9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea

Relationship between hardness, dilution and microstructure of hardfacing of

Colmonoy in the groove of Grid Plate made of SS 316
Deenadayalan. K1*, Balaguru. S2*, Velamurali3, Chellapandi. P4
1, 2 & 3 Engineering Design Division, Department of Mechanical Engineering, Anna University, Chennai.
4 - Director, Nuclear & Safety Engineering group, IGCAR, Kalpakkam, Tamilnadu, India
deename2012@live.com, balaguru_iit@yahoo.co.in
Abstract: Plasma transferred arc welding (PTAW) is used to deposit Colmonoy over SS-316 LN as hard faced
coating in grid plate and sleeves for Prototype fast breeder reactor applications. Welding speed is varied from 1.5 to
3.0 mm/sec at small increments of 0.50 mm/sec. Hardness survey, base metal dilution and fusion line width were
analyzed for different welding speeds viz. 1.5 mm/sec, 2.0 mm/sec, 2.5 mm/sec and 3.0 mm/sec. Lower dilution and
higher hardness is obtained at higher welding speed due to lesser heat input. Results indicate that using precise
control of the welding speed, voltage, Current, it is possible to optimize dilution at the interface between Colmonoy
and SS 316 LN.
Keywords: PFBR, Hard facing, PTAW, Hardness, Dilution, Microstructure.

1. Introduction
Prototype fast breeder reactor (PFBR) is a pool-type liquid-sodium-cooled reactor having two separate sodium
circuits with the intermediate heat exchanger providing thermal contact between the primary pool and the secondary
circuit. Sodium acts as a reducing agent and removes the oxidation prevention coating from the 316 LN SS surface
[3]. Many of these structural components in contact with other parts would be in contact with each other or would
have relative motion during operation, and their exposure at high operating temperatures (typically 550C) coupled
with high contact stresses could result in self-welding of the clean metallic mating surfaces. In addition, the relative
movement of mating surfaces could lead to galling, a form of high temperature wear, in which material transfer
occurs from one mating surface to another due to repeated self-welding and breaking at contact points of mating
surfaces. Further, susceptibility to self-welding increases with temperature for 316 SS. Hard facing of the mating
surfaces has been widely used in components of water-cooled and liquid-sodium cooled FBRs to avoid self-welding
and galling. Cobalt-base hard facing alloys have been traditionally used for high temperature application in many
critical hard facing applications due to their excellent wear-resistance properties. Due to induced radioactivity
consideration arising from Co isotope, it was necessary to switch over from more widely used Cobalt based hard
facing alloys to cobalt free alloys for hard facing application in various PFBR components. Ni base hard facing
alloys, which have already been used in various fast breeder reactors worldwide was the alternative material though
weldability of these alloys are poor compared to Co based alloys[3]. A systematic study on hard facing of these
alloys using PTAW process and evaluation of optimum technological parameters which directs to meet the
requirements of hard facing is mandatory. The technological parameters which influence the weld are found to be
voltage, current, powder feed rate and welding speed. Here, to study the influence of welding speed specimens were
prepared at different welding speeds and its effects are evaluated using micro hardness, microstructure and base
metal dilution.

2. Experimental work
In this study, Colmonoy was deposited in the trapezoidal groove made in the base metal 316 LN SS using PTAW
process same as actual grid plate groove dimensions. A trapezoidal groove dimension of typical grid plate model is
shown in Fig.1. The chemical composition of 316 LN SS and Colmonoy is shown in table 1. By keeping all other
welding parameters such as voltage, current, pressure and powder feed rate constant, specimens were prepared by

Corresponding authors: Email: deename2012@live.com; balaguru_iit@yahoo.co.in; Tel +91 9941717817.

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea
varying welding speeds. Before welding, base metal 316 LN SS was preheated upto 400 to relieve the residual
stresses and to limit the cracking after solidification. To evaluate the welding speed, welding was performed linearly
inside the groove. The voltage and current were maintained at 24 volts and 120 Ampere. Welding speed is varied
from 1.5 to 3.0 mm/sec at a small increment of 0.5 mm/sec. Colmonoy powder feed rate, inert gas, centre gas and
shield gas pressures are kept constant for all four different welding speeds. Theoretical heat inputs during different
welding speeds are found using the formula (1) given below:
Heat input, Q =

1000

60

(1)

Where, Q = heat input (kJ/mm), V = voltage (V), I = current (A), S = welding speed (mm/min),
Efficiency = 90%
Using this equation, heat input for welding speeds 1.5 mm/sec, 2.0 mm/sec, 2.5 mm/sec and 3.0 mm/sec are found to
be 1.728 KJ/mm, 1.296 KJ/mm, 1.036 KJ/mm and 0.864 KJ/mm respectively.
After welding, the specimens were cut in the transverse direction to expose the interface between base metal and
Colmonoy as shown in Fig.3 for micro hardness and dilution evaluation.
Table. 1 Chemical composition of 316 LN SS and Colmonoy
Element

