Downloaded 228 times
![Weldability of C-Mn Steel
• C – 0.15% max, Mn- 1.65%max, Cu & Si- 0.60% max
• SA516 Gr60 / 70, SA537 Cl.1, SA 106 Gr.B, SA 105
• CE (IIW) = C + (Mn/6) + [(Cr+Mo+V)/5]+ [(Ni+Cu)/15]
• Excellent weldability upto CE = 0.45
• Comparatively less susceptible to Hydrogen cracking
• Preheat / PWHT called for only higher thk (>30mm)
• Suitable for all type of Arc & other Welding processes
• Weld soundness is not problem with Killed steels](https://image.slidesharecdn.com/weldabilitypc-140723105734-phpapp02/85/Weldability-pc-4-320.jpg)
Uploaded byJithu John
Weldability pc
This document discusses the weldability of various metal types including carbon-manganese steel, low alloy steel, quenched and tempered steel, stainless steel, nickel alloys and aluminum alloys. For carbon-manganese steel, it notes their excellent weldability and suitability for arc and other welding processes. It also discusses preheat requirements and filler metals for different welding methods. For low alloy and quenched tempered steels, it highlights their susceptibility to hydrogen cracking and need for proper joint design, preheat and control of heat input during welding. The document also briefly summarizes weldability considerations for martensitic and ferritic stainless steels.
More Related Content
Weldability pc
- 1. Metals & TheirWeldability Pallav Chattopadhyay
- 2. Weldability • No universallyaccepted meaning • AWS 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 the intended service”
- 3. Weldability • C-Mn Steel •Low Alloy Steel (Cr-Mo / Cr-Mo-V steel) • Quenched & tempered Steel • Stainless Steel • Ni Alloys • Al Alloys • Ti Alloys
- 4. Weldability of C-MnSteel • C – 0.15% max, Mn- 1.65%max, Cu & Si- 0.60% max • SA516 Gr60 / 70, SA537 Cl.1, SA 106 Gr.B, SA 105 • CE (IIW) = C + (Mn/6) + [(Cr+Mo+V)/5]+ [(Ni+Cu)/15] • Excellent weldability upto CE = 0.45 • Comparatively less susceptible to Hydrogen cracking • Preheat / PWHT called for only higher thk (>30mm) • Suitable for all type of Arc & other Welding processes • Weld soundness is not problem with Killed steels
- 5. Weldability of C-MnSteel
- 6. Weldability of C-MnSteel Typical CCT Diagram
- 7. Weldability of C-MnSteel • SMAW – Matching electrodes available for chemistry / strength level – Low Hydrogen electrodes (E7018) reduce chance of Hydrogen cracking – Baking & Storage of electrode – Moisture free • GTAW / GMAW – Suitable bare electrodes available like SMAW – Electrodes with de-oxidizer preferred to reduce chance of porosity (e.g. ER 70S-2) – Argon based gas mixtures for GTAW – CO2 / Argon-CO2 Mixture for GMAW – Proper cleaning / packing / storage of Filler metal & good quality Shielding gas required
- 8. Weldability of C-MnSteel • FCAW – Self Shielded / Gas Shielded consumables available – Shielding Gas – CO2 / CO2-Argon mixture (e.g. E71T-1) – Normally low in Hydrogen level – baking not required • SAW – Solid (even Metal Cored wires) wire + Suitable Flux – Fused / Agglomerated Flux (Mostly Neutral) – Solid wire – Cu coated / Flux – requires Redrying – Desired properties – As welded / With PWHT
- 9. Weldability of C-MnSteel • Other Welding Processes – Electro Slag / Electro Gas Welding: • Suitable Consumable available • May require additional Heat Treatment as per Code – Oxy Acetylene Welding: • Suitable consumable available • Slower than Arc Welding – Extensive heating of steel / slow cooling • Chance of imperfection more
