Laser welding was performed using different filler wires, ER70S steel, commercially pure iron, and pure nickel filler, in the context of welding X80 pipeline steel to assess the microstructure and mechanical properties of the weld metal. Introducing an ER70S wire promoted acicular ferrite formation in the fusion zone, compared to a bainitic microstructure in an autogenous laser weld. The use of pure iron wire was considered as a potential strategy for reducing hardenability, as it led to the dilution of alloying elements in the fusion zone, increasing ferrite content and reducing weld metal hardness to a level compliant with API pipeline standards. The addition of pure nickel wire was used to reveal the degree of weld metal mixing imposed by the laser (thus providing an unambiguous tracer element) when it is combined with filler material dilution in the fusion zone, revealing that the upper region contained 38% wire material and the lower region only 12%. This accounts for the differences observed between the upper versus lower portions of the weld metal when other wires are used, and the use of hardness mapping and micro-indentation demonstrates the correlation between the variations in mechanical properties and microstructural differences introduced by incomplete mixing of the filler wire elements.

A tempering cycle was developed via heat treatment to study the decomposition of detrimental martensite–austenite (MA). The heat treatment cycle was found to preferentially decompose hard MA with a critical size of ≥1 µm, which decreases the hardness of these microconstituents after tempering at 300°C for 10 min. The dislocation density inside the MA and in the surrounding matrix was also decreased. Tempering of the X80 weldments containing MA reveals a similar decomposition behaviour. During transverse weld tensile testing of welds, a fracture occurred in the heat-affected zone due to void formation at the MA/ferrite interfaces. However, a fracture occurred in base metal with improved strength and ductility after tempering, in comparison to the fracture in the heat-affected zone of as-welded samples.