Welding Metallurgy
Weldability of Structural
Steels
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Lecture 11
p1
Lecture Scope
Weldable grades of structural steel
Factors affecting weldability
Problem Areas
Welding Procedures
e 11
p2
Weldability
Definition
- "The capacity of a metal to be welded under the
fabrication conditions imposed into a specific suitably
designed structure and to perform satisfactorily in
service" (American Welding Society)
Lecture 11
pZ
Mechanical Properties of Welds
Notch Impact Toughness
Tensile Strength
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(UTS)
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Weldability of Steels
Factors affecting weldability:
-
Lecture 11
Steel composition & processing
Weld metal and HAZ properties
Choice of welding variables
Pre and post-weld processing
p5
Steel Composition & Processing
Weldable structural steels for use at ambient
or moderately elevated temperatures faIT into
four categories:
1.
2.
3.
4.
Carbon and carbon-manganese steel
High-strength low-alloy (HSLA) steels
Normalised and tempered high tensile steels
Quenched and tempered high tensile steels
p6
Main Alloying Additions in Steel
Carbon is a potent solid-solution strengthening
element in iron
Carbon increases tensile strength but
ductility
r~duces
High carbon content promotes formation of
hard, brittle microstructures on cooling from
above the phase transformation temperature
Manganese up to about 2% increases strength
without reducing ductility, improves natch
toughness, and reduces hot cracking.
Lecture 11
pi
Impurities
Past steelmaking practices also left high
impurity contents
P, 5, 0, N
P decreases toughness
P and 5 form low-melting compounds that
promote weld and HAZ solidification cracking
0 & N form dispersions of oxides and nitrides
that strengthen the metal and reduce its ductility
, 11
p8
Carbon and C-Mn Steels
Traditional C-Mn structural steels relied on
solid solution strengthening from carbon and manganese to reach a given strength
Higher strength meant higher contents of
these elements (C<= 0.35%)
Combined with high impurity contents, led
to poor weldability
Lecture 11
pS
Steel Developments
In recent decades new steels have been developed which
offer a combination of strength, ductility, and toughness
Steps in achieving these benefits include some or all of: - lower carbon contents,
-lower impurity contents,
- full deoxidisation, fine-grain practice,
- small alloy additions of Ni, Cr, Mo, Cu, V, Ti, Zr, AI,
- controlled rolling temperatures, and
- normalising and quenching treatments
11
p10
HSLA Steels
Steels incorporating small alloy additions are known as
high-strength low alloy (HSLA) steels or microalloyed
steels.
HSLA steels up to about 500 MPa UTS with carbon
contents up to 0.25% and made with deoxidised fine
grain practice are readily weldable.
Lecture 11
P 11
Q&T Steels
Steels that rely on quench and temper heat treatment to
obtain very high strength are more susceptible to welding .
problems and require specific metallurgical expertise. e.g.
G40.21 Grade 700Q, ASTM A 514.
I
, 11
p 12
Typical Steel Specifications
Canadian Standards Association
- GSA G40.21: Structural Quality Steels
~ Plates. shapes. hollow sections, sheet piling and bars
for general construction and engineering purposes
~ Weldable grades of carbon-manganese steels and
high-strength quenched and tempered steels
Lecture 11
p 1:
Steel Specifications
American Society for Testing & Materials
(ASTM)
- A36 Structural Steel
- A 105 Forgings, carbon steel, for piping components
- A 106 Seamless carbon steel pipe for high-temperature
service
- A514 High yield strength, quenched and tempered alloy
steel plate, suitable for welding
-A515 Pressure vessel plates, carbon steel, for
intennediate and higher-temperature service
- A516 Pressure vessel plates, carbon steel, for moderate
and lower temperature service
- Al06 Structural steel for bridges
11
p14
Steel Specifications
American Society for Mechanical Engineers
.- ASME adopts many ASTM materials specifications for
use in its Boiler and Pressure Vessel Code, including
those listed above
- .
- ASME material specifications are used for pressure
vessels and piping in CANDU reactors
American Petroleum Institute (API)
- API 5L: Line Pipe
- Peartite Reduced Steels (PRS) & Acicular Ferrite Steels
(AFS)
Lecture 11
p15
Properties of the HAZ
The response of the parent material and reheated weld
metal in multi-pass welds to the weld thermal cycle
determines the properties of the heat affected zone. The
main factors are:
Steel composition and processing
Peak temperatures and cooling rates
The yield and ultimate strength of the HAZ are usually
higher than the parent material, so the main properties of
interest are hardness and toughness
d1
p16
HAZ Hardness
Hardness is a measure of tensile strength and degree of
embrittlement
In C-Mn steels, HAZ hardness exceeding 350 Hv is
considered excessive.
HAZ hardness is determined by alloy content and cooling
rate in the transformation temperature range.
