In Situ Analysis of Stress and Microstructure Evolution during Welding of High-Alloy Steels Using Energy-Dispersive X-Ray Diffraction

Abstract Constrained thermal expansion and contraction during welding cause a compression-tension cycle and plastic deformation in the heat-affected zone, leading to work hardening. The nature of this hardening effect—isotropic or kinematic—determines the final local yield stress and thus affects the residual stress state. Therefore, mechanical hardening must be modeled correctly in welding simulations for accurately predicting welding residual stresses. Previous studies, relying on comparisons with experimental ex situ results, led to different recommendations regarding the choice of the hardening model and thus require clarification. In this work, the stress evolution in the heat-affected zone of a tungsten inert gas weld is studied in situ using energy-dispersive x-ray diffraction and a novel method of stress analysis based on crystallite anisotropy. Additionally, microstructural information is gathered through line profile analysis. Results are shown for both austenitic and ferritic high-alloy steels and compared to ex-situ results including a validation of the new method of stress analysis. Finally, conclusions on the nature of work hardening are drawn.