Filler metals play an important role in reducing the weld cracking in nickel-based superalloys. In order to improve the welding conditions of IN939 superalloy, a wide range of solid solutions and age-hardenable filler metals were investigated in this study. Five solid solutions (HAYNES 230, IN625, IN617, HASTELLOY X, HAYNES 25) and two precipitation-strengthened alloys (IN718, HAYNES C-263) were used as filler metal to weld IN939 superalloy via gas-tungsten-arc welding. Microstructural studies were performed using optical microscopy and field-emission scanning electron microscopy. The results revealed that IN939 alloy is susceptible to liquation cracking in the heat-affected zone. In addition, the primary γ′ particles had grown into “ogdoadically diced cubes” of about of 2 μm in side length
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