Superalloy—Steel Joint in Microstructural and Mechanical Characterisation for Manufacturing Rotor Components

The structure of energy rotor components includes different structural materials in the sections, which are subjected to varying levels of thermal loading. The first component section has to include a precipitation-hardened nickel-based alloy, while the second one may be manufactured from other materials. Due to the installation cost, the use of expensive nickel-based materials is not recommended for applications in sections with a lower degree of thermal loading. Therefore, this aspect is still actually from an engineering point of view and is discussed in the paper by means of manufacturing and experimental approaches. The paper follows the welding problems related to a hybrid joint made of superalloy (Alloy 59) and hard rusting steel (S355J2W+N steel). The problem is solved using the MIG process at various parameters. With respect to the joint quality, microstructural features and mechanical parameters of the examined zone are presented. In the case of microstructure analysis, the dendritic and cellular natures of austenite were dominant elements of the joint. Mechanical tests have expressed a 50% reduction in elongation of the steel and alloy steel weld and lowering mechanical parameters. Mechanical parameters of the joint were on the level of their values observed for the steel, while the hardening coefficient followed the hardening curve of the alloy. Decohesion of the steel and mixed weld has reflected the constant proportion of values of axial and shear stress components up to the total separation. It is noted the tensile curves of the alloy and alloy steel joint follow a very similar shape, reporting the same response on the monotonic tension. The materials can be analysed by applying constitutive equations at very similar values of their coefficients. The obtained results enabled elaborating and examining the MIG welding process for thick-walled structures (not smaller than 8 mm) in detail giving all parameters required for technology. Finally, the technology for producing a hybrid joint using difficult-to-weld materials with different physical and mechanical properties, such as nickel alloys and low-alloy steels, is proposed. Results have shown it possible to develop a technology for producing of hybrid joints (supper alloy + hard rusting steel) with assumed physical and mechanical properties for rotors applied in the power boiler. This solution was proposed instead of previously used elements of rotors from expensive materials. It was assumed that the newly proposed and utilised method of welding will allow for obtaining good properties in terms of energy devices.