Effect of welding heat input on the microstructure of dissimilar metals: Inconel 625 and 316L stainless

Journal of Basic and Applied Advances in Sciences Vol. 4, No. 2 (2016), 1-17
1

Effect of welding heat input on the microstructure of dissimilar metals: Inconel 625 and
316L stainless
Esmail Ahmadi Zadeh1
, Mohammad Masaeli1
, Reza Dehmolaye1
1
Advanced Materials Research Center, Faculty of Materials Engineering, Najafabad branch, Islamic Azad
University, Najafabad, Isfahan, Iran
Abstract
In dissimilar joining, the correct selection of filler metal and appropriate joining heat input is critical. In the current
study, two dissimilar alloys (Inconel 625, 316L stainless steel) and a super alloy of Inconel 625 were welded using
the tungsten arc method under inert gas protection. Welding was performed using three filler metals (Inconel 625, 82
and 309 L stainless steel) and three different heat inputs (1.5, 1.9, 2.3 kJ/mm) under the protection of argon gas.
Microstructures of different areas of welding joints were investigated under all welding conditions using optical
microscopy and a scanning electron microscope equipped with energy dispersive spectroscopy (EDS). The results
showed that all joining have a good continuity with no splits or discontinuity at the joint point. All filler metals
microstructures were observed in austenitic form with frozen dendrite structure. This investigation showed the
presence of an unadulterated region in some joining, and it became clear that this area increased with increased heat
input.
Keywords: Dissimilar welding, microscopic microstructure, filler metals, Inconel 625, 316L stainless steel
Introduction
Welding is commonly used to connect a wide range
of metals and alloys with different mechanical and
physical properties. In recent years, many studies
have been conducted on welding nickel-based alloys
to stainless steels with a focus on finding the ideal
filler metal. Studies have demonstrated that nickel-
base filler metals show superior properties compared
with austenitic stainless filler metals; cracking caused
by freezing occurs when stainless steel filler metals
are used for these joining [1-2]. Sireesha et al.
evaluated dissimilar welding between austenitic
stainless steel 316 and alloy 800 using four types of
filler metals. Their results showed that the nickel-
based filler metals had a higher tensile strength and
thermal stability than the austenitic stainless filler
metals [3-5]. Lee et al. examined the effect of various
amounts of titanium in filler metals on the weldability
and mechanical properties of dissimilar welds
between nickel-based ally 690 and austenitic stainless
steel L304. The results showed that as the titanium
content increased in the chemical composition of the
filler metal, the microstructure changed from
columnar dendrite to coaxial dendrite [6]. In another
study, Nafakh et al. studied the microstructure and
dissimilar joining weldability between Inconel 657
and austenitic steel 310. Their results showed that the
filler metal Inconel A (a nickel-base filler metal) had
an optimal weldability at room temperature [7-8].
However, a study of literature in the area of
dissimilar metal joining indicated that there is no
systematic study of fusion welding between alloy 625
and austenitic steel 316L, nor is there an ideal filler
metal for a joining between them. Therefore, we
examined the microstructures of welded metals, and
heat-affected zones were evaluated using different
filler metals. The effects of the welding process and
heat input on microstructure and metallurgical
properties of the welding metals were also
investigated.
Methodology
A super-alloy of Inconel 625 (nickel-based) and
austenitic stainless steel 316L were used as base
metals, and filler metals Inconel 82, Inconel 625, and

