For More Info Fabrication of Functionally Graded Transitions for

Contact: Joining Dissimilar Alloys

Yatin Karpe
Senior Manager Overview
Office of Technology Laser Engineered Net Shaping (LENS) is the tool by which graded transition joints are made
Transfer from dissimilar alloys. LENS is a tool that uses a computer controlled laser system integrated
(610) 758-5883 Phone with dual powder feeders. The dual powder feeders can be controlled independently so that
(610) 758-5888 Fax the composition can be changed at various locations within the part for optimized mechanical
ott@lehigh.edu and/or corrosion performance. The transition joints are produced by initially injecting a ferritic
steel powder which is gradually graded into a stainless steel. In the graded transition, the
compositional change from ferritic steel to stainless steel is spaced over 60 mm while it occurs
Inventors
over only 80 µm in the dissimilar metal weld joint. This smoothed compositional variation
affects the mechanical properties in a similar fashion. The hardness profile generated in the
John N DuPont graded transition joint is less severe and occurs over a much greater distance (60 mm) as
Lehigh University compared to the dissimilar metal weld (80 µm). The smooth compositional and mechanical
Associate Professor, property variation produced in the graded transition joint improves the mechanical properties
Materials Science and and corrosion resistance of the component and will enhance the lifetime of the graded
Engineering transitions joints.
Jeffrey Farren
Lehigh University
College of Engineering Applications and Advantages
Materials Science and Dissimilar metal failures remain to be a significant problem to the power generation, oil, and gas
Engineering industries. In the power generation industry alone, failures of dissimilar welds could cost a
company $250,000 - $750,000 a day in lost revenue, repair/replacement costs, and down time.
These transitions joints have the potential for significantly reducing and even eliminating the
occurrence of these failures, thus providing the power generation industry with significant
saving associated with forced plant outages. In addition, the fabrication of a functionally graded
transition joint using LENS provides:
• Smooth microstructural and mechanical property transitions from carbon steel to stainless
steel.
• Eliminates the abrupt microstructural and mechanical property changes that are associated
with dissimilar metal weld failures.
This method can be used on other multiple-material weld systems.

Licensing Status and Intellectual Property

Opportunities A U.S. utility patent application has been filed.

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