The Welding of Structural Steels without Preheat

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1 WELDING RESEARCH SUPPLEMENT TO THE WELDING JOURNAL, APRIL 2 Spnsred by the American Sciety and the Research Cuncil The f Structural Steels withut Preheat A prgram was initiated t evaluate whether current guidelines fr preheat shuld apply t lw hardenability steels BY A. J. KINSEY ABSTRACT. As a result f recent steel making trends tward lw hardenability thermmechan ical ly cntrl led prcessed (TMCP) steels and the develpment f lwer hydrgen-ptential welding cnsumables, the pssibility f welding even thick-sectin structural steels withut preheat is becming mre feasible. Current British guidelines fr very lw-hydrgen-ptential cnsumables that depsit less than 5 ml H2/1 g depsited weld metal (Scale D cnsumables accrding t BS 5135) are largely based n cracking data btained mstly n high-carbn equivalent steels. A prgram was therefre cnducted at TWl t assess the validity f the current guidelines when applied t lw hardenability steels. In general, gd agreement was bserved between the HAZ cracking behavir and that predicted by the TWl nmgrams. Steels f lw-carbn equivalent were successfully welded using the shielded metal arc welding (SMAW) and flux cred arc welding (FCAW) prcesses withut the applicatin f preheat using lw-hydrgen, Scale D cnsumables. In mst cases, the present TWl nmgrams crrectly predicted cracking behavir, althugh the deleterius effect f lw sulfur n cracking tendency was nted when welding sme steels. The use f very lw-hydrgen cnsumables is t be encuraged since, in cnjunctin with lw-carbn equivalent steels, they can reduce the requirement fr preheat t A. J. KINSEY, previusly with TWl, is nw with Ryal and Sun Alliance Engineering, Manchester, U. K. avid HAZ hydrgen cracking and, therefre, reduce fabricatin csts. The TWI nmgrams prvide a gd basis fr the derivatin f prcedures fr such cnsumables. Intrductin A cmprehensive scheme fr predicting statistically based, safe welding prcedures fr structural steels was first published in 197 (Ref. 1). Industry is nw familiar with the nmgrams that were develped frm this wrk and are presented in BS 5135:1984 (Ref. 2). Such nmgrams enable the predictin f suitable safe welding cnditins fr the avidance f heat-affected-zne (HAZ) cracking in carbn and C-Mn steels. Based n practical experience, these nmgrams have been updated and mdified since their first intrductin in 1972 (Ref. 3), ntably by the intrductin f a revised secnd editin f the TWI publicatin Steels withut Hy- KEY WORDS Preheat TMCP Lw Hardenability Lw Hydrgen SMAW FCAW Nmgrams Diffusible Hydrgen drgen Cracking (Ref. 4) and the prpsed pr EN (Ref. 5). Currently, fur hydrgen levels are recgnized in BS 5135:1984 (viz Scale A thrugh D). T cnfrm t scale D, which represents the lwest weld metal hydrgen cntent, the hydrgen ptential f a given cnsumable must be less than 5 ml H2/1 g depsited weld metal. Mre recently, hwever, a fifth Scale E level (<3 ml H2/1 g depsited weld metal) has been prpsed fr pr EN (Ref. 5). With the emergence f lw hardenability thermmechanically cntrlled prcessed (TMCP) steels, and the develpment f lwer hydrgen-ptential welding cnsumables, the pssibility f welding even thick jints withut preheat has arisen. This wuld bviusly lead t a favrable reductin in fabricatin csts in a wide variety f situatins and industries. Hwever, at present, few cntrlled thermal severity (CTS) test cracking data exist at hydrgen levels belw the Scale D limit (5 ml hydrgen/1 g depsited weld metal). Indeed, mst f the previus tests were perfrmed n lder, high-carbn equivalent steels (Ref. 1 ) and a need exists t extend the data t lwer carbn equivalent steels. Therefre, the principal aim f this wrk was t define quantitative limits n material cmpsitin, hydrgen level and weld thermal cycle that wuld enable preheat abve nrmal ambient t be avided withut inducing HAZ hydrgen cracking. In additin, sme cncern has been raised ver the necessity t apply preheat t "dry the plate" and eliminate any adverse effects f water that may be present. Practically, misture f this nature usu- WELDING RESEARCH SUPPLEMENT [ 79-s

