Experimental Investigation on Stainless-Steel Weld Overlay on Carbon Steel Plates Using Different Electrodes

This study presents an experimental investigation of stainless-steel weld overlays on 10-mm-thick carbon steel plates (ASTM A 36) using different electrodes in the shielded metal arc welding process widely used in structural joints, pressure vessels and maintenance due to its versatility and simplicity. The weld overlay for sample 1 was created using electrodes of class E 309 L-16 and E 308 L-16, while sample 2 used electrodes of class E 309 L-16 and E 316 L-16. The selection of electrodes aimed to meet the procedure qualification records standards of the American Society of Mechanical Engineers and Saudi Aramco Engineering Standard (SAES). Visual inspection, penetrant testing after each layer, and four side bend tests were performed for corrosion-resistant overlays (CRAs), while hard-facing overlays (HFOs) underwent visual inspection, penetrant testing, macroexamination and three hardness measurements per zone. Ferrite measurements and chemical analysis were conducted for both CRA and HFO as per SAES-W-014. Results indicated that both samples were acceptable based on visual inspection, penetrant testing, macroexamination and side bend tests. But, hardness measurements, ferrite measurements and chemical analysis tests preferred the E309L/E316L weld overlay (sample 2) over the E309L/E308L weld overlay (sample 1) for superior corrosion resistance in stainless-steel weld overlays.