In this paper, a three-dimensional (3D) finite element model was established by ABAQUS software to simulate the welding temperature field of a Ti-6Al-4V alloy under different welding currents based on a Gaussian heat source model. The model uses thermo-mechanical coupling analysis and takes into account the effects of convection and radiation on all weld surfaces. The microstructure evolution of the molten pool was calculated using the macro-micro coupling cellular automaton-finite different (CA-FD) method. It was found that with the increase of the welding current, the temperature in the central region of the moving heat source was improved and the weld bead became wider. Then, the dendritic morphology and solute concentration of the columnar to equiaxed transition (CET) in the weld molten pool was investigated. It is shown that fine equiaxed crystals formed around the columnar crystals tips during solidification. The coarse columnar crystals are produced with priority in the molten pool and their growth direction is in line with the direction of the negative temperature gradient. The effectiveness of the model was verified by gas tungsten arc welding experiments.

The relation between the microstructure and mechanical properties of the Fe–Nb dissimilar joint were investigated using nanoindentation. The weld metal consists mainly of Fe₂Nb, α-Fe + Fe₂Nb, Nb (s,s) and Fe₇Nb₆ phases. Radial cracks initiate from the corners of the impressions on the Fe₂Nb phase (~20.5 GPa) when subjected to a peak load of 300 mN, whereas the fine lamellar structures (α-Fe + Fe₂Nb) with an average hardness of 6.5 GPa are free from cracks. The calculated fracture toughness of the Fe₂Nb intermetallics is 1.41 ± 0.53 MPam^1/2. A simplified scenario of weld formation together with the thermal cycle is proposed to elaborate the way local phase determined the mechanical properties.

Due to the huge difference in thermophysical properties, it is difficult to obtain a defect-free bonding interface between copper and steel. A Cu-Ni-Ti interlayer was added between a TiC-reinforced copper matrix composite coating and Q235 steel in this study to improve its interfacial bond. The influence of the interlayer on its microstructure and properties was studied by characterizing microstructure, phase composition, and wear resistance of the composite coatings. Both coatings were found to consist of α-Cu matrix, in situ-generated TiC, and Fe-rich phases. With the addition of the Cu-Ni-Ti interlayer, the high-hardness unmixed zone at the interface was successfully eliminated due to the sufficient mixing of the molten pool. Even more importantly, liquid metal embrittlement cracks were also restrained, resulting from the Fe-rich solid solution band that reduced the contact probability around liquid copper atoms with the steel grain boundaries formed. In addition, the results showed that the microhardness of composite coatings was improved and the wear loss reduced by 4.2% after adding that interlayer, which was related to the combined action of solid solution strengthening, second-phase strengthening and grain-refinement strengthening mechanisms.

The structural integrity of pipeline girth welds is critical, especially when the welds involve heterogeneous materials and non-uniform wall thicknesses. Current evaluation methods that compare the strength of the weld to that of the base metal (BM) are inadequate for such complex welds. This paper addresses this gap by applying micro-tensile specimen testing to characteristic zones within heterogeneous girth welds that exhibit non-uniform wall thicknesses. We conducted tensile performance tests on X80 and X60 steel pipes featuring unequal wall thickness butt joints. The analysis focused on the wall thickness direction of the girth weld as well as the transverse direction, examining differences and patterns in performance across various regions. The findings provide an improved understanding of property gradients in heterogeneous girth welds and offer practical guidance for more reliable safety evaluation of pipelines with unequal wall thickness joints.