2 Table 1 -- Cmpsitins f Steel Plates Used fr CTS Testing Element wt-% Plate Grade f Identity Steel Pla~ C S P Si Mn Ni Cr M V Cu Nb ~ AI 1B < B789 5D.19 < <.5 < < B < <.5 < B457 5E < B485 5E B859 5D B885 5E Plate Grade f B Sn C As Identity Steel Plate 1 B433 5 < B789 5D.... 1B74 55 <.3.1 <.5 <.5 1B457 5E <.3 <.5 < B485 5E.5 <.5.1 <.5 1B859 5D <.3 <.5 <.5 <.5 1B885 5E <.3 <.5.1 <.5 Element wt-% Ca Pb Zr O N CE,w <.3 <.2 < <.3 <.5 < <.3 <.5 < <.3 <.5 < <.5 < Table 2 -- Depsited Weld Metal Diffusable Hydrgen Levels fr CTS Test Weld Cnsumables Cnsumable Type/ Specificatin Medium ally highly basic flux cred wire AWS E8T5-G/Argshield 2 gas (18 Umin) flw rate, 2-mm electrde extensin Misture-resistant basic cated lwhydrgen (vacuum packed) BS639 E5155B AWS 5.1 E718-1 Basic cated lwhydrgen BS E5154B (12 2 6H) AWS E718 Basic cated BS E5154B (12 2 6H) AWS E718 ally frms as cndensatin when a cld plate is brught int a warmer fabricatin shp. Therefre, the effects f misture cntaminatin n the prpensity fr hydrgen cracking was als briefly assessed using a variety f methds t simulate this phenmenn. The abve bjectives were met by generating cntrlled thermal severity (CTS) test data n a range f steels, using cnsumables with hydrgen levels that cnfrmed t the Scale D level. Tests were perfrmed at ambient temperature bth with and withut the applicatin f a cntaminant such as water. Drying Diffusible Cnditins Cnditins Hydrgen Cntent ml/1 Depsited Metal TWl Temperature, Time, Current, Vltage, Final Analysis C (h) A V (21 day) N. As-received H93/6 As-received H92/ H92/ H92/21 Experimental Details Materials and Cnsumables In all, seven steels were studied that were representative f ld and new steels, and a brief descriptin f each is prvided belw in rder f carbn equivalent. 1).31 CE,w,.6%C, TMCP steel (Grade 5E), TWl identity N.1 B885. 2).33 CE,w,.1%C, TMCP steel (Grade 5D), TWl identity N.1 B859. 3).37 CEIl w,.1 7%C, micrallyed, nrmalized C-Mn-Nb steel (Grade 5E), TWl identity N.1 B457. 4).37 CE,w,.8%C, micrallyed, nrmalized, C-Mn-Ni-Cu-Nb-V-Ti, Catreated steel (Grade 5E), TWl identity N.lB485. 5).4 CEuw,.5%C, cntrlled rlled and aged steel (Grade 55), TWl identity N.1 B74. 6).43 CE~lw,.19%C, lw sulfur C- Mn steel, lw xygen cntent, Al-treated (Grade 5D), TWl identity N.1 B789. 7).45 CE,w,.18%C, high sulfur C- Mn steel (Grade 5), TWl identity N.1 B433. Mst f the steels were btained while the nw superseded BS 436 standard was in existence and have been assigned a grade cvered by that standard. The steels designated Grade 5 wuld have had a minimum yield strength typically f arund 35 N/mm 2 (-5 ksi), while the Grade 55 wuld have had a minimum yield strength f arund 45 N/mm 2 (-65 ksi). Grades 5D and 5E wuld be equivalent t Grades S355J2G3 and $355N in BS EN 125:1993 and BS EN 1113:1993, respectively, while Grade 55 wuld be similar t $46N. All CTS tests were cnducted using 5-mm (-2-in.) thick plate. The xygen and nitrgen cntents f the steels were determined by inert gas fusin; all ther elements were determined using a direct reading ptical spectrmeter n remelted samples. Grades and cmpsitins are given in Table 1. Three shielded metal arc (SMAW) electrdes and ne flux cred wire (FCAW) were chsen. Details f the cnsumables, the drying cnditins and diffusible weld metal hydrgen levels are given in Table 2. Prcedures given in BS 6693: Parts 3 and 5 were fllwed t determine the depsited weld metal hy- 8-s ] APRIL 2

3 drgen levels (Refs. 6, 7). Hydrgen was cllected at rm temperature ver mercury. All fur cnsumables cnfrmed t Scale D hydrgen level as defined in BS 5135: All cnsumables were used in the same cnditin as emplyed fr the hydrgen analyses. Shielded metal arc welds were prduced using an autmatic welding system as described by Pedder and Watkinsn (Ref. 8). All welds were prduced using 4-mm (s/~2-in.) diameter electrdes. current and vltage were held essentially cnstant, and the travel speed was adjusted s that a range f arc energies culd be investigated fr each plate/cnsumable cmbinatin. Fr SMAW, V and A were used such that arc energies f between.8 and 1.45 kj/mm (apprximately 2 and 37 kj/in., respectively) were btained. Flux cred arc welds were depsited autmatically by fixing the welding gun t an autmatic traverse machine usually used fr submerged arc welding (SAW). A wire diameter f mm ('/16-in.) was used thrughut. Apprximately 23 V and A were emplyed such that the arc energy was varied between.6 and 1.5 kj/mm (apprximately 15 and 38 kj/in., respectively). Cntrlled