2

stainless steel 309L were used for better resistance
against splits. Table 1 shows the chemical
composition of the base and filler metals.
Table 1: Chemical composition of base and filler
metals used (wt percentage)
CSi
M
n
C
r
Ni
M
o
N
Nb
+T
a
Fe
Base
and
filler
metal
s
0.
0
2
0.
5
7
1
.
4
1
6.
5
10.4
2
.
1
0.
02
0.0
1
Rem
ainin
g
316L
0.
0
4
0.
1
5
0
.
2
2
3
Rem
ainin
g
8
.
5
0.
02
3.33.5
Incon
el 625
0.
0
3
0.
4
0
.
2
2
1.
7
63
9
.
3
-3.32.0
ERNi
CrMo
-3
0.
0
2
0.
1
3
2
0.
0
Rem
ainin
g
--2.5-
ERNi
Cr-3
0.
0
2
0.
4
1
.
6
2
4.
0
0.13
0
.
1
>0
.1
1
-
Rem
ainin
g
309L
Base alloys were chosen from sheets with a thickness
of 4 mm, and, in accordance with the standards of
electrodes and welding wire (AWS), welding wire
with a high nickel content was used for sample
welding. To establish the joining between the base
metals, sheets with a length of 300 mm, width of 150
mm, and thickness of 4 mm were prepared. To ensure
fusion welding operation and proper penetration, the
sheet was prepared in accordance with the joining
plan. The joining was created under gas (for butt)
using the arc tungsten welding process. The sample
joining plan was prepared in a one-way zigzag form
with an angle of 70 °C. Sample chamfering
operations were performed using a milling machine
with the joining design shown in Figure 1.
Thickness
(mm)
Root
Opening
(mm)
Groove
Angle
(°)
Root
Face
(mm
42.4702
Figure 1: Joining design and its dimensional
specifications
To perform the welding, samples of both base alloys
were assembled together (for butt) with a distance of
4.2 mm (equivalent diameter of welding wire used)
using welds. Welding of samples was performed
under different conditions without preheating and
using the tungsten arc-electrode welding method with
shielding gas and electrode negative polarity (DCEN)
(two filler metals of Inconel nickel base 82.625, and
austenitic stainless filler metal 309L). Table 2 shows
the sample specifications. One of the most important
parameters in welding is the heat input because it
impacts preheat and inter-pass temperatures, thus
affecting the structure and properties of the weld
metal and the HAZ area. The heat input cannot be
directly measured; therefore, equation (1) is
(1) Heat input = µ (UI / V1).
In this relationship, µ is the welding efficiency, which
is equal to 0.65. Welding voltage, current strength,
and welding speed are represented by V, mA, and
mm/s, respectively. Table 2 shows the variables used
to calculate the heat input for the three welding filler
metal (Inconel 625, Inconel 82, and austenitic
stainless filler metal).
Table 2: Welding parameters and filler metals
used
Sam
ple
Sample
characteri
stics
Curre
nt
stren
gth
(A)
Volta
ge
(V)
Mean
weldi
ng
speed
(mm/
S)
Heat
input
(KJ/m
m)
1
Inconel
82
Inconel
625
stainless
309L
90 12 1.87 1.5
2
Inconel
625
Inconel
82
stainless
309L
105 14 1.98 1.9
3
stainless
309L
Inconel
625
Inconel
82
120 16 1.83 2.3

