In our robotic welding process, we are carrying out a fillet welding of 1 Inch thick circular part which has been case hardened( material AISI 1020) with part of SAE 1008-1010 material in the shape of a plate with thickness of 0.312 inch. Case depth is in the range of 0.012 Inch. There are incidents of failure/ separation of case hardened ring from weld joint in the field application.. Final part undergoes static and dynamic load including impact. We have optimized the welding processes to the maximum to have adequate fusion only to avoid welding distortion of the plate.
This is a typical tube to plate welding of dissimilar materials. You think that you have optimized the welding processes but this may not be true. You should use the failed parts to carry out failure analyses to find the causes of failure: is it due to fatigue or monotonic fracture? Where is the fracture path located? With the information, you may be in a much better position to improve your welding parameters. I suspect the premature failure is due to presence of embrittled microstructures in the heat-affected zones. Regards, Wei Zhou [email protected]
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