Materials and Design 53 (2014) 645650

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Materials and Design

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Technical Report

Experimental investigations on welding behaviour of sintered and forged

Fe0.3%C3%Mo low alloy steel
R. Chandramouli , T.K. Kandavel, P. Karthikeyan 1
School of Mechanical Engineering, Shanmugha Arts, Science, Technology and Research Academy (SASTRA University), Thanjavur, Tamil Nadu 613 401, India

a r t i c l e i n f o a b s t r a c t

Article history: Tungsten Inert Gas (TIG) welding is considered as one of the cleanest welding methods. It is generally
Received 20 March 2013 adopted for thinner materials with moderate weld joint strengths. Welding of sintered porous materials
Accepted 19 July 2013 continues to be a challenge due to the inherent porosity of the parent metals. The present research work
Available online 27 July 2013
attempts to address some of the issues relating to the welding behaviour of sintered and forged Fe
0.3%C3%Mo low alloy steels under TIG welding. Rectangular strips of size 70 mm  15 mm  5 mm,
obtained by blending, compacting and sintering of elemental powders of iron, graphite and molybdenum,
were upset forged both hot and cold in order to obtain alloy steel strips of various porosities. Two identical
alloy steel strips of equal density were then welded both along longitudinal and transverse directions, by
TIG welding, employing ller metal of suitable composition. The welded strips were then subjected to ten-
sile test, hardness test, microstructural and Scanning Electron Microscope (SEM) fractography studies.
Cold/hot upsetting of the sintered alloy preforms has led to enhanced density. As a result of improved den-
sity, their tensile strength and hardness values were also found to be enhanced. The welded alloy exhibited
higher tensile strength compared to the un-welded base metal, due to strengthening by residual stress. Sim-
ilarly, the strength and hardness of the welded alloy strips were found to be enhanced with increase in den-
sity. The tensile strength of welded joint is found to be higher compared to that of the base metal due to alloy
metals segregation, rapid cooling and formation of acicular ferrite at the weldment of welded joint. No
porosity was observed in the weld metal or Heat Affected Zone (HAZ) of the weld joint. However, the base
metal had numerous micro pores, though pore migration towards weldment has not been observed.
2013 Elsevier Ltd. All rights reserved.

1. Introduction
Powder metallurgy (P/M) is one of the most cost-effective and
technologically competitive manufacturing processes. Small com-
ponents are being manufactured through powder metallurgy route
for applications such as automotive, defense, aerospace etc. Rapid
progress in P/M manufacturing, currently achieved, certainly
points to the possibility of larger and heavier parts through P/M
route. Production of heavier parts of assembly through P/M tech-
nology certainly calls for joining of P/M parts to conventional or
other P/M parts. Welding of sintered alloys with inherent porosity
is a challenging task, because of issues such as reduced thermal
conductivity of the porous metal, reduced hardenability and pres-
ence of impurities such as oxides. Pores themselves act as sink for
gas inclusions and hence may lead to cracking and inclusion type
defects after welding. Heat transfer characteristics of the porous
base metal have greater inuence upon cooling rate, heat input
and tendency to harden. Porous base metal as well as weld metal
Corresponding author. Tel.: +91 04362 264101; fax: +91 04362 264120.
E-mail addresses: cramaswamy@gmail.com, rcm@mech.sastra.edu (R. Chandramouli).
1
Junior Research Fellow.
may render them very hard but brittle. Toughness of the welded
powder metallurgy alloy is likely to be compromised due to poros-
ity. The present research is aimed at study of feasibility of joining
sintered alloy steel through conventional welding technique, viz.
TIG welding. Low alloy steels containing Mo are good candidate
materials for high strength and high hardness structural applica-
tions. A weldability study on sintered steels is an area of research
which has been scarcely attempted. Very limited number of
researchers has reported the results of such studies.
Hamil [1] has provided an overview of the feasibility of various
welding processes for sintered steels. Gas tungsten arc welding
(GTAW/TIG), laser beam welding (LBW) and friction resistance
welding (FRW) are reported to be successfully carried out on sin-
tered steels. He has reported that lower heat input, short circuit
metal transfer and near-theoretical density of the steel to be
welded could promote sound weld joint. Selcuk et al. [2] have re-
ported that rapid cooling rates could promote porosity of weld me-
tal due to trapping of gases. They have also reported that gas metal
arc welding (GMAW), LBW and GTAW could be successfully em-
ployed for welding of sintered materials with minimal porosity.
It has been concluded that some amount of porosity coupled with
lower carbon could promote pearlitic structure, thereby avoiding
martensite phase. Correa et al. [3] have found that porosity has