3

To study the microstructures of the base alloys,
welding, and cracks in the heat-affected zone,
metallography was used. For this purpose, samples of
welded base alloys with dimensions of 1× 2 × 4 cm
were made from welds under different conditions.
The samples were mounted hot, and then, using the
silicon carbide emeries, were struck from No. 120 to
2000. After this, with the help of alumina powder
(particle size 0.3 micrometers) and diamond powder,
the samples were polished in two stages. The samples
were etched using a marble solution (10 gr CuSO4 +
50cc HCl + 50cc H2O) for 35 seconds. Then, the
microstructures of the different weld areas, base
metals, and heat-affected zones were analyzed using
an optical microscope. Additionally, a scanning
electron microscope (SEM) equipped with energy
dispersive spectroscopy (EDS) was used to semi-
quantitatively and comparatively study and determine
the chemical compositions, and to more accurately
identify phases and different structural areas.
Results
Welding metal microstructures
Based on the chemical composition of the base and
filler metals, and given that all have a cubic crystal
structure with coaxial aspects; we found that the weld
metal has a cubic crystal structure with a centered
aspect. Since the ratio of nickel in this area is higher
than that of iron, and since it has a FCC structure, we
can use the term austenite. However, the solid nickel
solution has iron and chromium that embody other
alloying elements, such as titanium, niobium,
manganese, silicon, and carbon in its place (due to
the chemical composition of filler metal). Other
studies have shown such elements in weld metals [9].
The influence of microstructure on filler metals
Fine microscopic microstructures of the weld metals
resulting from three different filler metals at a heat
input of 1.5 KJ/mm were evaluated. Figure 2 shows
the microscopic metal microstructure of Inconel filler
metal 82. In Figure 2-A, the dendrite microstructure
of the coaxial weld grains is clearly visible, and the
figure shows that the microstructure in the form of
dendrite structure is axial, and secondary dendrite
branches are also detectable. The figure also shows
that the weld metal structure is fully austenitic
because no transformation occurred during its
freezing. In this figure, the grains at the cellular or
dendrite levels are variable depending on their
location. Near the fusion line, the microstructures of
columnar grains are more cellular-dendrite, and
secondary dendrite branches nearly absent. In areas
close to the welding line, the microstructures of axial
grains are more dendrite axial, and secondary
dendrite branches are detectable in these areas. The
change of the frozen state (by moving from the sides
towards the welding center) is schematically depicted
in Figure 2-B. In general, the content under combined
freezing in alloys is largely determinant of the
microstructure type created. The ratio of G / R is used
as a measure to describe the combination of contents
under combined freezing, where G is the thermal
gradient and R is the growth rate. On the sides of the
welds, R is the lowest and G is the highest value.
Therefore, the X / R ratio reflects the low combined
freezing in these areas. This leads to the formation of
cellular or cellular dendrite structures on the welding
sides or near the fusion line. As we move towards the
welding center, the numerical value of R increases
and the numerical value of G decreases. Therefore,
the (G / R) ratio also decreases, resulting in more
central welding points under combined freezing. This
leads to the creation of the axial dendrite
microstructure in this region. Moving from the edges
towards the welding center, the microstructure
becomes finer, in addition to changing the freezing
state. This can be discriminated both visually and
through measuring the distance between the dendrite
arms. Microstructure crashing results from the
cooling rate and more germination in the central
areas. The multiplication of G × R represents the
cooling rate. As mentioned previously, R increases in
the central parts of the welding, and G decreases.
Since the increase in the R value (increased from zero
at the edge of the RCL in the weld center line) is
higher than the decrease in the G value, the (G×R)
multiplication increases moving towards the welding
center and the cooling rate will be higher in these
areas. In addition, more offshoots will appear in the
central part of the weld. As the cooling rate in the
freezing temperature range gets higher, the freezing
time will be shorter, which gives less opportunity for
the growth of dendrites and dendrite branches.
Increases in grain number due to this higher
germination results in less time for dendrite
formation and growth from any grain. As the cooling
rate in the freezing temperature range will be lower,
there is more time for freezing, and this causes the
smaller dendrite arms to be replaced by larger arms.
This phenomenon is due to a reduction in the total
surface energy. Smaller dendrite arms have a greater
surface energy per unit volume; however, their level
increases as their branches get smaller. Thus, the total
surface energy reduction occurs due to the loss of
dendrite small arms (if time remains) and this results
in dendrite microstructure magnification and
increases in inter-dendrite distances with decreasing
cooling rate in the freezing temperature range. Other
studies have produced similar results [10]. Figure 2
(c) shows the Inconel 82 welding metal
microstructure electron micrograph where the

4

austenitic and sediment field is visible in the
background. The dendrites have been drawn from the
austenitic field border to the grains center. The pond
turbulence and cooling rate was slow, and dendrites
formed in a particular order. No split was observed in
the welding metal.
Figure 2: Inconel 82 welding metal microstructure (a) optical microscope image, (b) schematic of freezing
state changes (moving from the sides towards the center of welding), and (c) scanning electron microscopy
(SEM)
The microscopic structure of welding metal Inconel
625 is shown in Figure 3 (a). Inconel 625 has an
austenitic field with deposits scattered in the field.
This figure shows that the welding metal is frozen in
the dendrite form. Given that the chemical
composition of the filler metal and that of the base
metal are nearly identical, the welding freezing
structure is close to the freezing structure of Inconel
625, namely in its austenitic structure. There are
continuous dendrites, somewhat similar to column
dendrites, distributed equally around the welding,
which demonstrates the uniformity of the chemical
composition in the welding metal. In addition, as the
cooling rate is greater, the distance between the
dendrite arms will be less and the strength and
toughness improve. Figure 3 (b) is an electron
micrograph image of a weld with the filler metal
Inconel 625. Inconel 625 is shown with an austenitic
field with deposits scattered in the field, and the
welding metal is frozen in the dendrite form. The
deposits belong to molybdenum carbide and
chromium M6C (where M means molybdenum and
chromium is C). Due to the high content of
molybdenum in the composition of Inconel 625
(Table 1), the carbide formation is expected to