- 10. Weldability of C-MnSteel • Other Welding Processes – Resistance Welding: • Spot/ Seam/ Flash / Upset welding possible • Heating / Cooling rates higher – Electron / Laser Beam Welding: • Readily weldable • Rapid Heating & Cooling rates – Smaller grains in Weld / HAZ • Fully Killed steel preferred
- 11. Weldability of Cr-Mo/ Cr-Mo-V Steel • Cr : 0.5 ~ 9%, Mo : 0.5 ~ 1%, V : ~0.25% & C ≤ 0.20% • Cr provides improved oxidation & corrosion resistance • Mo provides better elevated temp properties • Good weldability • High hardenability (Most of them Air-hardenable) • Rapid cooling from above Ac3 temperature (~900°C)→ strength ↑, hardness ↑, ductility & toughness ↓ • Requires Tempering (~650°C) to restore the properties • PWHT at >680°C (Typical: 680-705°C) mandatory for all thickness
- 12. Weldability of Cr-Mo/ Cr-Mo-V Steel SA 387 Gr - 11 CL - 2 SA 336 Gr - F11 CL - 2 SA 336 Gr - F11 CL - 3 SA 387 Gr - 22 CL - 2 SA 336 Gr- F22 CL- 3 SA 335 Gr - P5 SA 387 Gr - 5 CL - 2 SA 542 Type D CL.4a Product From. Plate Forgings Forgings Plate Forgings Smls.pipe Plate Plate C, Max. 0.04 - 0.17 0.10 - 0.20 0.10 - 0.20 0.04 - 0.15 0.05 - 0.15 0.15 0.15 0.09 - 0.18 Mn, Max 0.35 - 0.73 0.30 - 0.80 0.30 - 0.80 0.25 - 0.66 0.30 - 0.600.30 - 0.600.25 - 0.660.25 - 0.66 Cr, Max. 0.94 - 1.56 1.00 - 1.50 1.00 - 1.50 1.88 - 2.62 2.00 - 2.504.00 - 6.003.90 - 6.101.08 - 2.62 Mo, Max. 0.40 - 0.70 0.45 - 0.65 0.45 - 0.65 0.85 - 1.15 0.90 - 1.100.45 - 0.650.40 - 0.700.85 - 1.15 V, Max. - - - - - - - 0.23 - 0.37 - SA 387 Gr - 11 CL - 2 SA 336 Gr - F11 CL - 2 SA 336 Gr - F11 CL - 3 SA 387 Gr - 22 CL - 2 SA 336 Gr- F22 CL- 3 SA 335 Gr - P5 SA 387 Gr - 5 CL - 2 SA 542 Type D CL.4a Tensile strength (Min) Ksi 75 - 100 70 - 95 75 - 100 75 - 100 75 - 100 60 75 - 100 85 - 110 Mpa 515 - 690 485 - 660 515 - 690 515 - 690 515 - 690 415 525 - 610 585 - 760 Yield strength (Min) Ksi 45 40,000 45,000 45 45 30 45 60 Mpa 310 275 310 310 310 205 310 415 Elongation in 8 inch (200mm) min,% 18.00 - - - - - - - Elongation in 2 inch (50mm) min,% 22.00 20.00 18.00 18.00 19.00 - 18.00 18.00 Reduction of area, min % - 40 40 45.00 40.00 - 45.00 - Chemical properties Mechanical properties
- 13. Weldability of Cr-Mo/ Cr-Mo-V Steel • Highly susceptible to Hydrogen Induced Cracking / Cold Cracking • Use of Low Hydrogen consumables is must • Control on welding Heat Input • Appropriate Preheat (~125-200°C), De Hydrogenation Treatment (300-400°C) and Intermediate Stress relieving (640- 660°C) mandatory to prevent cracking • In between cooling to room temperature not allowed – followed by DHT /ISR • High Cr(>5%)-Mo/ Cr-MoV steel calls for Direct PWHT after welding
- 14. Weldability of Cr-Mo/ Cr-Mo-V Steel • Susceptible to Temper Embrittlement while operating between 375-575°C – Control tramp elements (P, Sn, Sb, As etc) in Base metal & Weld metal (‘J’ factor & ‘X’ factor respectively) – “J” Factor : (P+Sn) x (Mn+Si) x 104 ≤ 100 “X” Factor : (10P+5Sb+4Sn+As) / 100 ≤ 15 ppm – Perform Step cooling treatment and measure shift in DBTT
- 15. . STEP COOLINGHEAT TREATMENT 1hr (1) 15hr (1) 24hr (1) 60 hr (2) 100 hr (3) STEP COOLING HEAT TREATMENT COOLING RATE ( °C / Hr. ) Sr.No. REQUIRED ACTUAL (1) 5.6 (MAX.) 5.0 (2) 2.8 (MAX.) 2.5 (3) 27.8 (MAX.) 25 538°C 524°C 496°C 468°C 315°C air/ furnace cooling 593°C 50 °C/hr
