Abstract
The microstructural response of directionally solidified René 80 (DS René 80) superalloy to gas-tungsten-arc (GTA) welding was investigated. Rapid heating during welding resulted in a significant grain-boundary liquation of solid-state reaction product γ′ precipitates, intergranular elemental segregation induced M5B3 borides, and secondary solidification constituents MC carbides and sulfocarbides, which were all present in the preweld heat-treated alloy. Liquation of these particles embrittled the grain boundaries in the heat-affected zone (HAZ) and caused microfissuring along the liquated grain boundaries. Nevertheless, contrary to the generally observed increase in HAZ cracking in superalloys with an increase in Ti and Al concentration, due to increase in the alloy’s hardness, significantly reduced cracking was observed in DS René 80 compared to the conventionally cast IN738 welded under the same conditions, despite its hardness being higher than that of IN738. This was related to the nature of base-metal grain- boundary intersections at the fusion-zone boundary in these materials.