5

contain a high content of molybdenum. No splits
were seen on the welding metal.
B A
Figure 3: Welding metal microstructure of Inconel 625, A- optical microscope image, (b) scanning electron
microscopy (SEM)
The microstructure of 309L stainless steel welding
metal is shown in Figure 4. The figure shows that the
welding metal is a fully austenitic structure with
dendrite morphology. In these areas, the welding
metal is solidified in an austenitic-ferrite structure.
Structures of the areas solidified in the (AF) state are
have some delta ferrite (δ) that is separated in the
boundaries between dendrites or cells. The freezing
types of austenitic stainless steel are sensitive to
composition (ratio, Creq / NieqNieq = Ni% + 30C%
+ 0.5Mn%, Creq = Cr% + Mo% + 1.55Si% +
0.5Nb%) and kinetic parameters (welding speed).
Other studies have shown similar results [11-12]. The
ratio of Creq / Nieq in stainless steel 309L is equal to
1.71 (Table 1), which is a high value, and the mean
welding speed for this is equal to 1.86 mm/s, which is
relatively low. With high ratios of Creq / Nieq and
lower welding speed, the freezing type orients
towards the AF type. Therefore, the dominant
freezing type of welding metal stainless steel 309L is
AF. Other studies have reported similar results [9,
13].
Figure 4: Optical microscope image of the
microstructure of the welding metal 309L
Effect of heat input on the microstructure of
different parts of welding metal
Effect of heat input on welding metal
microstructures
The microstructure of Inconel 82, resulting from
welding with three different heat inputs, will be
discussed in this section. Figure 5 shows the
microstructure of the welding metal and heat input. In
each of the three heat inputs, the welding metal has
an austenitic field with sediment particles, and the
welding metal for each of the three heat inputs is in
the form of dendrite freezing. Comparison of the
microstructures of the welding metal with different
heat inputs suggests that the dendrite growth
increases considerably with increasing heat input and
melt turbulence, and the highest growth of deposits in
the dendrite-based form was at the heat input of 2.3

6

kJ. Dendrite growth with heat input increase has also been reported by other researchers [3, 9].
A. 1.5, B. 1.9, C. 2.3 kJ/mm
Figure 5: Microscopic structure of Inconel 82 with different heat inputs
The microstructures of Inconel 625 with different
heat inputs are shown in Figure 6. The welding metal
for all three heat inputs has an austenitic field with
sediment particles, and the welding metal is solidified
in the dendrite form. Comparison of the
heat inputs suggests that the melt turbulence
increases with increasing heat input, and the deposit
growth increases. The deposits get longer, and the
cooling rate is smoothed as the heat input increases.
The dendrite structures change to columnar state, and
the highest growth rate occurs at the heat input of 2.3
kJ.

7

A. 1.5, B. 1.9, C. 2.3 KJ/mm
Figure 6: Microscopic structure of Inconel 625 with different heat inputs
The microstructures of Inconel 309L with different
heat inputs are shown in Figure 7. In all three heat
inputs the welding metal has an austenitic field with a
small amount of ferrite, and the welding metal is
frozen in dendrite form. Comparison of the
heat inputs suggests that with an increase in heat
input, freezing has increased, and consequently, the
cooling rate get smother and the ferrite
transformation to austenite decreases. The delta-
ferrite is high, and grains have the opportunity to
grow. Since the melting point of the filler metal is
very similar to the base metal 316L, the melt
turbulence is carried out slowly, and dendrites are
grown in the same proportion. As the heat input
increases, molybdenum, which is a ferrite-
encouraging element, this leads to the ferrite
formation and higher stabilization. A high content of
ferrite leads to frangibility of the welding metal and
freezing cracks on the grain boundaries. The prospect
of forming compressed phases topology (Sigma,
Lave, Chi) has increased because these brittle phases
will significantly reduce the mechanical properties of
the welding metal.