0261-3069/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
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646 R. Chandramouli et al. / Materials and Design 53 (2014) 645650
Table 1
Mechanical properties of sintered/forged Fe0.3%C3%Mo alloy steel.
Nature of P/M alloy steel (Fe0.3%C % Theoretical Mechanical properties
3%Mo) density
Hardness value
(HV)
Parent alloy steel 85 193
87 205
92 224
Welded alloy steel 85 242(WZ)
87 244(WZ)
92 249(WZ)
little effect on weldability of sintered iron with phosphorous and
nickel additions, if the sintered density is above 7 g/cc. They have
also concluded that pulsed current is favourable for plasma arc
welding (PAW) of the steels in view of lower heat inputs and grain
renement effect produced on weld zone. Joining of sintered iron
with phosphorous and nickel additions by pulsed current GTAW
process has been successfully demonstrated [4]. It is reported that
use of austenitic steel ller rod could promote a pore-free, tough
weldment, without solidication cracks in weld zones. Narrow
heat affected zone (HAZ) has also been reported as one of the ben-
ets of pulsed GTAW. Use of ller wire with high manganese, alu-
minium and titanium contents during laser welding of low carbon
sintered steel is reported [5] to promote weld joint without poros-
ity, blow holes, fusion zone cracking, etc., thereby making weld
joint possessing good strength. Arivazhagan et al. [6] have studied
the mechanical properties of welded dissimilar joints of AISI 304
and AISI 4140 made by TIG, FRW and electron beam welding
(EBW). They found that the joint prepared by EBW has higher ten-
sile strength compared to other welding process due to macro seg-
regation and enrichment of chromium, nickel, iron and carbon at
high temperature and also due to welding speed of the process.
Cao et al. [7] have compared the welding strength of high strength
low alloy steel (HSLA-65 plate) under LBW and GMAW and they
have found that the joint made by GMAW attributes to the higher
yield strength and hardness due to deep penetration of welding
and restricted heat affected zone and residual stress compared to
laser welding.
Mehta et al. [8] have investigated the feasibility of welding on
iron based low alloy steel (FePC) under tungsten inert gas weld-
ing process using two different ller metals (ER70S-6 and FePC).
They have observed that the hardness and tensile strength of
welded joint are slightly higher than that of the base alloy steel
due to the presence of pores and residual stress in the base metal.
They have also concluded that the joint obtained by using ER70S-
6 ller material possesses better strength due to elimination of
pores in the welded region and columnar ferrite structure. Mathu-
sudhan et al. [9] have studied the weldability of high strength low
alloy steel containing CNiSiCrMnMo with two austenitic ller
material 309L and 18Cr8Ni6Mn under TIG welding process. They
have observed that the tensile strength of the welded joint is 70% of
the base metal and the joint made by using CrNiMn ller has
higher strength and hardness than that obtained using 309L ller
metal. Lower strength of the welded alloy has been attributed to
weld-metal segregation. Lakshiminarayanan et al. [10] have stud-
ied the mechanical properties of ferritic stainless steel welded by
continuous current gas tungsten arc welding (CCGTAW), pulsed
current gas tungsten arc welding (PCGTAW) and plasma arc weld-
ing (PAW). They have observed that the welded joint made by
PAW has superior tensile and impact strength than the other weld-
ing processes. The higher strength is due to the formation of ne
grains in the fusion zone in the case of PAW process. It has been re-
ported [11] that though the welding strength of ferriticmartensitic
T91 steel is almost same, the percentage elongation in length is
Ultimate tensile strength(UTS) in % Elongation in % Reduction in
(MPa) length area
135.23 2.980 3.432
154.24 2.882 3.011
258.34 2.461 2.589
218.00 3.506 3.780
273.00 3.099 3.200
337.00 2.680 2.900
lesser due to liquid metal embrittlement in the case of TIG welding
compared to EBW. Chen et al. [12] have investigated the compati-
bility of China Low Activation Martensitic (CLAM) Steel under Hot
isostatic pressure (HIP) diffusion welding, TIG welding, LBW,
PAW, Arc-Ultrasonic welding and have found that the application
of ultrasonic energy during TIG welding signicantly improves
the impact strength of the steel. The formation of tempered mar-
tensite at the weld metal is reported [13] to result in higher welded
tensile strength compared to the base metal of CLAM steel under
TIG welding. Wang et al. [14] have studied the welding properties
of dissimilar welding using low alloy steel (API X70) and duplex
stainless steel (UNS S31803) under MIG and TIG welding process.
They have experimentally found that the mechanical and corrosion
resistance properties under MIG welding is superior than that of
TIG welding due to the formation more austenite in the weld metal.
Qinglei et al. [15] have investigated the TIG welding characteristics
of MoCu composite and 18-8 stainless steel joint and have found
that the microhardness value is increasing towards MoCu com-
posite due to the possible formation of FeMo compound at the
joint. It has been observed [16] that the activated TIG welding of
17Cr10Ni2Mo alloys using FeS and FeO powders has promoted
better welding characteristics such as deep penetration of joint,
good weld geometry, lesser angular distortion, lesser susceptibility
of hot crack, lesser heat input compared to Fe2F powder due to in-
creased content of delta-ferrite. Suresh Kumar et al. [17] have stud-