Thermal Severity Testing The self-restrained cntrlled thermal severity (CTS) test blck assembly used during this prgram is described in BS 7363:199 (Ref. 9) and is shwn in Fig.1. Single-pass welds were depsited in the flat psitin acrss the full width f the blck in accrdance with BS 7363:199 (Ref. 9). In ttal, six faces were examined metallgraphically fr cracking frm each test weld. A Vickers hardness survey f the carse-grained HAZ was carried ut n ne face taken frm each weld using an indenting lad f 5 kg. The face shwing maximum cracking was chsen fr cracked welds, while a face taken frm the midlength was used fr uncracked welds. Cntrlled Thermal Severity Testing with Misture Cntaminatin The prcedure utlined abve was als perfrmed n test blcks whse surfaces were cvered in misture t simulate cndensatin as may ccur when cld plate is brught int a warmer fabricatin shp and n preheat is used. Three methds were emplyed in rder t intrduce water nt a clean, de- Riling directin Test weld "~ L,,,,J,J,,~) CCC CCC C r..._ Clearance I I. ~ 1 hle "I._._Test weld CCC CCCCCCC CC _1 Fig Cntrlled thermal severity (CTS) test blck cnfiguratin. 13ram dimeter Oimensins in mm Table 3 -- Depsited Weld Metal Diffusible Hydrgen Level fr Cnsumable Used fr CTS Test Welds with Humidity-Cabinet-Induced Misture Cnsumable Type/ Specificatin Basic cated BS E5154B ( H) AWS E718 (a) individual values mean Drying Cnditins Cnditins Temperature, Time, Current, Vltage, C (h) A V Diffusible Hydrgen Cntent, ml/1g (~ Depsited Metal 5.2,5.1, Table 4 -- CTS Test Weld Data fr Plate 1 B885 (5-mm thickness, 15-mm cmbined thickness,.31ce.w) Diffusible H 2 ml/1 g Mean Weld HAZ f Faces Depsited Travel Arc HAZ Metal Cracking/N Cracked Weld Weld Speed, Energy, Ats-s, Hardness Hardness Cracking, frm a N. Metal mm/min kj/mm s HV5 (a) HV5 C/NC Ttal f Six W NC 233 W NC 235 (a) Presented as max.-min. greased test blck. First, test blcks were placed in a cld refrigeratr at 13 C r 6 C (55 F r 43 F) in rder t induce the frmatin f dew n the test blck surface when brught int the labratry. Secnd, blcks were placed in a freezer at -2 C (-19 F), which resulted in frst frmatin n the test blck. Finally, blcks were placed in a humidity cabinet at apprximately 3 C (86 F) and 87% relative humidity. This induced water drplet frmatin after apprximately 45 WELDING RESEARCH SUPPLEMENT[ 81-s

4 Table 5 -- CTS Test Weld Data fr Plate 1 B859 (5-mm thickness, 15-ram cmbined thickness,.33cell w) Diffusible H 2 ml/1 g Mean Weld HAZ f Faces Depsited Travel Arc HAZ Metal Cracking/N Cracked Weld Weld Speed, Energy, Ats_s, Hardness Hardness Cracking, frm a N. Metal mm/min kj/mm s HV5 <'~ HV5 C/NC Ttal f Six W NC W NC 35 (a) Presented as max.-min. Table 6 -- CTS Test Weld Data fr Plate 1 B485 (5-mm thickness, 15-mm cmbined thickness,.37ce,w) Diffusible H2 ml/1 g Mean Weld HAZ f Faces Depsited Travel Arc HAZ Metal Cracking/N Cracked Weld Weld Speed, Energy, At~3_s, Hardness Hardness Cracking, frm a N. Metal mm/min kj/mm s HV5 ~a~ HV5 C/NC Ttal f Six W NC 35 W NC 347 W NC 34 W NC 34O (a) Presented as max.-min. Table 7 -- CTS Test Weld Data fr Plate 1 B457 (5-mm thickness, 15-mm cmbined thickness,.37ceuw) Diffusible H~ m L/1 g Depsited Travel Arc Weld Weld Speed, Energy, Ats_~, N. Metal mm/min kj/mm s W W W W W W W W (a) Presented as max.-min Mean Weld HAZ f Faces HAZ Metal Cracking/N Cracked Hardness Hardness Cracking, frm a HV5 ~ HV5 C/NC Ttal f Six NC C C NC C NC NC NC 35 min f expsure. All test welds were made immediately after the blck was remved frm the freezer, refrigeratr, r humidity cabinet. Tw shielded metal arc cnsumables were used that prduced weld metal hydrgen levels f 3.9 ml r 4.4 ml/1 g depsited weld metal when welding was perfrmed under nrmal, dry cnditins (Table 2). A measure f the actual depsited weld metal hydrgen with humidity-cabinet-induced surface misture was made fr the 3.9 ml/1 g depsited weld metal cnsumable. This was cmpared t the result btained under nrmal, essentially dry, cnditins. Tw steels were evaluated using this technique, crrespnding t.45 and.33 carbn equivalents. Results Hydrgen Levels The hydrgen levels determined fr each cnsumable are shwn in Table 2. All are bserved t be within the Scale D level (<5 ml H2/1 g depsited metal) in BS 5135: The diffusible hydrgen present in the weld metal depsited n test