- 16. TEMPER EMBRITTLEMENT TEST 0 30 60 90 120 150 180 210 240 270 300 -50-40 -30 -20 -10 0 10 20 30 40 TEMPERATURE(°C) ABSORBEDENERGY(J) MIN.PWHT AVG.TW1 MIN.PWHT+ SC AVG.TW2 54J TT54= -27°C TT54SC= -22 °C TEMPER EMBRITTLEMENT PARAMETER : TT54 + 3∆TT54 <10 °C Where, ∆TT54 = TT54SC - TT54
- 17. Weldability of Cr-Mo/ Cr-Mo-V Steel • Arc Welding Processes – Suitable weld consumables available for all types of Arc Welding processes Consumable Table SMAW GTAW SAW 1.25Cr-0.5Mo E 8018 B2 ER 80S B2 EB2 + Suitable Flux 2.25Cr-1Mo E 9015 B3 ER 90S B3 EB3 + Suitable Flux 2.25Cr-1Mo-0.25V E 9018 G ER 90S G Union S1CrMo 2V (Brand name) 5Cr-0.5Mo E 8018 B6 ER 80S B6 EB6 + Suitable Flux 9Cr-1Mo E 8018 B8 ER 80S B8 EB8 + Suitable Flux 9Cr-1Mo-0.25V E 9018 B9 ER 90S B9 EB9 + Suitable Flux Weld Consumable Steel
- 18. Weldability of Cr-Mo/ Cr-Mo-V Steel • Other Welding Processes – Resistance Upset Welding: • Sometimes used for Longitudinal seam welding of Cr-Mo pipes & tubes • Strip roll formed to shape – continuously welded to make Tubes using high frequency AC and forging by pressure rolls • High localized heat inputs and fast cooling rates – low ductility • Sometimes PWHT performed in welding machine only – Electro Slag Welding: • Primarily used for ≥3” thickness • Filler wire same as SAW is used • Large build-up of heat – automatic preheating + Stress relief • Subsequent Annealing / Normalizing is mandatory
- 19. Weldability of Quenched& Tempered Steel • Heat Treatment Condition: Quenched & Tempered • High YS, UTS with good toughness, ductility & weldability • Alloy addition to achieve desired mechanical properties – mainly Ni, Cr, Mo, Mn, V • Welded structures normally don’t need PWHT except Stress Relieving
- 20. Weldability of Quenched& Tempered Steel Typical Chemistry & Properties CHEMICAL COMPOSITION SA 533 Gr - B CL-3 SA 517 Gr. - F SA 533 Gr - B CL-1 SA 533 Gr - B CL-2 HY-80 Product From. Plate Plate Plate C, Max. 0.25 0.08-0.22 0.25 0.25 Mn, Max 1.07-1.62 0.55-1.10 1.07 - 1.62 1.07 - 1.62 Si, Max. 0.13-0.45 0.13-0.37 0.13 - 0.45 0.13 - 0.45 0.15-0.35 Cu, Max. - 0.12-0.53 - - 0.25 Ni, Max. 0.37-0.73 0.67-1.03 0.37 - 0.73 0.37 - 0.73 2.00-3.25 Cr, Max. - 0.36-0.69 - - 1.00-1.80 Mo, Max. 0.41-0.64 0.36-0.64 0.41 - 0.64 0.41 - 0.64 0.20-0.60 V, Max. - 0.02-0.09 - - 0.03 Cb, Max. - - - - Boron, Max. - 0.005-0.006 N - - SA 533 Gr - B CL-3 SA 517 Gr. - F SA 533 Gr - B CL-1 SA 533 Gr - B CL-2 HY-80 Tensile strength (Min) Ksi 100-125 105-135 80 - 100 90 - 115 Mpa 690-860 725-930 550 - 690 620 - 795 Yield strength (Min) Ksi 83 90 50 70 80 Mpa 570 620 345 485 Elongation in 8 inch (200mm) min,% - - - - Elongation in 2 inch (50mm) min,% 16.00 14.00 18.00 16.00 Mechanical properties
- 21. Weldability of Quenched& Tempered Steel • Appropriate joint design (No Stress-raisers), good workmanship & adequate Inspection checks are MUST • Preheat extremely critical – to be chosen carefully • Excess preheat / Interpass temp– Slower coling rate – re-austenitized zone near weld metal transform to Ferrite + High C Martensite /Bainite • Heat input needs to be controlled on lower side • Excess heat input – Reduction in Strength, Toughness