ied the welding strength of AISI 304 and 316 steels under TIG and
MIG welding processes. They have found that the tensile strength
of TIG welded specimen is higher than that of specimens welded
by MIG welding process due to the absence of delta ferrite and en-
hanced austenite in the microstructure. Both MIG and TIG welding
processes are reported [18] suitable for high alloy martensitic steels
due to higher tensile strength and restoring the strength after post
treatment. It has been experimentally found [19] that the welding
of Cr+C steels equivalent to EN1.4003 with TIG welding using
309L consumable could result in better weld metal toughness. At
the same time, using 316LSi consumable gives better HAZ tough-
ness and strength due to coarsened microstructure. Malik and Mroz
[20] have investigated the inuence of TIG welding current and
speed on weldability of AZ91 magnesium alloy and they have found
that increase in welding current and weld speed results in better arc
and melt for optimized current value of 300A.
The welding behaviour of Mo added plain carbon steel is stud-
ied in two ways in this research. First, inuence of pores in welding
of the P/M alloy steel has been studied and secondly the welding
characteristics of the P/M alloy steel has also been studied in the
present research work.
2. Experimental details
Elemental powders of atomized iron (Fe) 100 lm, graphite (C)
5 lm and molybdenum (Mo) 100 lm were accurately weighed
and thoroughly mixed in an indigenously fabricated ball mill for
 R. Chandramouli et al. / Materials and Design 53 (2014) 645650
Fig. 1. Plots of tensile strength of parent and welded low alloy steels at various
densities.
Fig. 2. Plots of steels % elongation in length and % reduction in area of parent and
welded low alloy steel at various densities.
Fig. 3. Hardness prole of the welded alloy steels.
12 hrs to get the alloy composition of Fe0.3%C3%Mo. Powder mix
was then compacted to a rectangular shape of size 70  15  5 mm
using a computer interfaced 1000kN capacity Universal Testing
Machine (UTM). The green compacts were prepared using a suit-
able die-punch set by applying required axial compaction force
equivalent to 80% theoretical density. Indigenously made ceramic
coating was applied on the green compacts to prevent oxidation
during sintering. The coated and dried samples were then sub-
jected to nitrogen purged inert atmosphere sintering process at a
temperature of 1120 10 C for 20 min. The sintered specimens
647
were cleaned and subjected to different levels of cold upset forging
to get various densities of the P/M alloy steel namely, 85%, 87% and
92% of theoretical density. The maximum density for the study was
set at 92% due to the limitation in capacities of machine as well as
dies used for the upset forging. Tungsten inert gas (TIG) welding
was carried out on similar pairs of strips of the sintered and
upset alloy. The standard ER90S-G ller material was used for
the continuous TIG welding of the strips, without any joint prepa-
ration. After preliminary trials, the welding parameters were set at
9 V, 150A, DC straight polarity for the TIG. The strips were pre-
heated to 150 C along the joint area. The welding speed was main-
tained at 7075 mm/min. Standard tensile specimens were
prepared as per the ASTM: E8 standard from the weld joints to con-
duct tensile test on the specimens. Vickers micro hardness values
of parent metal and weldment of the P/M alloy steels were mea-
sured using Shimadzu micro Vickers hardness tester (Japan). Opti-
cal micro images of the P/M alloy steels were observed using
KYOWA, ME-LUX2, microscope tted with CCD camera, interfaced
with a computer and image analyzer. SEM images of the tensile
fractured surfaces of the alloy specimens were observed using
JEOL-Field Emission Scanning Electron Microscope (TSM-6701F, Ja-
pan). The tensile properties of the parent and welded alloy steels
were corroborated with microstructures and SEM images of the
same alloy steels.
3. Results and discussion
The welding behaviour of sintered Fe0.3%C3%Mo alloy steel
has been studied with respect to various parameters, namely, ten-
sile strength, hardness, microstructural changes, and fractography
of tensile fractured surfaces.
3.1. Tensile strength and hardness
Table 1 summarizes the mechanical properties of the un-
welded low alloy steel and the welded steel. In general, the per-
centage elongation and reduction in area for both the alloys are
found to be very low, irrespective of their density. Such low ductil-
ity of the alloy is basically attributed to the inherent porosity [3].
Further, the densied alloys were not subjected to any type of
stress-relieving heat treatment. The strain hardening effect pro-
duced by the cold upsetting treatment could have considerably re-
duced the ductility.
Figs. 1 and 2 exhibit the variation of tensile properties of the
base metal as well as the welded alloy with respect to density.
The general observation for both un-welded and welded alloy is
that the strength increases almost linearly with density. Similarly,
the percentage elongation and reduction in area are also found to
decrease linearly with enhanced density [3]. The welded alloy steel
is found to exhibit higher tensile strength compared to the base
material [8,13]. This increase in strength could be attributed to
three reasons, namely alloy metal segregation, the formation of
acicular ferrite at the weldment and residual stress in base metal
after welding. Further, the absence of porosity, blowholes and
other defects in the weld metal could have promoted greater
