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Microstructural Investigation and Integrated Optimization of Weld Bead Characteristics in Electron Beam Welding of Inconel 825

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Abstract

This work presents welding investigation of a popular Ni–Fe–Cr-based alloy (i.e. Inconel 825) using electron beam welding process, considering beam current (I), accelerating voltage (V), welding speed (S), and beam oscillation (O) as weld parameters. Microstructural investigations of the different zones of the welded specimen have been studied. Predictive models for depth of penetration (P) and width of the weld (W) are developed using response surface methodology (RSM). The novelty of this work is the metallurgical investigation and the development of RSM integrated with the JAYA algorithm to optimize weld parameters so as to minimize the width-to-depth ratio (W/P ratio) by maximizing P and minimizing W. Accelerating voltage (V) is found to be the predominant weld parameter on P and W followed by beam current (I). Microstructural study reveals the presence of beneficial twin boundary and strengthening precipitates like TiN and secondary phase precipitate Al4C3 in SEM/EDX analysis. Detrimental structures like migrated grain boundaries and unmixed zone are not witnessed. The RSM-JAYA optimization approach results in an optimum W/P ratio of 1.2405 mm at parameter setting V = 54.52 kV, I = 46 mA, S = 900 mm/min, O = 200 Hz. The validation result shows an improvement of 4.71% in the optimum fitness value. The proposed integrated optimization approach is found robust in locating the optimal solution with minimum numbers of iterations.

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Acknowledgements

The authors acknowledge the authorities of IIT, Kharagpur, IIT, Guwahati, NERIST, Arunachal Pradesh, for providing the requisite (experimental and measurement) facilities to conduct the investigation. The authors also acknowledge anonymous reviewers for their comments that enrich the quality of the manuscript.

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  1. Mechanical Engineering Department, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh, India

    Bishub Choudhury & M. Chandrasekaran

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  1. Bishub Choudhury
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Correspondence to M. Chandrasekaran.

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Choudhury, B., Chandrasekaran, M. Microstructural Investigation and Integrated Optimization of Weld Bead Characteristics in Electron Beam Welding of Inconel 825. Trans Indian Inst Met 74, 2681–2701 (2021). https://doi.org/10.1007/s12666-021-02343-1

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