Mn

Si

Cr

Mo

Ni

Fe

316 LN SS

0.03

2.0

0.75

0.045

0.03

18

3.0

14,0

0.10

62.045

Colmonoy

0.75

4.8

14.25

Fig. 1 Schematic representation grid plate

Fig. 2 Groove dimensions

73.7

4.9

1.6

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea

2.1 Hardness
Finally, a part of the cut surface was prepared for metallographic inspection by polishing and etching to display bead
shape and microstructure. To know the hardness variation across the interface, hardness survey has been carried out
for total distance of 10 mm with 0.5 mm interval using Micro Vickers Hardness Tester with 0.5 kg loading. Keeping
interface as midpoint (0), hardness was measured for every 0.5 mm gap upwards (Colmonoy) from the interface.
They were given positive signs (+1, +2,.+5). Similarly, hardness was measured down wards (316 LN SS ). They
were given negative signs (-1, -2,-5) as shown in table 1.

Fig. 3 Hardness survey

Table1. Hardness survey across the interface in HVN
Distance in mm across the interface

1.5 mm/sec

2 mm/sec

2.5 mm/sec

3 mm/sec

5
-4.5
-4
-3.5
-3
-2.5
-2
-1.5
-1
-0.5
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5

162.3
166.3
174.3
177
183.9
179.8
157.9
174.5
172.3
200.9
251.2
374.5
402.5
415.6
420.1
407
410.5
430.2
423.5
440.2
476.8

192.1
193.8
190.3
198.3
1201.2
210.5
202.7
195.2
217.69
204.2
272.5
325.9
381.6
475.9
489.1
506.6
540.2
560
575.8
592.5
597.6

162.5
161.8
159.9
163.3
166.7
173.4
182.8
186.7
187.8
201.8
303
412.3
422.2
436.5
441.2
455.4
464.3
477.6
510.2
562.3
600.6

167.2
161.7
164.5
172.1
179.6
183.2
195.1
191.2
190
265.5
373.1
407.2
465.7
489.2
520.3
557.6
580.1
592.3
627.8
663.6
682.1

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea
2.2 Microstructure
The microstructure of a material can strongly influence physical properties such as strength, toughness, ductility,
hardness, corrosion resistance, high/low temperature behavior and wear resistance. Micro structural tests were performed
using conventional optical microscope. The microstructure of the test specimen was investigated and electrolytically
etched using oxalic acid. Images of microstructure obtained using optical microscope at magnifications M 100X for test
specimens 1.5mm/sec, 2.0 mm/sec, 2.5 mm/sec & 3.0 mm/sec are respectively shown in figures 6.a, b, c, d.
Microstructure of these specimens show the weld metal, HAZ and parent metal grain structures. Scale placed in the
microstructure across the interface used to measure the fusion line width. Specimen with speed 1.5 mm/sec has
maximum width of 50micron. As speed increases, fusion line width decreases for 2.0 mm/sec (40micron), 2.5 mm/sec
(30 micron) and 3.0 mm/sec (20 micron).

Fig. 6 Microstructures of Interface (a) 1.5 mm/sec, (a) 2.0 mm/sec, (a) 2.5 mm/sec, (d) 3.0 mm/sec.
2.3 Dilution
The melting of base metal and the subsequent mixing with filler metal causes the final chemistry of the weld deposit
to be between that of the base and filler metals. Depending upon the amount of base metal that is melted and the
amount of filler metal that is added, the final chemistry of the weld deposit can be approximated using the dilution
equation(2).[2]
Dilution % =

(2)

For PFBR applications, dilution has considerable effect on hardness and wear resistance. In grid plate hard facing,
overlay (colmonoy) was deposited upto 4mm (3mm inside the groove and 1mm above the surface) from the base
metal [8]. To obtain maximum hardness at the top surface of hard faced coating, lesser dilution is required. Higher
base metal dilution allows maximum iron infiltration into Colmonoy which reduces the hardness. Hence, limiting of
base metal dilution is important to obtain maximum hardness at top surface. Here, base metal dilution was measured
for the specimens prepared with four different welding speeds using the equation (2). The areas of weld beads are
measured using image analysis software.
For 1.5 mm/sec
Total fusion area

149.09 mm2

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea
Base metal melted area

54.84 mm2

Dilution %

36.24 %

Similarly, for welding speed 2.0 mm/sec, 2.5 mm/sec and 3.0 mm/sec, the dilution percentages were calculated as
38.13%, 29.88% and 18.7 % respectively. Using these dilution percentages final weld composition can be
determined by the formula (3) given below. [5]
Xx = X A (% of base metal dilution) + X F (% of filler metal dilution)

(3)

Where X X = average percentage of element X in the weld,

X A = percentage of element X in the base metal A, and
X F = percentage of element X in the filler metal F.
Calculations are normally made only for major alloy constituents such as iron, chromium, nickel and molybdenum.
Weld composition obtained for different welding speeds are shown in table 3.
Table3. Percentage of chemical composition of weld for different welding speeds
Elements
Iron
Chromium
Nickel

1.5 mm/sec
25.58
15.60
52.088

2.0 mm/sec
26.67
15.60
50.95

2.5 mm/sec
21.97
15.37
55.86

3.0 mm/sec
15.58
14.95
62.53

3. Results and discussions

The weld beads show the characteristics of PTAW. No welding cracks were found in any of the welds shown in Fig.
7. This may be partly due to the good crack resistance of base the metal and the correct welding parameters. No
discontinuities were observed in the fusion metal of the beads, which demonstrates the efficiency of the shielding
gas in preventing oxidation, large porosities and gas inclusions, which cause poor weld quality.