blcks cvered with humidity-cabinet-induced surface misture was bserved t be 4.9 ml H2/1 g depsited metal (Table 3). This represents an increase f 1 ml H2/1 g depsited weld metal in cmparisn with the previus result btained under nminally dry cnditins. Further assessment and data generatin wuld be required t establish if this is a "real" difference. Hwever, the value f 4.9 ml H2/1 g still cnfrms t the Scale D level stipulated in BS 5135: CTS Test Data All CTS test weld results (withut misture cntaminatin) are presented in Tables 4-1 fr each individual steel cmpsitin. The HAZ cracking behavir is presented in Figs The predicted arc energy fr the avidance f hydrgen cracking, as defined by TWl nmgrams fr 5-mm (2-in.) thick steel/n preheat/scale D hydrgen is als shwn. (Nte that the term "arc energy" describes the energy supplied by the arc, while the term "heat input" refers t the heat input int the steel being welded. The difference between the tw terms is accunted fr by the "arc efficiency" f the welding prcess. The arc efficiency f SMAW and FCAW is 8% fr the purpses f the TWl scheme). The maximum HAZ hardness is recrded adjacent t each crack/n crack data pint. Cracking was seen t ccur in steel 1 B789 at a marginally higher arc energy 82-S I APRIL 2

5 than that predicted as being safe by the TWl nmgram fr a carbn equivalent f.43 (Figs. 2 and 5). Steel 1 B74 (.4 CEuw) shwed a single cracked weld at an arc energy assumed t be safe, accrding t the TWl predictive scheme (Fig. 3), while steel 1B457 prduced cracking in three test welds at cnditins als predicted t be safe by the nmgram -- Fig. 5. Hwever, the ther steels behaved in accrdance with the TWl predictive scheme. Indeed, fr steels 1 B885, 1 B859 and 1 B485, which crrespnded t carbn equivalents f.31,.33 and.37, respectively, n HAZ cracking culd be prduced, even when the lwest practicable arc energies (~.8 kj/mm) were emplyed. In three steels fr which a crack threshld culd be established, the critical HAZ hardness at which cracking ccurred (defined as the lwest value f maximum hardness in a cracked sample, HVcrit) was bserved t vary between 376 and 437 HV5 and generally appeared t decrease with lwer CEuw -- Fig. 6. Hwever, fr steel 1 B74 where a single cracked weld was bserved, this cracking ccurred at a maximum HAZ hardness f 296 HV5. CTS Test Data with Misture Cntaminatin All CTS test weld results with misture cntaminatin are presented in Tables 11 and 12 fr each steel cmpsitin examined. The cracking behavir is presented graphically in Fig. 7. The highest arc energy at which cracking was bserved under dry cnditins is als pltted. Fr the steel f lwest carbn equivalent,.33 (1 B859), n HAZ cracking was bserved, even when cnsumables with a ptential hydrgen level f 4.4 ml H2/1 g (when used in nminally dry cnditins) were emplyed t weld a blck cvered with frst. The cmbinatin f frst, n preheat and use f the highest Scale D cnsumable (4.4 ml H2/1 g) cnstitutes the wrst case examined, but cracking was nt induced fr the lwest practicable arc energy. The lwest uncracked result fr the CTS tests perfrmed n steel 1B433 f.43 CEIl w was bserved t be at 1.46 kj/mm. This is ~.2 kj/mm higher than that bserved fr the same steel/cnsumable cmbinatin when welding was perfrmed withut cntaminatin and des nt represent a significant effect f surface misture. Metallgraphic Observatins f Transverse CTS Test Specimens CTS welds made by the SMAW and FCAW prcesses shwed similar flat r cnvex bead surface prfiles. Hwever, ~1.2 t.-, uz T ~ c I B ' ,>c~ 358 / IB llw carbn equivalent [ ~ cracked(i.7i ~' uncracked(12)] Fig Cntrlled thermal severity test cracking data (1.5 mm cmbined thickness, n preheat, FCAW, 1.7 ml H2/1 g) E ~ 1.2.., t~ TW/ 435 /,v c~,/ /i!~ <> ]IW carbn equivalent Cracked(3.3) " ~, UncZked(3B)] Fig Cntrlled thermal severity test cracking data (15 mm cmbined thickness, n preheat, SMAW, 3.3 ml H2/1OO g). the rt gemetries fr bth prcesses were ften different as shwn in Fig. 8A and B. The flux cred wire welds invariably shwed an acute angle between the weld metal and tp plate in the rt regin f the vertical leg f the CTS test blck. This was always an btuse angle in shielded metal arc welds. When heataffected-zne cracking was bserved, it was always in the vertical leg f the fillet weld and initiated at the rt regin in the grain-carsened HAZ. Discussin Cmparisn f CTS Test Results with TWI Predictive Scheme The CTS results presented in the plts shwn in Figs. 2 5 indicated that, in general, gd agreement was bserved between the HAZ cracking behavir and that predicted by the TWl nmgrams. Fr the Scale D hydrgen level and a cmbined thickness f 15 mm, the WELDING RESEARCH SUPPLEMENT 83-s

