| Abstract Scope |
Improving efficiency in high-temperature energy systems demands structural alloys with exceptional mechanical reliability. In this study, Inconel 800, a Ni-Fe-Cr alloy, was fabricated via Gas Metal Arc Welding (GMAW), a scalable and cost-effective method essential for industrial assembly. Welded joints were tested in tension at 25 °C, 400 °C, and 800 °C. Advanced characterization using SEM, EDS, EBSD, and fractography revealed temperature-induced degradation mechanisms, including grain boundary weakening, elemental segregation, and a shift from transgranular to intergranular fracture. At 800 °C, tensile strength declined by nearly 50% due to thermal softening and recrystallization in the weld zone. Despite this, the alloy exhibited robust performance, confirming its suitability for components such as superheaters and reformer tubes. The results emphasize the critical role of welding in maintaining structural integrity under extreme conditions and provide insight for optimizing welds in high-temperature service environments. |