strength of the welded joint [5]. The maximum ultimate tensile
strength attained by the welded specimen for 92% density is
337 MPa as against 258 MPa for the parent alloy steel. The lower
tensile strength and poor ductility of the base metal is basically
due to the retained porosity [3]. The moderate improvement in
tensile strength for the welded joint categorically shows that the
welded joint is stronger than the base metal. The welded alloy also
exhibits slightly enhanced ductile properties such as percentage
elongation in length and percentage reduction in area compared
to the parent alloy steel.
648 R. Chandramouli et al. / Materials and Design 53 (2014) 645650
25 m
(a)
10 m
(c)
Fig. 4. Microstructures of (a) parent metal, (b) weld metal of the alloy steel with 92% density, (c) weld metal of the alloy steel with 87% density, (d) fusion zone.
Fig. 3 shows the hardness prole for the welded alloy steel. It is
clearly evident from the gure that there is minimal variation of
hardness values even with variation of base metal density, along
the weld zone due to homogeneity of microstructure in the weld
zone. Further, the highest hardness of the weld zone (HV 245) is
clearly due to the homogeneous acicular/lath ferritic structure as
well as absence of porosity and blow holes [8,13,15]. The micro
hardness values of the welded metal are found to vary steeply
along the base metal and HAZ, due to variation in density [15].
The base metal with the highest density of 92% shows almost at
hardness prole along the weld metal. Higher density of the parent
metal is found to promote homogeneity in hardness along the
weldment. On either side of the weld zone, the HAZ is found to ex-
tend through a distance of about 2500 lm, as against 5000 lm
length of the WZ.
3.2. Microstructures
Photomicrographs of both parent metal and the welded region
are shown in Fig. 4. The parent metal microstructure is found to
be ferriticpearlitic, with well dened equiaxed ferrite grains pres-
ent all over. The ne-grained ferrites are observed to have well-de-
ned grain boundaries. Fineness of the ferrite structure is
attributed to the forging treatment carried out after sintering.
Unresolved pearlites along with numerous, round Mo carbide par-
ticulates are observed along grain boundaries. A few rounded pores
are also observed along the grain boundaries. The fusion zone and
heat-affected zone exhibit coarse ferritic structure, as seen in
Fig. 4(b). The ferrite grains are large, irregular shaped with little
pearlites. Lack of pearlites in these zones may be attributed to car-
bon migration by diffusion towards the weld metal, thereby
depleting these zones of carbon. Further, a few rounded pores
are observed along the HAZ. Very near to fusion zone, a few micro
pores are also observed. Fig. 4(c) shows the structure of the weld
metal of the alloy with 87% density. The WZ microstructure is ob-
served to be uniformly ferritic, with acicular as well as lath struc-
ture of the ferrite grains. The WZ does not exhibit porosity or
blowholes. However, the base metal microstructure shows a num-
ber of rounded pores, with ferritic microstructure. Fig. 4(d) exhibits
100 m
(b)
10 m
(d)
the microstructure of the weld zone of the alloy with 92% density.
The entire zone has acicular or feathery ferritic microstructure
with a few lath ferrites. Formation of acicular structure in the weld
zone is basically governed by cooling rate, alloy content and heat
input during welding. The moderate heat input of the welding pro-
cess, primarily due to pre heating and inter-pass heating has re-
sulted in faster cooling rates but not excessively high cooling
rates. As a result the weld zone contains acicular ferritic structure,
without forming martensite. Another important reason for the
non-martensitic structure of the weld zone is the low carbon con-
tent of the base metal, namely, 0.3%. Literature reports [1] that ex-
cess carbon content in base metal may promote brittle martensite
phase in the weld metal. The ller metal composition has also
played a role in promoting acicular structure of the weld zone. A
few tiny micro voids are observed within the weld zone, very near
to fusion. However, these voids appear to have no inuence on the
hardness of the WZ or tensile strength of the welded alloy. Higher
strength and hardness of the welded low alloy steel, therefore,
could be attributed to the acicular/lath ferritic structure of the
WZ, along with the absence of voids, blow hole porosity and fusion
cracks along the WZ. The HAZ also does not exhibit any such com-
mon weld defects, though the inherent porosity of P/M alloys is
still observed in HAZ. Overall, it is observed that density of the base
metal appears to have almost nil inuence on the microstructural
integrity and superior hardness of the weld zone.
3.3. SEM fractographs
SEM fractographs of the fractured surfaces of both un-welded
base metal as well as the TIG welded alloy steel are shown in
Fig. 5. The basic mode of fracture of the base metal is brittle. This
is evident from the presence of large voids along which the metal
has undergone de-cohesion. A few microvoids are also found,
which could have contributed to de-cohesion. Presence of deep
valleys and depressions in the fractograph also conrms the pre-
dominantly brittle nature of the fracture. A few micro dimples,
which form a honeycomb structure are also observed. Very few
shear lips are also observed in the structure. Presence of deep, large
size void indicates the pull off of carbide particulates during tensile
 R. Chandramouli et al. / Materials and Design 53 (2014) 645650 649