6 Table 8 -- CTS Test Weld Data fr Plate 1 B74 (5-mm thickness, 15-mm cmbined thickness,.4ceuw) Diffusible H2 ml/1 g Depsited Travel Arc Weld N. Weld Metal Speed, Energy, Dts-s, mm/min kj/mm s W W W W W W W W W W (a) Presented as max.-min '-a 1.2 ~ Mean Weld HAZ f Faces HAZ Metal Cracking/N Cracked Hardness Hardness Cracking, frm a HV5 (a) HV5 C/NC Ttal f Six NC NC NC NC NC NC C NC NC NC / /><441 x // 435 x423 / x429 i, i ' I,, I I ' i ~, I I,,, I IIW carbn equivalent x Cracked(3.9) Uneracked(3.9)] Fig Cntrlled thermal severity test cracking data (15 mm cmbined thickness, n preheat, SMAW, 3.9 ml H2/1 g). scheme predicts HAZ cracking can be avided withut preheat at lw arc energies (~.8 kj/mm) with steels whse carbn equivalent is less than apprximately.42. Fr the majrity f situatins ex- amined experimentally, this was indeed the case. Hwever, three steels exhibited behavir that required further cnsideratin, and these will be treated individually belw. First, the lw-sulfur steel 1B789 (.43CEllw,.19%C) shwed cracking at marginally higher arc energies than predicted when welding was perfrmed with cnsumables that gave 1.7 ml H2/1 g depsited weld metal and 4.4 ml H2/1 g depsited weld metal (Fig. 2 and 5, respectively). Hwever, it shuld be nted that the cracked result f highest arc energy was nly -.25 kj/mm abve the TWl "safe" predictin line. T put this in perspective, BS 7363 states that crack/n crack bundaries shuld preferably be quted t within.3 kj/mm. Thus, it is questinable whether the behavir f this steel is adequately described by the scheme r nt. Hwever, this steel des have a very lw sulfur cntent (<.2%), and the pssible adverse effect f this n the risk f HAZ hydrgen cracking (Ref. 1) has nt been taken int accunt in initially pltting the results in Figs If allwance fr a lw sulfur effect is taken int accunt by increasing the carbn equivalent value (Ref. 4 suggests it may be necessary t increase this by.3), then the behavir is adequately described. Anther steel that shwed apparently anmalus cracking behavir was 1 B74 (.4 CEllw). Again, this may be cnsidered as a lw-sulfur steel fr the predictin f weld prcedures t avid HAZ cracking, thus effectively making this a.43 CEIl w steel. One incidence f cracking was bserved at.95 kj/mm arc energy when welding was perfrmed with the 3.3 ml H2/1 g depsited weld metal, hydrgen-ptential shielded metal arc cnsumables -- Fig. 3. This result is therefre in accrdance with the TWl scheme. In additin t the effect f lw-sulfur cntent, hwever, the high weight percent f nickel and cpper (.8 and.94 wt-%, respectively) is als nted in the cmpsitin, and this may als have cntributed t cracking behavir. Indeed, a steel f this cmpsitin was reprted by Pargeter and Hart t prduce HAZ cracking under cnditins nt expected based n the TWl nmgrams (Ref. 11); it may be that such levels f nickel and cpper are nt adequately described by the CEll w. Finally, the ther steel in which HAZ cracking was bserved under apparently safe welding cnditins was 1 B457 (.37 CEtlw,.1 7 wt-% carbn) -- Fig. 5. Ntably, cracking was bserved nly when welding was perfrmed with the cnsumables that shwed the highest hydrgen ptential (4.4 ml H2/1 g depsited weld metal), which still cnfrmed t Scale D. Als, the maximum HAZ hardnesses bserved with this steel were significantly higher than thse f similar carbn equivalent steels used in this 84-S ]APRIL 2