Lecture 11
pl1
HAZ Hardness
Steel hardenability can be correlated with the carbon
equivalent (CE), e.g.:
CE
C + Mn + Cr + Me + V + Ni + Cu
15
Steels with CE below about 0.45 are readily weldable
with appropriate procedures
Preheat and weld heat input should be selected to give
cooling rates that produce acceptable hardness
CE greater than 0.45 indicates a need for caution
11
P 18
Effect of Cooling Rate
Cooling rate vs carbon equivalent for a HAZ hardness
of 300 Hv
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Cooling Rate at 540C (Cis)
Gravile, B: The Principles of Cold Crackilll Control in - .
Dominion Bridge Company, Montreal, 1975.
Lecture 11
P 1
Fracture Toughness of the HAZ
The factors affecting toughness are
-
weld thermal cycle
grain coarsening temperature of the steel
transformation characteristics
alloy and impurity content
p20
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--
---
- -
---
Fracture Toughness of the HAZ
If the fracture toughness of the parent steel is low, the
toughness of the HAZ is usually low, and conversely..
- Fine grain practice and microalloying benefit the HAZ
as well as the original material
Low heat input welding procedures give a finer HAZ
grain structure and better toughness in low CE steels
However, in steels with a high CE content, HAZ
hardness considerations set a minimum heat input.
It is sometimes difficult to get adequate toughness in
high CE steels
Lecture 11
p21
Weld Metal Tensile Strength
The factors that govern the tensile strength of the
weld metal are
Composition
- C and Mn increase strength
Ferrite grain size
- Tensile strength increases as ferrite grain size is reduced
e 11
p22
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Weld Metal Toughness
The notch toughness of weld metal varies with
- grain size
- the number of inclusions and other phases
Notch toughness is reduced by
- coarse, blocky pro-eutectoid ferrite grains
- presence of retained martensite
- numerous oxide and sUlphur inclusions
Optimum notch toughness is reached by:
- Acicular ferrite weld metal microstructure, obtained
through controls on heat input and alloy content
- Deoxidized and desulphurized weld metal by use of basic
fluxes.
Lecture 11
p23
Effects of Welding Variables
Heat input
-Increased heat input coarsens the weld metal solidification
structure and decreases strength and toughness
- High heat input processes such as SAW or ESW produce
coarse-grained weld metal with relatively poor as-welded
properties
- SMAW, GMAW or GTAW give finer grain structure and
better as-welded strength and toughness
re 11
p24
Effect of Heat Input on UTS
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Stout, RD. Weldabilily of Steels Weldilll Research Council, New York
Lecture 11
p25
Effect of Heat Input on Notcb
Toughness
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Stout, R.D. Weldabil~y of Steels Welding Research Council, New York
-811
p26
------------
-- . _ - -
Effect of Flux Type
Flux type
- Fluxes or slags that leave high weld metal oxygen
contents give lower weld metal toughness.
- Basic fluxes reduce weld metal sulphur and oxide
inclusion content and give improved notch toughness and
lower transition temperatures
Lecture 11
p27
Effect of Flux Type on Toughness
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Lancaster, J.F. Metallurgy of Welding George Allen & Unwin, london
"e 11
p28
Welding Procedures
C-Mn and HSLA steels up to CE 0.45 and UTS< 500 MPa are weldable
by any arc welding process with appropriate procedures
The table below gives general recommendations for preheat and
interpass temperatures for typical steels
Steel Spec
Carbon
Thickness
(mm)
Min Preheat &
interpass temp,
other than
low-hydrogen
Min preheat &
Interpass temp,
Iow- hydrogen
PWHT
A516Gr70
<.31%
10
>SOC
>OC
19
>100C
SOC
75
175C
150C
25
>OC
>OC
75
1SOC
100C
optional
600-675C
optional
600-675C
ASMECode
req'd
Optional
600-675 C
Optional
600-675C
A36
Lecture 11
<.25%
p29
Welding Problem Areas
Cracking
-
Solidification Cracking
Hydrogen Induced Cracking
Lamellar Tearing
Reheat Cracking
Porosity and Inclusions
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p30
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Solidification Cracking
Solidification cracks develop at elevated temperature dUring
the latter stages of solidification
In low-carbon steels, the first phase to solidify from the melt
is delta ferrite. This transforms to austenite below J 500 C
Elements such as sUlphur, phosphorus and boron are less
soluble in austenite than in the delta ferrite. They tend to
segregated to the bQundaries of the primary austenite grains
The resulting low-melting point films promote intergranular
weakness and may cause cracking in the presence of
thermal strains
Solidification cracking is intergranular with respect to the
primary austenite grains.
Lecture 11
p31
Solidification Cracking-Avoidance
Solidification cracking is minimised by:
- maintaining a low carbon content in the weld deposit
- keeping sulphur and phosphorus as low as possible - ensuring that manganese, which inhibits the effect of
sulphur, is high enough to allow for possible dilution (and
ingress of sUlphur) from the base material.
- choosing welding parameters to avoid "centreline" type
solidification structures.