8

A. 5.1 B. 9.1 C. 3.2 KJ/mm
Figure 7. Microscopic structure of Inconel 309L with different heat inputs
The effect of heat input on the microstructure of
the heat-affected zone
Heat input is one of the significant factors on the
weldability of metals and alloys, particularly in
dissimilar metals welding. To study the effects of
heat input on the dissimilar joining of Inconel 625
alloy to austenitic stainless steel 316L, dissimilar
welding between these two alloys were performed
using Inconel 82 filler metal at different heat inputs
of 1.5, 1.9, and 2.3 kJ/mm. The interface between the
welding metal and stainless steel 316L with the three
different heat inputs is shown in Figure 8. Welding
under all the heat inputs had good continuity, and
there were no splits at the intersections. There is a
small, unadulterated area between the welding metal
and stainless steel 316L in each heat input that
increased with increasing heat input in this area.
Increase of the unadulterated area with the increase of
heat input is due to the movement of the molten
welding metal and the melted border area from the
base metal and, consequently, more mixing of the
base and welding metals.

9

A. 1.5, B. 1.9, C. 2.3 KJ/mm
Figure 8: Structure of heat affected by austenite Stainless Steel 316L with different heat inputs
The Inconel 625 intersection with three different heat
inputs with the filler metal Inconel 82 is shown in
Figure 9. In all three heat inputs, the joining had good
continuity and no splits were observed. Comparison
of these figures and the intersection of welding metal
with Inconel 625 did not show an unadulterated area.
Based on Figure 9, sediments in the heat-affected
zone near the fusion boundary have been largely
solved. The figure also shows that, with an increase
in heat input, the sediments are resolved to a greater
extent, and sediments solution areas developed in the
vicinity of the fusion line. The deposit solutions,
especially in higher heat inputs, is due to a sharp
increase in temperature in the heat-affected zone due
to different temperature cycles of different pass-
welding. Figure 10 (A & B) is an electron micrograph
image and carbide point analysis, showing a large
amount of sediment in the area affected by Inconel
625 heat. According to the elemental analysis
characteristics of point B in Table 3, the high content
of elements, such as Ti and Nb, and C, cause carbides
of titanium and niobium to be formed at the
temperature of 650 to 870 °C.

10

A. 1.5, B. 1.9, C. 2.3 KJ/mm
Figure 9: Structure of the area affected by Inconel 625 heat with different heat inputs
A.
B.
Figure 10: Area affected by Inconel 625 heat, A.
scanning electron microscopy (SEM), B. energy
dispersive spectroscopy (EDS)
Table 3: Elemental analysis characteristics of
sediment B

11

Figure 11 shows the intersection of Inconel 625 filler
metal with three different heat inputs. According to
the figure, the intersections of the base and welding
metals are completely continuous and without any
cracks. Due to the use of Inconel 625 and a heat input
increase in each of the three areas affected by Inconel
625 heat, the unadulterated impact is not shown. This
figure shows that the secondary deposits (dark) are
established at the grain boundaries in the area
affected by Inconel 625 heat, with the heat raise
further away from the fusion line. Inconel 625 weld
metal has high levels of chromium and molybdenum,
and the base metal has carbon (0.04%), chromium,
and molybdenum. An increase in heat input can
penetrate from the molten and even solid welding
metal towards the base metal, react with carbon, and
form the secondary sediments, such as chromium and
molybdenum carbides. Carbon also can penetrate
from the base metal to the welding metal and form
sediments near the fusion line in the welding metal.
The highest deposits are seen at the heat input of 2.3
kJ/mm. A linear analysis of carbide elements, such as
Cr, Mo, and Nb, in the area affected by heat increases
and causes the formation of carbides M23C6 and
M6C (Figure 12).
A. 1.5, B. 1.9, C. 2.3 KJ/mm
Figure 11: Microscopic structure of the area affected by Inconel 625 heat with different heat inputs
Atomic
percentage
Weight
percentage
Electron
layer
Elements
70/267/2KaNickel
32/1127/29LNiobium
59/607/2KaCarbon
35/4256/13KaTitanium