7 wrk. Frm cnsideratin f the maximum hardness values btained fr a given cling rate, it wuld appear that the hardenability f this steel is clse t r beynd the upper bund f behavir riginally intrduced by Bailey (Ref. 3) Diffusible H~ int the nmgram scheme. Why this ml/1 g shuld be is nt clear frm the chemical Depsited Travel Arc analysis f the steel, but it shuld be Weld Weld Speed, Energy, At~,> ~, nted that this steel has an untypically N. Metal mm/min kj/mm s high nibium level fr tday's structural w steels, and the steel als has higher carbn and lwer manganese levels than are w typical f many f tday's structural steels. The increased hardenability ass- w ciated with nibium-cntaining steels is accunted fr in certain ther carbn w equivalent frmulas used t assesss a w given steel's weldability (Refs ). T summarize, the present CTS test W wrk fr cmbined thicknesses up t 15 mm has cnfirmed that, in general, steels w with a lw-carbn equivalent can indeed be welded successfully in line with TWl w i guidelines withut the applicatin f pre- Wll heat when lw-hydrgen cnsumables (<5 ml H2/1 g depsited weld metal) Wl are used. The data btained in this wrk cnslidate the limited CTS data previ- w22 L usly acquired at TWl fr identical plate thicknesses and hydrgen levels withut W preheat (Ref. 15). N shrtcmings in the w27 ; TWl predictive scheme were highlighted by the previus wrk, althugh nly tw w steels were investigated. It wuld be expected that, as the hydrgen level f the w cnsumable is lwered, the cracking tlerance f hard heat-affected znes wuld w3~ ~ increase, i.e., the critical hardness fr w cracking wuld be expected t rise. Cmparisn f the critical hardnesses w measured in the present wrk with thse btained fr test welds depsited with w Scale B (-12 ml/1 g) shwn in Fig. 9 d indicate that this expected trend has w been bserved (Ref. 1 6). W Cmparisn f SMAW and FCAW Prcesses Steel 1B789 prduced similar crack/n-crack bundary cnditins f -1.3 kj/mm fr bth the flux cred arc welds at 1.7 ml H2/1 g and the shielded metal arc welds at 4.4 ml H2/1 g, while sme reductin in critical arc energy might reasnably have been expected. As was nticed earlier, the rt prfiles f the test fillet welds were different fr bth prcesses. The acute angle bserved between the weld metal and tp plate f flux cred arc welds represents an increased lcal stress cncentratin in cmparisn t the same regin fr shielded metal arc welds -- Fig. 8. This may be an explanatin fr the absence f an imprvement in the cracking risk f the lwer hydrgen flux cred Table 9 -- CTS Test Weld Data fr Plate 1B789 (5-mm thickness, 15-mm cmbined thickness,.43cell w) W N data W W (a) Presented as max. min. arc welds relative t the shielded metal arc welds referred t abve. Thus, until mre data have been generated, these results suggest that sme cautin shuld be exercised when develping weld prcedures fr this prcess. CTS Test Results with Misture Cntaminatin Turning nw t the CTS test welds that Mean Weld HAZ f Faces HAZ Metal Crackin~N Cracked Hardness Hardness Cracking, frm a HV5 ~ HV5 C/NC ~tal f Six NC C NC C NC NC C C NC NC NC NC NC NC C NC NC NC C C C C NC NC 37 were depsited with misture cntaminatin, the results are pltted in Fig. 7. Testing perfrmed n the 1B433 (.45 CEi. w) steel shwed the presence f water cntaminatin prir t welding nly shifted the crack/n-crack threshld frm 1.3 kj/mm t rughly 1.5 kj/mm fr welds depsited using Scale D cnsumables withut preheat. This shift is within the.3 kj/mm tlerance limit fr threshld arc energy as defined in BS 7363: WELDING RESEARCH SUPPLEMENT I 85-s

8 E ~" 1.2 t IB /396 ~ IB / 418 ~ i t I t J I I I I i I I I I i t I I ~ F ~ IIW carbn equivalent Cracked(4.4) Untracked(4.4) I Fig Cntrlled thermal severity test cracking data (15 mm cmbined thickness, n preheat, SMAW, 4.4 ml H2/lO g). Table 1- CTS Test Weld Data fr Plate 1 B433 (5-mm thickness, 15-mm cmbined thickness,.45ce.w) Weld N. Diffusible H2 ml/1 g Mean Weld HAZ f Faces Depsited Travel Arc HAZ Metal Cracking/N Cracked Weld Speed, Energy, Ats_5, Hardness Hardness Cracking, frm a Meta I mm/min kj/mm s HV5 ~a~ HV5 C/NC Ttal f Six Wl 4.4 W7 4.4 W5 4.4 W3 4.4 W9 4.4 W2 3.9 Wl 3.9 W8 3.9 W6 3.9 W4 3.9 W W (a) Presented as max.-min C (HVl) (HVl ) NC NC NC NC C C C C NC NC NC x In this cntext it shuld be nted that the appreciable quantity f surface water nly led t an increase f ~1 ml H2/1 g in depsited weld metal diffusible hydrgen giving 4.9 ml H2/1 g, still just meeting Scale D. Further indicatins f a minimal effect f surface misture were demnstrated by the uncracked results btained in steel 1 B859 (.33 CE), which was successfully welded with.9 kj/mm arc energy. Observatin f the welding peratin revealed that mst surface misture was evaprated by heat frm the arc befre depsitin f weld metal. This culd accunt fr the small increase in diffusible weld metal hydrgen bserved despite the apparently appreciable surface cverage