Influence of cold metal transfer welding parameters on the welding hot crack of Mar-M247 nickel-based superalloy

Mar-M247 is widely used in several fields as a material with excellent overall performance at high temperatures. However, its complex fabrication process and extremely poor weldability make it very difficult to repair and fabricate. In this study, a novel flux-cored wire with microstructures and composition similar to that of Mar-M247 nickel-based superalloy had been successfully developed, and the superalloy had been effectively repaired by cold metal transfer welding technique. Under the strict control of welding parameters, good metallurgical bonding between the weld and the base metal can be realized, and the hot cracking problem of the joint was successfully suppressed. In the weld, there were closely arranged γ′ phase precipitates with nanoscale and γ/γ′ eutectic structure, granular carbides dispersed at grain boundaries. The hardness of the weld was about 410–430 HV. It had been found that solidification cracks in welds were caused by intergranular liquid films, and grain orientation was found to be an important factor affecting solidification cracking. Optimized welding parameters of cold metal transfer could control the grain orientation of weld and reduce the size of intergranular liquid film, which could effectively suppress the size of weld solidification cracks. Additionally, liquefaction cracks were caused by eutectic reaction liquefaction in the heat-affected zone. The cold metal transfer welding process with optimized parameters can effectively reduce welding heat input, weaken eutectic reactions, and successfully obtain joints without crack in heat-affected zone.