Microstructure and Characteristics of the Welded Joint between Ni-Cr Alloys and Copper

In the field of petroleum extraction, the welding technology of the core wire (the hybrid structure of copper and the Ni-Cr alloy) in high-power oilfield heaters is a key process that determines the efficiency of the heater. Using the tungsten inert gas (TIG) welding method of filling pure copper wire, this work effectively joins the dissimilar metals of red copper and the Cr20Ni80 nickel–chromium alloy. The microstructure, mechanical properties, and conductivity of the joint were analyzed. The results showed that the surface of the welded dissimilar metal joint was smooth and uniform; radiographic nondestructive testing did not reveal any macroscopic forming defects such as pores or cracks. The microstructure of the joint fusion zone exhibits an equiaxed grain morphology. The interface between the copper and the fusion zone displays a columnar grain structure, growing perpendicular to the fusion line. An interdiffusion layer of elements was formed at the interface between the Ni-Cr alloy and the fusion zone. The microhardness of the joint shows a stepwise decreasing trend, with the highest hardness on the nickel–chromium alloy side, followed by the fusion zone, and the lowest on the copper side. The joint fractures at the copper base material, with a tensile strength greater than 220 MPa, indicating a ductile fracture mode. During the electrical heating process, the joint temperature does not significantly increase compared to the copper side, demonstrating good thermal stability.