- 22. Weldability of Quenched& Tempered Steel • All Arc Welding processes available • Electro Slag / Electro Gas/ Multiple wire SAW requires re-heat treatment due to high heat input • EBW / LBW preferred • Small stringer weld beads – good toughness • Selection of weld consumable – based on mechanical property requirement (many times non-matching chemistry) • Very sensitive to Hydrogen cracking – allows extremely low level of moisture / Hydrogen in weld metal (target: 2ml/100gm)
- 23. Weldability of Quenched& Tempered Steel • Manual / Mechanized oxy fuel cutting allowed – remove 2-3mm hardened zone by grinding • Machine cutting preferred • Arc gouging allowed – with less heat input • Gas gouging not allowed • Brazing allowed – but may require Q&T since brazing temp is high
- 24. Weldability of StainlessSteel • Major types: – Chromium Martensitic SS – Chromium Ferritic SS – Austenitic SS – Precipitation hardenable SS – Duplex / Super Duplex SS • Relatively high coefficient of thermal expansion / low thermal conductivity • Protection of molten arc mandatory – prevent chromium oxide formation • Pre-weld & Post-weld cleaning crucial – prevent C contamination / Surface oxidation • All welding processes other than Oxy-acetylene welding recommended
- 25. Weldability of MartensiticStainless Steel • Essentially Fe-Cr-C alloys with 11.5-18% Cr • Rapid cooling – hardened structure • E410NiMo, E410 are commonly used consumables • Weldability improved if welded by Austenitic SS cons. • Weld joints require PWHT to get optimum property • Susceptible to Hydrogen cracking • Preheat & Interpass control required • Suitable for all Arc welding processes • Resistance welding (Spot & Flash) possible • EBW, FSW possible
- 26. Weldability of FerriticStainless Steel • Fe-Cr-C alloys with>11.5% Cr+ other Ferrite stabilizer (Mo, Al, Ti, Cb etc) – Low C content • Non Air-hardenable • Few Matching filler metal available – however Austenitic SS / Ni based alloys used as weld metal • Susceptible to cracking under high restraint / surfacing • Preheat (~150°C) may be required • Mostly used in ‘As-welded’ condition – No PWHT • All types of Arc welding possible • Resistance welding / Other welding processes available
- 27. Weldability of AusteniticStainless Steel • Typical 18%Cr-8%Ni steel • Cr- Oxidation / Corrosion resistance, Ni & Mn- Stabilize Austenite • Better Ductility & Toughness (FCC structure) • Intentionally little Delta Ferrite (3~8%) added in Weld metal– to reduce hot cracking sensitivity • Excessive Delta Ferrite also not allowed – compromise in corrosion resistance / sigma phase at high temp exposure
- 28. Weldability of AusteniticStainless Steel Delong Diagram
- 29. Weldability of AusteniticStainless Steel • Improper welding condition (long arc, lack of proper shielding etc) change Delta Ferrite content • Sensitization: Slow cooling between 750-375°C – Cr carbide precipitation at Grain boundaries – Corrosion attack • Preheat not required • Interpass temp control extremely important • Stress corrosion cracking – Presence of stress + Halogen atmosphere • PWHT not required • Suitable for all types of Arc welding / Plasma welding, Resistance and other welding processes (EBW, FSW)
- 30. Weldability of PHStainless Steel • Precipitation Hardenable (PH) SS possess high strength with reasonably simple heat treatment – Martensite formation / Precipitation hardening • Three types – Martensitic, Semi-Austenitic & Austenitic • Martensitic: Martensitic structure + Ageing • Semi-Austenitic: Initially Austenite after Cooling – Reheat and cool to convert to Martensite + Ageing • Austenitic: Austenite + Ageing • Mostly require PWHT after Welding to restore properties • All Arc welding / Resistance Welding is possible • Stringent control on weld parameters / heat input
