部位未发现晶间腐蚀的现象.

    图  14  Inconel 600合金PA + TIG接头晶间腐蚀SEM
    Figure  14.  Corrosion SEM image of Inconel 600 PA + TIG joint

    经退火处理后焊接接头析出δ相的TEM图像如图15所示,通过TEM可以清楚地观测到有δ相析出且分布较为密集. 在退火处理的过程中,Inconel 600镍基合金晶体结构发生变化,形成新的δ相. δ相的出现会影响材料的硬度、强度和塑性. 高温退火后δ相的出现导致了焊接接头的抗拉强度以及屈服强度的增加,与图9(a)中所描述的结果一致. 晶粒内孪晶的对称性为δ相的析出提供了有利的条件. 结合文献[19]可知,在保温过程中,随着时间的推移,δ相逐渐从基体中分离出来,而空洞则逐渐合并形成裂纹.

    图  15  退火处理后焊接接头析出δ相的TEM显微图像
    Figure  15.  Precipitation in welded joints after annealing treatment TEM micrographs of δ phases

    退火过程中的微观结构示意图如图16所示. 在退火过程中,随着温度的升高,γ״强化相逐渐拉长和粗化,最终演变成为针状的δ相. 结合文献[20]可知,针状的δ相在晶粒内部的析出不仅影响了晶体的力学性能,还在晶界和孪晶界处作为物理障碍阻碍了晶界的移动,从而形成了一定的强化效应,因此退火中γ״强化相和δ相的形成及演变抑制了晶粒的长大,同时还影响了材料的整体性能.

    图  16  退火过程中微观结构转变示意图
    Figure  16.  Schematic diagram of the microstructure changes during annealing. (a) γ״ phases growth; (b) δ phases growth

    (1) 采用PAW + TIG方法可实现厚度为6 mm的Inconel 600镍基合金的有效焊接,焊缝表面成形光滑平齐,半椭圆状的鱼鳞纹均匀分布.

    (2) 焊缝分为PAW焊缝和TIG焊缝两部分,且具有清晰的分界线. 母材和热影响区的组织均为等轴晶奥氏体,但热影响区晶粒的尺寸比母材大,焊缝区域的组织为树枝晶,该部位金属间化合物为Ni3Fe相.

    (3) 退火后的焊接接头抗拉强度和屈服强度都有所增加,较未进行退火的焊接接头抗拉强度提高了7.3%,退火后的焊接接头断后伸长率有所下降,说明高温退火试验使得焊接接头的塑性降低.

  • 图  1   Inconel 600 PAW + TIG接头填充示意图

    Figure  1.   Schematic diagram and welding test diagram of Inconel 600 PAW + TIG jionts. (a) PAW + TIG diagram; (b) groove form

    图  2   Inconel 600 PAW + TIG接头形貌

    Figure  2.   Morphology of the Inconel 600 PAW + TIG joint. (a) macroscopic morphology; (b) cross-sectional morphology

    图  3   Inconel 600 镍基合金PAW + TIG接头微观组织

    Figure  3.   Cross section of the Inconel 600 PA + TIG joint

    图  4   Inconel 600 PAW + TIG接头元素线扫描分析

    Figure  4.   EDS liner scan of the Inconel 600 PAW + TIG joint. (a) EDS liner scan direction; (b) EDS liner scan 1; (b) EDS liner scan 2

    图  5   Inconel 600 PAW + TIG接头XRD分析

    Figure  5.   XRD analysis of Inconel 600 PAW + TIG joints

    图  6   焊接接头显微硬度分布规律

    Figure  6.   Microhardness distribution of the welded joints

    图  7   Inconel 600 镍基合金PA + TIG接头拉伸试样

    Figure  7.   Macromorphology of Inconel 600 tensile samples of the Inconel 600 PA + TIG joints

    图  8   Inconel 600 镍基合金PA + TIG接头断口形貌

    Figure  8.   Tensile fracture morphologies of Inconel 600 tensile samples. (a) fracture morphology; (b) a partial enlargement of Fig.8(a)

    图  9   热处理前后接头工程应力—应变曲线与力学性能对比

    Figure  9.   Comparison of stress-strain curves and mechanical properties of the welded joints before and after heat treatment. (a) engineering stress-strain curves; (b) comparison of mechanical properties

    图  10   接头弯曲宏观形貌

    Figure  10.   Macro morphology of the welded joints bend samples

    图  11   焊缝与母材位置极化曲线

    Figure  11.   Polarization curves of weld seam and base metal

    图  12   Nyquist图与Bode图

    Figure  12.   Nyquist curves and Bode diagram. (a) Nyquist curves; (b) Bode digram

    图  13   母材与焊缝位置电化学腐蚀形貌

    Figure  13.   Electrochemical corrosion morphology of base metal and weld seam positions. (a) base material position; (b) weld position

    图  14   Inconel 600合金PA + TIG接头晶间腐蚀SEM

    Figure  14.   Corrosion SEM image of Inconel 600 PA + TIG joint

    图  15   退火处理后焊接接头析出δ相的TEM显微图像

    Figure  15.   Precipitation in welded joints after annealing treatment TEM micrographs of δ phases

    图  16   退火过程中微观结构转变示意图

    Figure  16.   Schematic diagram of the microstructure changes during annealing. (a) γ״ phases growth; (b) δ phases growth

    表  1   Inconel 600及焊丝ERNiCr-3化学成分(质量分数,%)

    Table  1   Chemical composition of the Inconel 600 and ERNiCr-3 metal wire

    材料NiCrFeCuMnCSiSPAlTi
    Inconel 60073.4115.987.830.501.000.1500.500.0150.0150.300.3
    ERNiCr-374.7519.581.750.013.220.0210.280.0050.0040.080.3
    下载: 导出CSV

    表  2   基本工艺参数

    Table  2   Basic welding process parameters

    层数焊接方法送丝速度
    vf/(cm·min−1)
    焊接电流
    I/A
    电弧电压
    U/V
    1PAW210~25027~29
    3TIG22230~26015~17
    下载: 导出CSV

    表  3   Tafel拟合的自腐蚀电流密度与自腐蚀电位

    Table  3   Self corrosion current density and self corrosion potential fitted by Tafel

    位置自腐蚀电流密度
    icorr/(µA·cm−2)
    腐蚀电位
    Ecorr /V
    母材0.73990.334 6
    焊缝0.73160.786 7
    下载: 导出CSV
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  • 收稿日期:  2023-12-24
  • 网络出版日期:  2024-05-21
  • 刊出日期:  2024-06-24

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