Microstructure and electrochemical evaluation of ER-308L weld overlays on AISI 321 stainless steel for repair applications

Weld overlaying is a promising and economical solution for repairing stainless steel structures. The present work deals with the deposition of ER-308L weld overlays on AISI 321 plate with Robotic gas metal arc welding setup. Microstructural examination depicts the presence of dendritic structures (equiaxed and columnar) and ferritic stringers. Energy-dispersive X-ray analysis confirmed the absence of precipitates and phases susceptible to corrosion in the as-deposited weld overlays. Specimens from ER-308L (weld overlay) and ER-308L&321-SS (interface) regions were subjected to electrochemical analysis using the Potentiodynamic polarization and double-loop electrochemical potentiokinetic reactivation measurements. Both overlay and interface sections exhibited comparable corrosion rate – 3.30 and 3.62 mils penetration per year, respectively with different passivation behaviour. The improved passivation behaviour of the ER-308L weld overlay authenticates the presence of δ-ferrite stringers. Double-loop electrochemical potentiokinetic reactivation tests highlighted the absence of sensitization on both weld overlay and interface specimens. This study presents the initial assessment results for repairing structural steel components subjected to corrosion damage.