12

Figure 12: Carbide-forming element changes in the area affected by Inconel 625 heat
Figure 13 shows the intersection of Inconel 316L
with Inconel 625 filler metal for three different heat
inputs. The heat input increase caused many changes
in the intersection and no cracks were seen in the
heat-affected area. A partial melting area is clearly
visible between the welding fusion line and the base
metal. As the heat input increased in all three partial
areas, metal freezing changed from page to cellular.
The cause for the partial area formation is that
stainless steel 316 L has a melting point (1450 °C)
higher than the melting point of the filler metal of
Inconel 625 (1350 °C). This causes the areas near the
fusion line to be melted due to the high temperature
of the melted welding metal, but not mixed with the
welding metal. Growth in the area will occur in
cellular form due to rapid cooling. With an increase
in heat input, the welding metal, which has a melting
point lower than that of the base metal, freezes faster
than the base metal at the freezing time. Thus, the
area of the base metal that is near the welding metal
is in the molten state, while the welding metal and
base metal are solid. With the increase of heat input,
dendrite growth increased up to 2.3 kJ/mm.

13

A. 1.5, B. 1.9, C. 2.3 KJ/mm
Figure 13: Microscopic structure of the area affected by 316L stainless steel heat with different heat inputs
Figure 14 shows the intersection of stainless steel
316L with three different heat inputs and the stainless
filler metal 309L. The microstructure for all three
heat inputs had an austenitic field with some ferrite
content. With an increase in heat input, the area
affected by stainless steel 316L heat expanded.
Freezing of the heat-affected area is softened by the
heat input increase, but no other important changes
were observed. Figure 15 shows the electron
micrograph image (SEM) of the area affected by
stainless steel 316L heat. In this area, no track was
observed, and the area that was heat-affected
expanded with increased heat input. Dendrite growth
can be seen from the fusion line towards the welding
metal.

14

A 1.5, B 1.9, C 2.3 KJ/mm
Figure 14: Microscopic structure of the area affected by stainless steel 316L heat with different heat inputs
Figure 15: Scanning electron microscopy (SEM) of microstructure of the area affected by stainless steel 316 L
heat with filler metal 309L
Figure 16 shows the intersections of Inconel 625
welding metal with three different heat inputs and the
stainless filler metal 309L. With an increase in heat
input, the intersection of Inconel 625 and welding
metal in each of the three heat inputs is completely

15

continuous with no cracks. No significant change was
observed, except for minor melting near the fusion
line in the area affected by Inconel 625 heat. This
partial melting area is visible due to the difference in
the melting point of the filler metal with that of the
base metal in the area affected by Inconel 625 heat. In
this area, the borders were melted and thickened, and
the melt area increased slightly with the increase of
heat input. Figure 17 shows the linear analysis of the
area affected by Inconel 625 heat. In this area, the
nickel has decreased and the iron has increased. The
reason is that the iron content is high in the chemical
compositions of the 309L filler metal, and the Inconel
625 base metal is nickel-based (Table 1).
A 1.5, B 1.9, C 2.3 KJ/mm
Figure 16: Microstructure of the area affected by Inconel 625 with different heat inputs

16

Figure 17: Linear analysis of the area affected by Inconel 625 heat with the filler metal 309L
Conclusions
The most optimal heat input for the dissimilar joining
was recorded as 1.5 kJ/mm. With an increase in heat
input, the HAZ and partial melting area increased, but
the synthetic gradient decreased. The welding
structure was fully austenitic for all filler metals.
Cellular-dendrite structure occurs for L309, while
dendrite freezing occurs in Inconel 625 and 82 filler
metals. Inconel 625 filler metal microstructure is
smaller than the grain of Inconel 82 filler metal.
When comparing the ultimate strength of the filler
metals, Inconel 625 was highest. The fully austenitic
microstructure of Inconel 82 had coaxial grains. The
sediment analysis results show that the grain
boundary is the NBC carbide type.
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