Research Progress on the Strength and Toughness of High-Strength Steel Weld Metal

doi:10.11900/0412.1961.2025.00218

Acta Metall Sin

2026, Vol. 62

Issue (1): 64-80 DOI: 10.11900/0412.1961.2025.00218

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Research Progress on the Strength and Toughness of High-Strength Steel Weld Metal

CAO Rui¹^,²(

), LIU Zishen¹^,²

1 State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals, Lanzhou University of Technology, Lanzhou 730050, China
2 School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China

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CAO Rui, LIU Zishen. Research Progress on the Strength and Toughness of High-Strength Steel Weld Metal. Acta Metall Sin, 2026, 62(1): 64-80.

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Abstract

In recent years, due to the rapid development of high-strength and high-toughness steels, the requirements for the strength and toughness of the steel and weld metal have increased. The development of welding materials, welding processes, and post-weld heat treatment systems compatible with high-strength, high-toughness steels remains a major challenge. To address the challenge of achieving both high-strength and high-toughness in high-strength steel weld metals, this paper systematically summarizes the research status of high-strength steel weld metals in composition design, phase transformation kinetics and behavior, and strengthening and toughening mechanisms. The summary is based on prior research on welding material composition optimization, welding process optimization, and post-weld heat treatment, combined with the work of our research group. Furthermore, the study reviews the key challenges and solutions related to the insufficient strength and toughness of current high-strength steel weld metals and summarizes the research directions and key points that must be considered in the future.

Key words: high-strength steel weld metal strengthening and toughening bainite transformation alloying

Received: 02 August 2025

ZTFLH:

TG407

Fund: National Natural Science Foundation of China(52175325);Central Leading Local Science and Technology Development Special Project(24ZYQA054);Top Leading Talents Project of Gansu Province, Key Research and Development Program of Gansu Province(23YFGA0057);Major Scientific and Technological Project of Gansu Province(24ZD13GA018);Major Scientific and Technological Project of Gansu Province(23ZDGA010);Major Scientific and Technological Project of Gansu Province(22ZD6GA008)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00218 OR https://www.ams.org.cn/EN/Y2026/V62/I1/64

CE	f_AF / %	f_GB / %	f $B U$ / %	f $B L$ / %	f_LM / %
0.240-0.265	20-45	≈ 10	20-30	5	30-50
0.265-0.275	10-20	10	15-25	5	50-65
0.272-0.285	5-15	10	10-20	5	60-75
0.285-0.295	5-12	5	10-15	5	70-85
0.293-0.300	10	5	10	5	80-95
0.300	0	0	5	5	95-100

Table 1 Relationship between volume fraction of microstructure and carbon equivalent (CE) of high-strength steel weld metals^[8]

Fig.1 Typical ductile-brittle transition curve (a), load-displacement curves (b-e), and fracture morphology (f)
(b-e) load-displacement curves and fracture morphology schematics (insets) at different ductile-brittle transition stages of upper shelf (b), transition regions (c, d), and lower shelf (e) (Orange lines in Figs.1c-e show the instan-taneous brittle cleavage fracture)
(f) fracture morphology showing the stretch zone width (SZW), stable-plastic crack length (SCL), and the cleavage fracture distance (X_f) from cleavage fracture initiation origins to the blunted crack tip

Fig.2 Effects of Ni content on microstructure, strength, and toughness of weld metal of high-strength steel^[30,31,33] (Samples with Ni mass fractions of 0%, 2%, 4%, and 6% were designated as Ni0, Ni2, Ni4, and Ni6, respectively)
(a1-a8) in situ laser confocal observation results of bainite nucleation sites in samples Ni6^[33] (1, 2, 3, 4—the first, second, third, and fourth growing bainitic laths)
(a9) Euler figure (EF) color map of the investigated grain for identifying various variants—the symbols and numbers indicate the variant numbers^[33] (V1, V4, V6, V10, V11, V12, V14, V16, V20, V22, and V23—different variant types) (a10) plot of growing length against time (t) for three typical growth modes at various average rates^[33] (b1-b5) microstructures (b1-b4) and fractions (b5) of weld metals in samples Ni0 (b1), Ni2 (b2), Ni4 (b3), and Ni6 (b4)^[30] (DUB—degenerate upper bainite, PF—pro-eutectoid ferrite) (b6) prior austenite grain size distributions of weld metals with different Ni contents^[30] (c1-c5) effects of Ni content on tensile strength^[30] (c1), hardness^[30] (c2-c4), and impact energy^[31] (DBTT—ductile-brittle transition temperature) (c5) of weld metal

Table 2 Fracture micro-parameters of high-strength steel weld metals with different Ni contents at -196 ^oC^[31]

Fig.3 Effects of Si content on microstructure and mechanical properties of weld metals^[42] (Samples with Si mass fractions of 0.3%, 1.2%, and 2.0% were designated as Si0.3, Si1.2, and Si2.0, respectively)
(a1-a3) microstructures of weld metals in samples Si0.3 (a1), Si1.2 (a2), and Si2.0 (a3) (BF—bainite ferrite, M—martensite)
(a4) grain sizes of weld metals with different Si contents
(b1) oxide initiation origin for Si2.0 specimen at -196 ^oC
(b2) local cleavage fracture stresses and the critical values of the stress intensification of specimens with different Si contents at -196 ^oC
(b3) relationship between impact energy (CVN) and SCL + SZW (c1-c3) effects of Si content on strength and hardness (c1), elongation and reduction rate of fracture area (c2), and impact energy (c3) of weld metal

Fig.4 Effects of Ti on inclusions in weld metal of high-strength steel^[53] (I, II, III—the locations of selected area electron diffraction (SAED) analysis)
(a, b) STEM image and EDS mappings (a), bright-field TEM image and the SAED patterns (insets) (b) of inclusion in weld metal with low Ti content (c, d) STEM image and EDS mappings (c), bright-field TEM image and the SAED patterns (insets) (d) of inclusion in weld metal with high Ti content

Fig.5 Effects of B content on the microstructure, strength, and toughness of high-strength steel weld metals^[65] (Samples with B mass fractions of 0.008%, 0.0020%, 0.0031%, 0.0042%, 0.0057%, and 0.0087% were designated as B08, B20, B31, B42, B57, and B87, respectively)
(a1-a4) positive ion distributions of carbon-containing and oxygen-containing composite anion of B87 (PAGB—prior austenite grain boundary. White arrows in Figs.5a2 and a4 indicate B-carbide and B-oxide, respectively)(b1-b6) microstructures (b1-b3) and EBSD images showing the high-angle grain boundary (b4-b6) of weld metals in samples B08 (b1, b4), B42 (b2, b5), and B87 (b3, b6) (M-A—martensite-austenite)
(b7) misorientation angle distributions of the weld metals with different B contents (RZ—reheated zone)
(b8) grain size distributions of weld metals with different B contents (c1-c3) mechanical properties of weld metals with different B contents (c1) ductile-brittle transition curve (c2) ductile-brittle transition temperature (c3) micro-hardness (CGZ—columnar grain zone)

Fig.6 Effects of pre-tempering on microstructure and impact toughness of high-strength steel weld metal^[83]
(a1-a3) heat treatment process diagrams of tempered (types II and III) (a1, a2) and pre-tempered + tempered (type IV) (a3)
(b) impact energies of types I-IV weld metals (type I—as-welded) (c1-c4) microstructures of types I (c1), II (c2), III (c3), and IV (c4) weld metals

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