Research Progress on Microstructural Design and Strengthening-Toughening Mechanisms of Weld Metal in High-Strength Steels

doi:10.11900/0412.1961.2025.00201

Acta Metall Sin

2026, Vol. 62

Issue (1): 1-16 DOI: 10.11900/0412.1961.2025.00201

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Research Progress on Microstructural Design and Strengthening-Toughening Mechanisms of Weld Metal in High-Strength Steels

LU Shanping(

), SUN Jian

Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

LU Shanping, SUN Jian. Research Progress on Microstructural Design and Strengthening-Toughening Mechanisms of Weld Metal in High-Strength Steels. Acta Metall Sin, 2026, 62(1): 1-16.

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Abstract

High-strength steel, renowned for its optimal balance between strength and toughness as well as its exceptional weldability, has become a key structural material in critical applications such as long-distance oil and gas pipelines, offshore engineering structures, construction machinery, and hydropower facilities. The microstructure and mechanical properties of the weld metal—an integral component of the welded joint—directly impact the service safety and reliability of the entire welded structure in high-strength steel applications. Moreover, the solidification behavior and phase transformation processes of the weld metal play a pivotal role in determining its microstructure and mechanical properties. This study focuses on three crucial aspects: the synergistic effects of multi-component alloying, the design of welding process parameters, and the formulation of post-weld heat treatment regimes. It reviews recent advances in microstructure design and elucidates the strengthening and toughening mechanisms of weld metal in high-strength steel fusion welding. Furthermore, the correlation between strength and toughness inversion in weld metal is elucidated from the perspectives of chemical composition design and process parameters. Recent advancements and prospects in relevant fields are summarized, providing theoretical guidance for the development of welding materials and the preparation of weld metal in high-strength steels of 1000 MPa grade and above.

Key words: weld metal of high-strength steel microstructure strengthening and toughening alloy element process parameter

Received: 15 July 2025

ZTFLH:

TG442

Fund: National Natural Science Foundation of China(52101060)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00201 OR https://www.ams.org.cn/EN/Y2026/V62/I1/1

Fig.1 Effect of Ti contents on the inclusions in weld metals^[19]
(a) 0.0028%Ti (b) 0.0255%Ti

Fig.2 Calculation of inclusion types and experimental characterization of the inclusion^[24]
(a) thermodynamic calculation results (b1, b2) TEM image (b1) and line scan results in Fig.2b1 (b2) (MDZ—Mn-depleted zone)

Fig.3 SEM images of the weld metals with different Ni contents^[40] (CB—coalesced bainite)
(a) 5.5%Ni (b) 6.5%Ni (c) 7.5%Ni

Fig.4 Inverse pole figures (a-c), band contrast maps (d-f), and grain boundary misorientation distribution maps (g-i) of weld metal with 0.3%Cr (a, d, g), 0.6%Cr (b, e, h), and 1.0%Cr (c, f, i)^[41]

Fig.5 V-rich clusters with different iso-concentration (atomic fraction) surfaces measured by atomic probe^[53]

Fig.6 Characterization of nanoscale Cu-rich precipitates^[55]
(a) bright-field TEM image showing the Cu precipitates within matrix in reheated region
(b) corresponding dark-field TEM image taken in a precipitate reflection
(c) selected area electron diffraction pattern for bcc Cu₃Fe₁₇

Fig.7 Cross-section profiles of the welded joints^[65] (FZ—fusion zone, HAZ—heat affected zone, CGHAZ—coarse grained HAZ)
(a) gas metal arc welding (GMAW)
(b) ultra-narrow gap laser welding (U-NGLW)

Fig.8 Mechanical properties of weld metal with different shielding gases^[68]

Fig.9 Mechanical properties of weld metal with different welding heat inputs^[70]

Fig.10 Schematic of the microstructure evolution of weld metal during post weld heat treatment (PWHT) process^[78] (T600—tempering temperature at 600 ^oC and holding time for 1.5 h, IA730—730 ^oC insulation for 1.5 h and water quenched to room temperature; AF—acicular ferrite, GBF—grain boundary ferrite, M-A—martensite-austenite)

Fig.11 Precipitates evolution of weld metal during PWHT process^[81] (PAGB—prior austenite grain boundary; black arrows show the PAGB, purple arrows show M₃C precipitates, and green arrows show M₂C precipitates)
(a) 530 ℃ insulation for 2 h (b) 570 ℃ insulation for 2 h (c, d) 610 ℃ insulation for 2 h

Fig.12 Electron probe microanalyses of V20 weld metal in as-welded (AW) (a) and PWHT (b) conditions, and characterization of precipitates of weld metal of V00 (c-f), V10 (g-j), and V20 (k-n) PWHT specimens^[82] (ID—inter-dendritic, V00—V content is less than 0.005%, V10—V content is 0.10%, V20—V content is 0.18%. A representative local area containing M₃C carbides in the dendritic core region is marked by the blue dashed outline; a representative local area containing nanoscale carbides (MC or M₂C carbides) in the ID region is marked by the red solid outline)

Fig.13 Impact fractures of weld metal (620 ^oC)^[85]
(a) surface (b) cross-section

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