Effects of welding parameters on residual stress and distortion in high strength low alloy steel cladded with Monel 190

In vessel construction, the use of steels with high ductility, durability, yield strength and adequate thermal conductivity is essential to enhance the operational efficiency and service life of both surface and subsurface hulls. HSLA steels are commonly employed in hull sections exposed to elevated temperatures, such as areas near the engine room. These regions are susceptible to cracking and wear over time. To improve resistance to such defects, Monel 190 alloy is applied as a cladding layer using the Gas Metal Arc Welding (GMAW) process. This study investigates the effects of key process parameters-including heat input, preheat temperature, external constraints, and welding speed-on the interfacial stress distribution between the steel substrate and Monel cladding, as well as the resulting sheet deformation. An increase in heat input intensifies distortion, expands the heat-affected zone, and elevates residual stress levels, while higher welding speeds and optimal preheating reduce these effects by lowering thermal gradients and thermal contraction. Clamping during cooling is the most effective and consistent method for distortion control, regardless of heat input. Residual and von Mises stresses peak in the cladding, HAZ, and especially at the cladding–substrate interface, making these zones most prone to crack initiation and failure.