Characterization of Gas Metal Arc Welding welds obtained with new high Cr–Mo ferritic stainless steel filler wires

• New metal cored filler wires for welding 444 grade stainless steel are manufactured.
• The effect of Nb and Ti minor elements on the fusion zone properties is investigated.
• The relation between composition of fusion zone and grain structure is investigated.
• Oxidation rates of fusion zones and base metal are compared.
• High temperature behavior of the welded samples are studied.

Several compositions of metal cored filler wire were manufactured to define the best welding conditions for homogeneous welding, by Gas Metal Arc Welding (GMAW) process, of a modified AISI 444 ferritic stainless steel dedicated to automotive exhaust manifold applications. The patented grade is know under APERAM trade name K44X and has been developed to present improved high temperature fatigue properties. All filler wires investigated contained 19% Cr and 1.8% Mo, equivalent to the base metal K44X chemistry, but various titanium and niobium contents.Chemical analyses and microstructural observations of fusion zones revealed the need of a minimum Ti content of 0.15% to obtain a completely equiaxed grain structure. This structure conferred on the fusion zone a good ductility even in the as-welded state at room temperature. Unfortunately, titanium additions decreased the oxidation resistance at 950 °C if no significant Nb complementary alloying was made. The combined high Ti and Nb additions made it possible to obtain for the welded structure, after optimized heat treatment, high temperature tensile strengths and ductility for the fusion zones and assemblies, rather close to those of the base metal. 950 °C aging heat treatment was necessary to restore significantly the ductility of the as welded structure. Both fusion zone and base metal presented rather homogenized properties.Finally, with the optimized composition of the cored filler wire – 0.3 Ti minimum (i.e. 0.15% in the fusion zone) and high Nb complementary additions, the properties, including the thermal fatigue strength, of the K44X assemblies are excellent.