- 31. Weldability of DuplexStainless Steel • Typical 40-50% Ferrite + Balance Austenite • Corrosion (mainly Pitting) resistance + High strength / toughness • Low coefficient of Thermal expansion – like CS • Less prone to hot cracking • High heat input / interpass: HAZ loses Ductility/ toughness, Phase balance disturbs • Clean joint, good fit-up very important • Preheating not required • PWHT must be avoided (Sigma/ Chi/ Alpha Prime embrittlement) • Arc Welding processes / High energy beam welding done
- 32. Weldability of DuplexStainless Steel Micro Of Standard Duplex Dark Areas:- Ferrite Light Areas:- Austenite
- 33. Weldability of NiAlloys • Ni – FCC structure upto Melting point • Pure Ni & Solid solution of Ni-Cu, Ni-Cr-Fe, Ni-Cr-Mo widely used CHEMICAL COMPOSITION Nickel 200 Monel 400 Incoloy 825 Inconel 625 C, Max. 0.08 0.2 0.03 0.05 Mn, 0.2 1.00 0.5 0.2 Si, 0.2 0.20 0.25 0.2 Cu, . 0.1 31.5 2.25 0.2 Ni 99.5 66.5 42 61 Cr, 21.5 21.5 Mo, 3 9 Fe 0.1 1.2 30 2.5
- 34. Weldability of NiAlloys • Extremely sensitive to surface cleaning / preparation • Suitable filler metal available for most arc welding process • Resistance Welding, Oxyacetylene Welding, High Energy Beam welding possible • Preheat not required • Heat input and Interpass temp must be restricted • Viscous weld metal – prone to solidification / end cracker cracking – suitable technique required • PWHT usually not required – however not detrimental
- 35. Weldability of AlAlloys • Thermal & electrical conductivity – 4 times of Steel • Higher heat input required • Highly prone to oxidation - Refractory oxide formed – removed / broken during welding • Most fusion / solid state welding possible • Suitable filler wires available for arc / oxy-fuel welding • Weld prone to cracking – hot shortness, HAZ inter-granular crack, lesser strength + shrinkage stress
- 36. Weldability of AlAlloys • Prevented by using higher alloyed filler wire • Surface / Joint cleaning very important • Preheat – normally not required except high thickness • AC / DC welding suitable • Special technique required to prevent crater cracking • GTAW / GMAW / Solid state welding - most preferred • Usually PWHT not required
- 37. Weldability of TiAlloys • Highly reactive – requires protection from atmosphere • Extremely sensitive to cleaning – special reagents used • GTAW, GMAW, Plasma & Solid state welding popular • Gas shielded welding: Use of Trailing gas in addition to High purity Shielding & Purging gases • Highly susceptible to porosity • Colour of weld bead confirms protection from oxidation • PWHT normally not required • No Preheat • Very stringent Interpass temp & Heat input control • Solid state welding preferred for dissimilar welding
- 38. Weldability of TiAlloys Weld Colour Probable Cause and Treatment Light Straw, Dark Straw, Light Blue Surface oxide. Remove by wire brushing with new stainless steel wire brush. Dark Blue, Grey Blue, Grey Metal contamination. Welds should be removed and done over after corrections in shielding are made. White (loose deposit) Metal contamination. Welds should be removed and done over after corrections in shielding are made