Synergic investigation of microstructure, precipitation, and micro-segregation on Inconel 825 weldments: A comparative study between GTAW and EBW

Inconel 825, a Ni–Fe–Cr alloy highly regarded for its exceptional corrosion resistance and high-temperature strength. This investigation studies the effect of heat input, precipitation, and micro segregation of Inconel 825 weldments and compares the effectiveness of two welding techniques: gas tungsten arc welding (GTAW) and electron beam welding (EBW). The findings indicate that increasing heat input generally enhances weldment quality by reducing the lack of penetration. However excessive heat input in GTAW leads to root cracking and solidification cracking; while EBW demonstrates better control over undercut and maintains consistent weld quality even at higher heat inputs. Both GTAW and EBW samples exhibit dendritic grain morphologies with distinctive grain boundaries. Precipitates, such as Al₄C₃ and TiN, are observed in both processes, contributing to improved mechanical properties. While GTAW weldments show some degree of segregation for Mo, Cu, Ti, and Al, EBW weldments demonstrate negligible segregation for major alloying elements but micro-segregation of Ti and Al. EBW weldments additionally showcase higher average hardness, superior tensile strength, and ductility compared to GTAW weldments. This can be attributed to lower heat input, faster cooling rates, and a reduced rate of elemental segregation. Fractographic analysis reveals the presence of voids and micro-voids, indicating a ductile mode of failure for both GTAW and EBW samples. These void characteristics vary based on the heat input and microstructural features.