A Presentation on

Use of copper heat sink to improve quality of weld in AISI 304L

PROJECT ADVISER PRESENTED BY :

Dr. J S GILL RAKESH RANJAN - GWT-SL/14/4715
Associate Professor
Mechanical Engineering
 PROBLEM FORMULATION
When steels cool from a high temperature,
austenite transforms into other phase
configurations according to the austenite
composition and cooling rate. As result of phase
transformation, the steel crystal structure and,
consequently, both the shape and the lattice
parameter of the unit cell, change. These
changes may introduce dilatational strains into
the microstructure, which result in the creation
of residual stress concentration zones within the
microstructure. These stress concentration zones
are vulnerable regions to the formation of micro
cracks or growth of the flaws in these regions.
COMPARISON OF SPECIFIC HEAT CAPACITY OF VARIOUS MATERIAL

• Best heat conductor is copper, so we can use

it as For making heat sink.

• Heat energy = mass x specific heat capacity

x temperature change
ADVANTAGE AND DISADVANTAGE OF STAINLESS STEEL OF SAE Type 304L
Advantages:
1. Stainless steel with excellent corrosion resistance and good resistance to intergranular corrosion. Of oxidizing
acids, such as concentration ≤ 65% below the boiling temperature of nitric acid, with strong corrosion
resistance. Most of the alkali solution and organic acids and inorganic acids also has good corrosion
resistance.

2. Excellent hot and cold forming process and performance. Can processing board, tube, wire,tape, type of
product, for the manufacture of cold heading, deep drawing, deep drawing forming parts.

3. Better low temperature performance. At -180 ℃ condition, strength, elongation, area reduction rate is very good.
In the absence of brittle transition temperature, often used at low temperatures.

4. Has good weldability. Welding method can be used often, both before welding without heat treatment after
welding.

Disadvantages:
1. Large section size steel intergranular corrosion after welding sensitive;
2. C1-containing water (including wet air) is very sensitive to stress corrosion;
3. Low mechanical strength, such as poor cutting performance.
COMPOSITION AND PROPERTIES OF STAINLESS STEEL OF SAE Type 304L
ADVANTAGE AND DISADVANTAGE OF COPPER AS HEAT SINK

ADVANTAGE
• High thermal conductivity.
• Can be operated under high operating temperature.
• Requires less maintenance.
• Naturally resistant to corrosion in tight spaces.
• Very durable in cold weather.

DISADVANTAGE
• Difficult to install.
• Storage issue.
• Comparatively costly than galvanized cast iron.
PROPERTIES OF COPPER
 Heat Affected Zone (HAZ)

The heat-affected zone (HAZ) is the area of

base material, either a metal or a thermoplastic,
which is not melted and has had its
microstructure and properties altered by welding
or heat intensive cutting operations. The heat
from the welding process and subsequent re-
cooling causes this change from the weld
interface to the termination of the sensitizing
temperature in the base metal. . The extent and
magnitude of property change depends
primarily on the base material, the weld filler
metal, and the amount and concentration of
heat input by the welding process.
 HEAT SINK THEORY
To understand the principle of a heat sink, consider Fourier's
law of heat conduction. Fourier's law of heat conduction,
simplified to a one-dimensional form in the x-direction,
shows that when there is a temperature gradient in a body,
heat will be transferred from the higher temperature region to
the lower temperature region. The rate at which heat is
transferred by conduction, is proportional to the product of
the temperature gradient and the cross-sectional area through
which heat is transferred.

Where ‘k’ is thermal conductivity , ‘q’ is heat transfer rate and ‘A’ is
area of cross section.
Heat transfer in a flat plate with internal heat generation can be studied
in the case of SMAW of stainless steel plate.
 WORKPIECE SAMPLE PREPERATION

1. We took a 10 mm thick stainless steel plate of type 304L

and cut 2 pieces of size 12x7 sq. cm

by using a hand grinder.

2. For making the heat sink a copper plate 5 mm thick of size

12x4 sq. cm was cut from a large plate.

3. Grooving of both the stainless steel samples is done on

shaper machine. The depth of groove made is 5mm and angle
of groove is 60 degrees.

4.Surface preparation is done by cleaning the sample with

cotton and wiping it with water.
 ATTACHING HEAT SINK TO SAMPLE

1. The sample and the sink is held in a closed position

by using a C-clamp.

2. The sink is then tack welded using TIG welding

using a spoke of stainless steel as filler material and
argon as a shielding gas at a pressure of 80 kg/sq.cm.
It is tack welded at 83A.
 WELDING OF WORKPIECE

1. Each sample is preheated up to a temperature of

100 deg. Celsius by using an oxy-acetylene flame.

2. Welding is done using SMAW machine on both

samples keeping an AC source of 88 A current and 36
V potential difference.