a(i) a(ii)

a(iii)

b(i) b(ii)

b(iii)
Fig. 5. SEM images of fracture surfaces of (a) parent alloy steel, (b) welded alloy steel.

loading. Fig. 5(b) illustrates the morphology of the fractured sur- seen in the structure. A few large sized voids with deeper, vertical
face of the welded alloy steel subjected to tensile test. Mixed mode facets are seen, which are indicators of crack origination and stress
of fracture is predicted for the alloy based on the presence of a concentration. A few irregular shaped micro cracks as well as elon-
large number of dimples. Flat shear facets and shear lips are also gated, attened pores are also visible.
650 R. Chandramouli et al. / Materials and Design 53 (2014) 645650
4. Conclusions
Based on the experimental results obtained from various tests
for weldability, microstructures and SEM fractographs of sintered/
forged steel, the following major conclusions have been drawn:
(1) Porosity of the P/M low alloy steel has notable inuence on
tensile strength, but not on the weldability of the steel.
(2) Density of base metal has negligible inuence on micro-
structural integrity and hardness of the weld zone.
(3) Favourable ferritic microstructure of the weld zone has con-
tributed signicantly towards the improvement in tensile
strength and hardness of the welded steel.
(4) Formation of acicular ferrite in the weld zone has improved
the overall integrity of the weld joint of the low alloy steel.
(5) Feasibility of TIG welding of porous sintered low alloy steel
has been proved through selection of appropriate weld
parameters as well as suitable ller metal with chromium
and molybdenum content.
Acknowledgements
This research work was carried out under the research grant of
D.S.T. S.E.R.C. scheme, sanction no. 100/IFD/4543/20092010,
Govt. of India. The authors express their sincere gratitude to Prof.
R. Sethuraman, Vice Chancellor, SASTRA University for granting
permission to publish their research work. We thank M/S Shanmu-
gha precision forgings, a sister concern of SASTRA University and
M/S G.B. Industries, Thuvakudi, Tiruchirapalli for their support in
the research work.
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