>11
p32
Hydrogen Induced Cracking
Steels at ambient temperatures may suffer from hydrogen
embrittlement.
Hydrogen embrittlement can result in cracking in welds
called hydrogen induced cracking or cold cracking.
Lecture 11
p33
Typical Forms of Hie
--underbead crack
311
weld metal crack
p34
Causes of HIC
HIC in welds occurs in the presence of four
predisposing factors:
1. hydrogen in the weld metal
2. a crack-sensitive microstructure
3. tensile stress
4. temperatures below 200 C
Lecture 11
p3~
Causes of HIC
1- Sources of Hydrogen
Hydrogen comes from
- hydrogenated compounds in electrode coverings and
fluxes
Rutile and cellulosic fluxes contain organics and water, and produce weld
metal high in hydrogen
Basic electrodes are all-mineral and can be baked to drive off moisture
- contamination of joint surfaces with grease, paint, etc.
- poor gas shielding or contamination of shielding gases
with water vapour and hydrogen
p36
11
- - - - - - - - - - - - - - --------
Hydrogen content resulting from
various welding processes
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GraviUe, B: The Principles of Cold Cracking Control in Welds,
Dominion Bridge Company, Montreal, 1975.
Lecture 11
P 37,
Causes of Hie
2- Microstructure
The most susceptible microstructure is high-carbonmartensite in the coarse-grained HAZ
HAZs with hardness below 300 Hv have a low
susceptibility to cracking
The risk is significant above 350 Hv.
p38
e 11
~-------
Causes of HIC
3-Stress
The stress that acts as the driving force for HIC in-most
instances is the residual stress from welding.
The level of residual stress depends on
- the yield strength of the material
- the degree of restraint
HIC is more probable in high-strength materials or when
welding highly restrained joints
Lecture 11
p3
Causes of Hie
4- Temperature
Hydrogen is absorbed into the weld metal at high temperatures
Hydrogen solubility in iron decreases on cooling to ambient
temperature
Hence hydrogen tends to diffuse from the weld to the HAZ
after welding
Cracking may appear days or even longer after welding
11
p40
-----
- - - - - -
Hie-Avoidance
Use low-hydrogen welding processes
- baked basic electrodes or fluxes
- gas shielded processes (GMAW, GTAW or PAW)
- ensure cleanliness and freedom from contaminants
control steel composition
- carbon equivalent < 0.45
reduce cooling rates and peak HAZ hardness
(dependent on thickness and CE)
- preheat joint
- minimum heat input, bead area or fillet weld size
minimise joint restraint
Lecture 11
p4t
Hie-Avoidance
1/1-
0.25
Relationship between fillet weld leg
length and heat input for SMAW
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III
~ 0.081-
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Gnotle. B: The PrInclpIoo d Cold CIadcIng Contn>Iln
_ . Don*lIon Blfdge Company, Montreal, 1975.
10 20 30 40 50 10 10 80 90 100
ENERGY INPUT (kJnn)
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p42
Lamellar Tearing
Lamellar tearing occurs in the base metal due to the
combination of high local stress and low ductility in-the
through-thickness direction
It is associated with welds on thick sections where the weld
boundary is approximately parallel to the plate surface.
The cracking is near the weld boundary and lies mostly
parallel to the surface of the plate
Lecture 11
Lamellar Tearing--Avoidance
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(a) & (b) replace fillets with solid
weld metal or forgings -
(c) "buttering" with ductile weld metal
(d) comer joint redesign
Je
11
p44
Reheat Cracking
Reheat cracking occurs in the HAZ of alloy steels during
PWHT
- Results from strengthening by precipitation within the HAZ
grains. Concentrates deformation at the grain boundaries
Cracks are intergranular and follow the prior austenite grain
boundaries
Contributing factors are
- a susceptiqle alloy composition
- a susceptible HAZ microstructure
- a high level of residual strain
- temperature in the strain relaxation range
Not usually a problem with C-Mn or HSLA steels.
Lecture 11
p4!
Reheat Cracking-Avoidance
Material selection
- Limit carbide formers
Minimize restraint
Rapid heating to stress-relief temperature to minimize
precipitation
Non-destructive examination after PWHT
I
111
p46
Porosity
Porosity in weld metal is formed by entrapment of gas
evolved during solidification.
In steels, the gases that participate in porosity formation are
CO from reaction of oxygen with carbon in the steel, H2,
N2, and H2S.
Excessive porosity is avoided by
- proper welding conditions,
- cleanliness of the joint surfaces and consumables
- deoxidizers such as AI, Ti or Si added to the welding filler.
Lecture 11
p47
Inclusions
Large non-metallic inclusions in steel are of two types.
The first is slag entrapped because it was not removed from
a previous weld or entrained by improper welding technique
Inclusions can also be generated by foreign materials
entering the weld pool, especially pieces of melted tungsten
electrode in GTAW or copper guide tubes in GMAW and
SAW.
.
, 11
p48
