The microstructure and impact toughness of weld metals (WMs) and heat-affected zones (HAZs) of a low-alloy CrMoV steel gas turbine rotor which had served for 14 years were investigated. The ex-service joints in the turbine part (serving at 500–540 °C) and the compressor part (serving below 300 °C) of the rotor were selected for comparative research. The microstructure of the WMs and HAZs between the turbine part and the compressor part was similar, indicating that there was no significant deterioration in microstructure of the turbine part during service. However, compared with the compressor part WM, the impact energy of the turbine part WM decreased significantly, and FATT₅₀ increased greatly. The degraded toughness of turbine part WM was related to more serious intergranular cracking caused by higher segregation level of phosphorus (P) at prior austenite grain (PAG) boundaries. Welding and post-weld heat treatment led to obvious segregation of P at PAG boundaries in WMs, and the segregation of P in turbine part WM was further aggravated during serving at 500–540 °C. Additionally, the inhomogeneous microstructure of the WMs also aggravated the segregation of P. The toughness of the HAZs in both turbine part and compressor part was high, which was because of fine grains. Furthermore, due to there being more grain boundaries and low P content, the segregation of P in HAZs was slight and its adverse effect on the toughness could be ignored.

Low pressure turbine rotors are manufactured by welding thick sections of 25Cr2Ni2MoV rotor steel using tungsten inert gas (TIG) backing weld, and submerged arc welding (SAW) filling weld. In this study, the microstructure of columnar grain zones and reheated zones in weld metal was characterized meticulously by Optical Microscope (OM), Scanning Electron Microscope (SEM) and Electron Back-Scatter Diffraction (EBSD). The results showed that, compared with SAW weld metal microstructure, TIG weld metal microstructure was relatively fine and homogeneous, due to its lower heat input and faster cooling rate than SAW. The maximum effective grain size in TIG and SAW weld were 7.7 μm and 13.2 μm, respectively. TIG weld metal was composed of lath bainite (LB) and blocky ferrite (BF), while SAW weld metal was composed of acicular ferrite (AF), lath bainite (LB)and ferrite side plate (FSP). Tempered martensite (TM) was detected along columnar grain boundaries in both TIG and SAW weld metals, which was related to the segregation of solute elements during weld solidification. Electron Probe Micro-Analysis (EPMA) results showed that the contents of Ni and Mn at the dendritic boundaries were 50% higher than those at the dendritic core in TIG weld. Similarly, 30% of Ni and Mn segregation at dendritic boundaries was also found in SAW weld. In addition, the microhardness of the two welded joints was tested.