Synthesis and Characterization of Novel Chromium-Free Nickel Alloy Electrode Materials

The synthesis of two Cr-free nickel-based alloys designated as 1S with 6.5 pct Mn and 2H without Mn of compositions varying between 40 to 43.5Ni, 20Mo, 22 to 25Fe, 10Cu, 6.5 to 0Mn, 1Ti, and 0.5Al (wt pct) as filler materials for TIG welding application was performed. New filler materials were developed to reduce carcinogenic hexavalent chromium (Cr 6+ ) fumes generated during the welding of 300 series austenitic stainless steel. The Cr-free nickel alloys were characterized for microstructure and mechanical properties. The developed alloys showed good microstructure stability in as-cast and solution-treated conditions. A material properties simulation software JMatPro predicted that 2H alloy has 2 wt pct more γ (solid solution) phase than in 1S but has 2.2 wt pct less γ ′ (strengthening precipitates) phase than in 1S alloy. The tensile strength of 1S alloy was about 2.2 pct more than 2H. The solution treatment of both alloys decreased the hardness, tensile and yield strengths by about 21 pct but ductility improved by about 17 pct. Fracture studies of both alloys showed the ductile mode of failure.