3. Both the welds are cooled in water kept at room

temperature.

4. Peening is done afterwards using a small hammer.

 VISUAL INTERFERENCE
1. Distortion
in case of weld using heat sink is less than
that of normal weld.

2.Burning of plate is more in normal weld as

compared to the weld with use of heat sink.

Fig. 15 Burning of plates

 WORKPIECE PREPARATION

1. The specimen is cut into a piece of width 10 mm

using a hand cutter.

2. Polishing is done using sandpaper of different

grades , starting from grade 100 to gradually rising up
to grade 3000.
 ETCHING PROCESS

1. An etchant is prepared using 5 gm copper sulphate , 10 ml

dil. HCl and 20 ml distilled water.

2. Both the samples were drowned in the solution for 2 mins.

30 secs.
 FRAME-1

MICROSTRUCTURE TESTING
SAMPLE 1 (WELD WITHOUT HEAT SINK) FRAME-1

The figure 1 represents microstructure of stainless

steel 304L base metal after the SMAW process.
The specimen is polished to mirror finish and
investigated using microscope. It consists of black
spots i.e. pearlite formation from austenite steel.
Fig. 1 Base material
The figure 2 represents the microstructure FRAME-2

fashions across the interface of weld metal and

parent metal of AISI 304L. After welding the bead
has more ferrite stringes than base metal as shown
in the fig.17.

Fig. 2- composite
SAMPLE 2 (WELD WITH HEAT SINK)
FRAME 1
The weld bead of the second sample has one defect
but the uniformity in the weld is much more. It is
very difficult to distinguish between the HAZ and
base metal. So we can conclude that using a heat
sink in AISI 304L can produce better weld
uniformity.

Fig:- 1 base metal

FRAME 2

Fig:- 2 composite
 RESULT OF MICRO HARDNESS TEST
Conditions :-
Load Applied – 500gm
Dwell Time – 20 seconds

SAMPLE BHN of HAZ obtained

1 221.5

2 209.3

Result obtained :-
BHN number of sample 1 (without heat sink) is more than
that of sample 2 which implies that residual stresses
present in sample 1 is more than in sample 2. So the use of
heat sink is advised.
 CONCLUSION

This paper presents a study of the heat sink technology to decrease the welding residual stress in 304L stainless steel welding
joint .An average heat transfer coefficient between the cooling water and the weld plate is applied to simulate the function of
heat sink. The effects of contact length and the average heat transfer coefficient on residual stress have been discussed. Based on
the obtained results, the following conclusions may be drawn:-
(1) It is found that the heat sink technology can decrease the residual stress greatly. Compared to the model without heat sink,
about 20% of the peak longitudinal stress has been reduced.
(2)The heat sink increases the weld cooling rate. It decreases the dwell time during the cooling from 850 °C to 400 °C, which is
helpful to decrease the risk of sensitization of 304L stainless steel.
(3)With the contact length increase, the transverse stress is decreased. Further increase of the contact length has no obvious
effect on reducing the longitudinal stress.
(4)With the average heat transfer coefficient increase, the transverse stress is decreased greatly while the longitudinal stress
decreases slightly, and some tensile residual stresses have been changed to compressive in some zone.
(5) It has been noticed that the micro hardness is decreased comparatively in the heat sink technology and hence it is concluded
that copper heat sink reduces the residual stress.
(6) The solidification mode of type 304L SS is primary ferrite. With increase in temperature, severe grain growth occurs in the
specimen, and melting begins with the nucleation of liquid phase at the triple junctions and grain boundaries followed by
propagation of the liquid phase along the grain boundaries.
 REFERENCES
• WenchunJiang ,YucaiZhangg , Wanchuckwoo, “Using heat sink technology to
decrease residual stress in 316L stainless steel welding joint: Finite element
simulation” published at International Journal of Pressure Vessels and Piping

• YuquanGuo ,DongjiangWu, GuangyiMa, DongmingGuo, “Trailing heat sink effects

on residual stress and distortion of pulsed laser welded” published at journal of
material processing technology.

• W t han, F r wan, G li, C l dong, J h Tong, “Effect of trailing heat sink on residual
stresses and welding distortion in friction stir welding Al .

• W. J. Shack, W. A. Ellingson, and L. E. Pahis: “The Measurement of Residual

Stresses in Type 304 Stainless Steel Piping Butt Weldments”, Argonne National
Laboratory, September 1978.

• K. K. Kanaujia”An Investigation of Dissimilar Welding Joint of AISI 304L Stainless

Steel with Pure Copper by Nd:YAG Pulse Laser: Optimization of Tensile
Strength” Department Of Mechanical Engineering National Institute Of
Technology Rourkela, India, 2011.