Microstructural Evolution in Welded Joints

This review paper presents a comprehensive analysis of microstructural evolution in welded joints, emphasizing intermetallic compound formation, grain refinement mechanisms, and their relationships with mechanical properties. It synthesizes current understanding of the microstructural zones within welded joints, including the heat-affected zone, fusion zone, and interfacial regions, highlighting the role of diffusion and phase transformations in solute redistribution and precipitate formation. The influence of welding parameters and advanced processing techniques on grain morphology and intermetallic thickness is thoroughly examined. Additionally, the review explores microstructure-property correlations, focusing on hardness, strength, impact toughness, and residual stresses, supported by a survey of characterization methodologies such as SEM, EBSD, and AI-assisted inspection. Challenges in achieving microstructural homogeneity and controlling intermetallic growth are discussed, alongside emerging trends involving additive manufacturing and real-time process monitoring. The paper concludes with prospective pathways to tailor weld microstructures through innovative process design, aiming to enhance joint integrity and performance.

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