Fig. 7. Cross sections of welded specimens exposing interface.

In all the four specimens, weld material (Colmonoy) was penetrated into the base metal. However, the amount of
penetration varies with heat supplied, which is inversely proportional to welding speed. When the welding speed is
increases, heat input decreases. This causes lesser penetration and ultimately lesser dilution. When the welding
speed decreases, heat input increases. Hence, more amount of base metal is melted and causes more penetration and

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea
more dilution which is evident from the table 3. At lower welding speed (1.5 mm/sec), maximum heat input was
found and it is equal to1.728 KJ/mm. As the speed increases, heat input decreases. (for 2.0 mm/sec = 1.296 KJ/mm,
2.5 mm/sec = 1.036 KJ/mm, 3.0 mm/sec = 0.864 KJ/mm).
Microstructure studies of the different welding speeds reveal that welding speed has considerable effect on the
microstructure. All four specimens show similar dentritic pattern around the interface but the fusion line width
varies with respect to speed (which causes variation in heat input) which can be explained using the Fig. 6.a. For the
welding speed of 1.5 mm/sec, specimen possess 50 microns as width of fusion line due to higher input as explained
earlier due to melting of more base metal. When the speed increases to 2.0 mm/sec, fusion line width reduces to 40
microns. Similarly, for 2.5 and 3.0 mm/sec, fusion line width of 30 microns and 20 microns were measured
respectively.
Studies show that hardness of Colomony in single pass welding is 440 HVN and two-pass welding 485 HVN.
Infiltration of iron into Colmonoy reduces the hardness and the property of Colmonoy is obtained at 1.7 mm height
from the interface (Fig. 8.a). Similarly for 2.0 mm/sec base metal8, intrusion was found upto 1.5 mm height (Fig.
8.b), for 2.5 mm/sec intrusion was found upto 1.25 mm (Fig. 8.c), and for and for 3.0 mm/sec intrusion was found
upto 0.6 mm (Fig. 8.d). Hardness measured towards the hard faced coating shows lesser hardness due to admixture
of base metal (316 LN SS) with Colmonoy. After some extent, hard faced coating exhibits its own property of
hardness. As the intrusion of base metal into Colmonoy decreases at higher speeds, dilution decreases. Comparative
study of variation of hardness across the interface has been shown in Fig. 9. As dilution decreases at higher speeds,
hardness increases.

Fig. 8 Variation of hardness across the interface (a) 1.5 mm/sec. (a) 2.0 mm/sec , (a) 2.5 mm/sec, (a) 3.0 mm/sec.

9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea

Fig.9. Comparative study of hardness across the interface

4. Conclusions
Results obtained from this study demonstrate the influence of welding speed over hardness, microstructure and
dilution.
When the speed increases, heat input decreases i.e. for 1.5 mm/sec 1.728 kJ/mm , 2.0mm/sec 1.296 kJ/mm ,
2.5mm/sec 1.036 kJ/mm, ,) subsequently base metal dilution decreases with increase in speed i.e for 1.5
mm/sec base metal dilution percentage is 36.24% similarly for 2.0mm/sec 38.13%, 2.5mm/sec 29.88%, 3.0
mm/sec 18.7% ).
From the hardness survey, maximum hardness (682.1 HVN) is obtained at higher velocity (3.0 mm/sec), due to
lesser heat input ( 0.864 kJ/mm ) and lesser base metal dilution (18.7%)
When the hardness at the same level for different welding speed is considered, it is directly proportional to
welding speed as dilution is inversely proportional to speed. At a height of 2mm from the interface, hardness
increases from 420.1 HVN to 520.3 HVN as the speed increases from 1.5mm/sec to 3mm/sec.
Specimen with speed 1.5 mm/sec has maximum fusion line width of 50micron. As speed increases, fusion line
width decreases for 2.0 mm/sec (40micron), 2.5 mm/sec (30 micron) and 3.0 mm/sec (20 micron).
From the results obtained, it is suggested that for hard facing using PTAW, higher welding speed can be
preferred, without sacrificing the required metallurgical bonding between Colmonoy and 316 LN SS.

References
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[3] Arun Kumar Bhaduri, Development of Welding and Hardfacing Technology for the Fast Reactor Programme in
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