f water. While it is clearly nt gd general practice t weld n jint preparatins cntaminated by misture r even frst, these results indicate that the cncern t use preheat t "dry the plate," even when preheat is nt needed fr cling rate cntrl t avid cracking, may have been unduly highlighted. Overall Status and Practical Implicatins The results btained in the present wrk have highlighted the benefits f emplying lw-hydrgen cnsumables in rder t carry ut the welding f structural C-Mn steels withut preheat. In additin t using a lw-hydrgen ptential wire/electrde, the benefit f lw-carbn equivalent steels has als been substantiated if welding is t be successfully perfrmed withut preheat. The guidelines presented in the TWl nmgrams wuld thus appear t be a gd starting pint fr generating safe welding prcedures withut preheat that avid HAZ cracking. The present results have als served t remind that lw sulfur levels may increase the risk f HAZ hydrgen cracking and that due cnsideratin f this pssibility shuld be given when devising welding prcedures. The present study has been aimed at val idati ng guidelines fr the avidance f HAZ hydrgen cracking at lw hydrgen levels, but due cnsideratin must als be given t aviding weld metal hydrgen cracking. Certainly fr welding C-Mn steels, general experience is that welding prcedures devised t avid HAZ cracking will als avid weld metal hydrgen cracking, althugh standards such as BS 5135 (Ref. 2) and pr EN 111 (Ref. 5) give guidance as t when these general rules may nt apply. If very lw-hydrgenlevel (<5 ml H2/1 g) cnsumables are being used t avid the need fr preheat t prevent HAZ hydrgen cracking, this will bviusly benefit the avidance f weld metal hydrgen cracking. Indeed, 86-SJ APRIL 2

9 Pargeter's data indicate that fr C-Mn steel weld metals, the weld metal cracking risk at Scale D (<5 ml H2/1 g) hydrgen level is lw such that preheat is nt needed (Ref. 1 7). Fr the welding f high-strength steels with allyed weld metal, hwever, this is less likely t be the case unless hydrgen levels much less than 5 ml/1 g -- perhaps f the rder f the prpsed Scale E (<3 ml H2/1 g) -- are used (Ref. 5). Hwever, there are currently few data fr higher strength steels fr a firmer statement t be made. Summary and Cnclusins A series f CTS tests has been perfrmed n seven C-Mn steels with carbn equivalents CEil w. Shielded metal arc welds and flux cred arc welds were depsited nt 5-mmthick plates using cnsumables that cnfrmed t the Scale D hydrgen level. An assessment f the HAZ cracking behavir has been made and cmpared t previus relevant data, in particular t predictive nmgrams develped at TWl. In additin, further CTS testing was perfrmed using identical materials with test blcks that were cvered with varius degrees f misture. The fllwing cnclusins were derived frm the wrk: 1) Heat-affected-zne hydrgen cracking can be avided in sme steels with a lw carbn equivalent when welded at cmbined thicknesses f up t 15 mm (6 in.) withut preheat using very lw-hydrgen cnsumables, i.e., giving <5 ml H2/1 g depsited weld. 2) The HAZ cracking behavir at very lw cnsumable hydrgen levels (<5 ml H2/1 g) f a range f ld and mdern C-Mn steels was fund t be generally satisfactrily described by the TWl predictive scheme, althugh recgnitin f the adverse effects f lw sulfur level needed t be taken int accunt. 3) The presence f sclrface misture n CTS test blcks just befre welding was fund t have little r n effect n the risk f HAZ cracking, in agreement with little r n effect n measured weld hydrgen level. Hwever, this des nt negate the need t fllw general gd practice in respect f cleanliness and freedm frm misture n weld preparatins. 4) Limited tests with a very lw (1.7 ml H2/1 g) hydrgen flux cred arc weld shwed n reductin in the risk f cracking cmpared t tests made with an SMAW cnsumable giving 4.4 ml H2/1 g. This may be due t a mre severe rt stress cncentratin bserved in the flux cred arc welds. Further testing is needed t establish if the behavir f flux cred arc welds is significantly different than that f shielded metal arc welds. Table CTS Test Data fr Plate 1 B859 (5-mm thickness, 15-mm cmbined thickness,.33ce,w) Welded with Misture Cntaminatin Using Cnsumables That Gave 4.4 ml/1 g under Dry Cnditins Mean Weld HAZ f Faces Nature f Travel Arc HAZ Metal Cracking/N Cracked Weld Misture Speed, Energy, ~t~ s,~, Hardness Hardness Cracking, frm a N. Cntaminatin mm/min kj/mm s HV5 HV5 C/NC Ttal f Six W48 Dew (13 C) NC 34 W49 Dew (13 C) NC 34 W5 Dew (6 C) NC 34 W51 Frst (-1 C) :} NC 313 * Presented as max.