Pneumatic bulge test (PBT), as a novel small specimen testing method, demonstrates significant potential for assessing mechanical properties of materials. The current method necessitates welding to ensure stable loading of pneumatic pressure. However, the influence of the welding process on PBT test results has not been effectively evaluated. This study examines the impact of this factor by analyzing the microstructure of welded joints between the specimen and the lower holder. It also evaluates the effects of Gas Tungsten Arc Welding (GTAW) and Laser Beam Welding (LBW) on SUS 304 specimens tested at 600 °C, comparing their pressure-deflection (P-D) curves with finite element simulations that exclude welding. The results reveal that both welded specimens ruptured at the center, but LBW curves closely matched simulations, in contrast to those for GTAW. This discrepancy is explained by morphological analysis, which indicates that GTAW joints are wider and deeper due to lower energy density and slower cooling, with LBW joint width and depth being 34.8 % and 45.9 % of those of GTAW joints. Additionally, LBW joints exhibit fine columnar dendrites and significant carbide precipitation, while GTAW joints show coarser grains and a broader heat-affected zone. Moreover, hardness tests reveal GTAW joints are ∼50 % harder with steeper gradients, leading to stronger constraints at the edges of GTAW specimens compared to LBW-welded specimens. Consequently, the GTAW specimens require greater deformation resistance during loading, resulting in higher P-D curves. These findings suggest that LBW is likely more favorable than GTAW for PBT tests.
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