Effect of weld parameters on porosity formation in electron beam welded Zircaloy-4 joints: X-ray tomography study

Zircaloy-4 to Zircaloy-4 (Zr-4) similar butt joints were prepared using Electron Beam Welding (EBW) technique under different weld conditions such as with beam oscillation, without beam oscillation and at different welding speeds. Three-dimensional (3D) visualisation of porosity in weld joints was carried out using X-ray computed tomography (XCT) technique. Quantification of porosity such as the average size, number and shape of the pores were evaluated and compared among weld joints produced under different conditions. XCT results show that the porosity of the welds increased substantially with the increase in the weld speed. More interestingly, the results also show that there is a significant decrease in porosity of the joint produced with beam oscillation condition. An increase in weld speed from 700 mm/min to 1000 mm/min resulted in a significant increase in pore density (from 16 to 313 per mm3) and it was observed that the average size of the macro pores increased from 96.4 μm to 121.5 μm. The joints prepared with beam oscillation produced least number of pores with minimum percentage of macro pores and maximum percentage of spherical pores in it. Raman spectroscopy results confirmed the presence of hydrogen gas in pores of all the weld joints.