Investigating the Effects of Iron Dilution on the Corrosion Resistance of Inconel 625 Welding Overlay on Carbon Steel

This study investigates the influence of iron dilution on the microstructure and corrosion behavior of Inconel 625 weld overlays deposited on carbon steel. Different deposition strategies were employed to control dilution and to evaluate its effect on elemental segregation. The overlays were characterized in terms of microstructural evolution, chemical distribution, and corrosion performance under standardized testing conditions. The results show that increasing iron dilution enhances chemical segregation within the dendritic structure, which governs the initiation of localized corrosion. A critical dilution condition associated with the onset of pitting was identified. These findings advance the understanding of dilution-controlled corrosion mechanisms in nickel-based alloy overlays.