-min. Table CTS Test Data fr Plate 1 B433 (5-mm thickness, 15-mm cmbined thickness,.45cell w) Welded with Misture Cntaminatin Using Cnsumables That Gave 3.9 ml/1 g under Dry Cnditins Nature f Travel Arc Weld Misture Speed, Energy, At~,~l I,;~, N. Cntaminatin mm/min kj/mm s W68 Water drplets W67 Water drplets W69 Water drplets W66 Water drplets * Presented as max.-min [ > r t - + ~? ~ t CEOW) Pr()prt in Mean Weld HAZ f Faces HAZ Metal Cracking/N Cracked t4ardness Hardness Cracking, frm a tlv5 HV5 C/NC Ttal f Six C 2 42O C NC 42O NC 415 $ Fig Critical hardness t cause cracking frm CTS test withut preheat. t.45.5 t WELDING RESEARCH SUPPLEMENT [ 87-s

10 - Cntrlled - Primary ~1.2 ~ DEW/FROST R.25 I I I I ] I I I I [ I I I I I i I I I I J I l l IIW carbn equivalent UNCR~CaZ~4~EW) UI~X~CKF/XI.Cl~RC O CRAC~OO,~W:mI~) UNCP.,~K~n(~g~VATSR) C~ 'KSD(DRV) Z~ UNCR^CKED(DRX) Fig. 7 - thermal severity test cracking data with misture cntaminatin (15 mm cmbined thickness, n preheat, SMAW, Scale D). Acknwledgments The authr wuld like t thank TWl staff fr their help with the experimental wrk and useful discussins thrughut the prject. The wrk was jintly funded by Industrial Members f TWl and the Materials and Metals Divisin f the U.K. Department f Trade and Industry. References 1. Bailey, N prcedures fr lw ally steels. The Institute Reprt Series, Abingtn, Cambridge. 2. BS Prcess f Arc f Carbn and Carbn-Manganese Steels. British Standards Institutin. 3. Bailey N The establishment f safe welding prcedures fr steels. Jurnal 51 (4): 169-s t 177-s. 4. Bailey, N., et al Steels withut Hydrgen Cracking. Secnd Editin, Abingtn Publishing, Cambridge. 5. pr EN 111:1993. Recmmendatins fr Arc f Ferritic Steels. 6. BS 6693, Part Diffusible Hydrgen, Part 3 -- Primary Methd fr the Determinatin f Diffusible Hydrgen in Manual Metal Arc Ferritic Steel Weld Metal. British Standards Institutin. 7. BS 6693, Part Diffusible Hydrgen, Part 5 - Methd f the Determinatin f Diffusible Hydrgen in MIG, MAG, TIG r Cred Electrde Ferritic Steel Weld Metal. British Standards Institutin. 8. Pedder, C., and Watkinsn, F Autmatic depsitin f SMAW cvered electrdes, Institute Research Bulletin, 12 (9): The Institute, Abingtn, Cambridge. 9. BS Cntrlled Thermal Severity (CTS) Test and Bead-n-Plate (BOP) Test fr Welds. British Standards Institutin. 1. Hart, P. H. M Lw sulfur levels in C-Mn steels and their effect n HAZ hardenability and hydrgen cracking. Internatinal Cnference n Trends in Steels and Cnsumables fr, Lndn, The Institute, Abingtn, Cambridge. 11. Pargeter, R. J., and Hart, P. H. M and prperties f welds in Nmm- 2 yield steels. Internatinal Cnference n Offshre Mechanics and Arctic Engineering, Stavanger, Nrway, The American Sciety f Mechanical Engineers, New Yrk, N.Y. 12. Yurika, N., Oshita, S., and Tamehir, H Study n carbn equivalents t assess cld cracking tendency and hardness in steel welding. AWRA Sympsium, Pipeline in the ~a 8s. 13. Cttrell, C. L. M Hardness equivalent may lead t a mre critical measure f weldability. Metal Cnstructin 16(12): Graville, B. A. Cld cracking in welds in HSLA steels. Cnference n f HSLA Structural Steels, Rme, ASM Internatinal, Materials Park, Ohi. 15. Jnes, A. R., and Hart, P. H. M Imprving prcedure predictin t avid hydrgen cracking when welding C-Mn steels. TW[ Members Reprt, 225/ Hart, P. H. M., Matharu, I. S., and Jnes, A. R The in- fluence f reduced carbn equivalent n HAZ cracking in structural steels. Internatinal Cnference n Offshre Mechanics and Arctic Engineering, Hustn, The American Sciety f Mechanical Engineers, New Yrk, N.Y. 17. Pargeter, R. J Effects f arc en- Fig Macrgraphs shwing crss sectins f CTS welds. A -- FCAW, 1.2 kj/mm arc energy; B -- SMAW, 1.2 kj/mm arc energy OO I.3 O O e -I O O O O I I J I I I t CE (IIW) CE (IIW) ~ C + Mn/6 (Cr + M + V),A3 (Cu + Ni)/15 Fig. 9-- Critical hardness vs. CEuw fr CT5 test data at Scale B hydrgen level. Filled circles represent data frm present wrk. ergy, plate thickness and preheat n C-Mn steel weld metal hydrgen cracking. TWl Members Reprt 461/ s I APRIL 2

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