THE EFFECT OF POST WELD HEAT TREATMENT AND DISTRIBUTION OF RESIDUAL STRESS IN WELD REPAIRED HIGH CHROMIUM STEEL

[AISI 410] COMPONENTS.

BY

ABDUL GHANI OLABI

This

thesis

is

submitted

as

the

fulfilment

of

the

requirement for the award of Master of Engineering (M.Eng) by research to :

DUBLIN CITY UNIVERSITY

Sponsoring Establishment :

Scientific Studies & Research Centre DAMASCUS - SYRIA

Collaborating Establisment :

Airmotive Ireland (Dublin)

November 1990

DECLARATION

here

by declare that all the work reported me

in

this

thesis was carried out by

at Dublin City University

during the period of January 1989 to November 1990.

To

the

best of my knowledge, the results presented originated from

in

this thesis

the present study, except No part of this thesis degree at any other

where references have been made. has been submitted for a

institution.

Signature of Candidate

ABDUL GHANI OLABI

CONTENTS

PAGE

DECLARATION CONTENTS ABSTRACT ACKNOWLEDGEMENT LIST OF FIGURES LIST OF PLATES

I II VI VII VIII XVI

CHAPTER ONE : INTRODUCTION

1.1 WELDING (HISTORICAL AND TYPES) 1.2 ADVANTAGES AND DISADVANTAGES OF

1
1 3

WELDED STRUCTURES i N G . J > 1.3 CRACK/IN WELDING COMPONENTS 1.4 RESIDUAL STRESS IN WELDING

6 8

COMPONENTS 1.5 MEASURING THE RESIDUAL STRESS IN 9

WELDING COMPONENTS 1.6 POST WELD HEAT TREATMENT 1.7 STRAIN GAUGES 1.8 REVIEW OF PREVIOUS WORKS 1.9 PRESENT WORK AND ITS OBJECTIVES , 11 12 14 26

II

CONTENTS CHAPTER TWO : EXPERIMENTAL EQUIPMENT AND 41

TEST PIECE PREPARATION 2.1 EQUIPMENT 2.1.1 ELECTRIC FURNACE 2.1.2 TENSILE TESTING MACHINE 2.1.3 HARDNESS TESTER 2.1.4 OPTICAL MICROSCOPE 2.1.5 TIG WELDING MACHINE 2.1.6 DIGITAL STRAIN INDICATOR 2.2 TOOLS & MATERIALS 2.2.1 CLAMPING DIES I 41 41 41 42 43 44 45 46 46 47 47

2.2.2 STRAIN GAUGES 2.3 SPECIMEN PREPARATION

2.3.1 BUILD-UP PREPARATION 2.3.2 CRACK PREPARATION

WELDING

SPECIMEN

47

REPAIRING

SPECIMEN

48

2.3.3 STRAIN GAUGE PREPARATION 2.4 TEST PROCEDURE 2.4.1 WELDING PROCEDURE 2.4.2 MICROSTRUCTURE & HARDNESS TESTING PROCEDURE 2.4.3 TENSILE TESTING PROCEDURE I

49 50 50 51

52

III

CONTENTS 2.4.4 STRAIN MEASURMENT PROCEDURE 2.4.5 POST WELD HEAT TREATMENT 52 53

PROCEDURE

CHAPTER THREE : ANALYSIS OF RESULTS 3.1 EFFECT OF STRESS RELIEF HEAT

70 70

TREATMENT 3.1.1 INTRODUCTION 3.1.2 METAL MICROSTRUCTURE 3.1.3 HARDNESS TESTING 3.1.4 TENSILE TESTING RESULTS 3.2 THE MAGNITUDE & DISTRIBUTION OF RESIDUAL STRESSES 3.2.1 INTRODUCTION 3.2.2 COMPUTING THE RESIDUAL STRESSES 3.2.3 THE RESULTS 92 93 97 70 71 72 90 92

CHAPTER FOUR : DISCUSSION^ 4.1 METALS MICROSTRUCTURE 4.2 HARDNESS TESTING 4.3 TENSILE TESTING 4.4 THE RESIDUAL STRESSES '

185 185 187 193 195

IV

CONTENTS CHAPTER FIVE : CONCLUSION &RECOMMENDATION 198 198 202 204

5.1 CONCLUSION AND RECOMMENDATION 5.2 FURTHER WORK REFERENCES

ABSTRACT THE EFFECT OF POST WELD HEAT TREATMENT AND DISTRIBUTION OF RESIDUAL STRESS IN WELD REPAIRED HIGH CHROMIUM STEEL[AISI 410] COMPONENTS. A.G.OLABI The aim of this work is to study the effect of Post Weld Heat Treatment on the micostructural and strength properties of high chromium steel [AISI 410] components. This work also aims to estimate the magnitude and distribution of the residual stress on the above type of welded components. In introducing this work an extensive literature survey on the historical development and the advantages and disadvantages of welding process has been presented. A review of the different technique which are used to determine the residual stress is also presented. In this work two types of Post Weld Heat Treatment were used. in the first type of heat treatment, the specimen was kept at 316C for 30 min, then at 427C for 30 min, and finally, at 546C for 2 hrs. In the second type of heat treatment the specimen was kept at 760 C for 2 hrs. Two types of specimens were used to simulate build-up welding and crack repair conditions, each type of these specimens have different parameters (thickness, bead length and width). Stress relaxation technique was used to detemine the magnitude and distribution of the residual stresses for the above specimens. The results show that the first type of heat treatment reduces the hardness in the welding zone by about 15% of the hardness of the as welded specimen and improves the tensile strength. The second type of heat treatment decreases the hardness in the welding zone by about 40% but decreases the tensile strength by about 10 %. The residual stress measurements show that there is a tensile stress around the welded zone, and that the greatest value recorded is about 72 N/mm*. These residual stresses decrease as the distance from the welding zone increases.

VI

ACKNOWLEDGEMENT

I would like to M.S.J. Hashmi,

express

my

appreciation to Prof. Mechanical and

Head of the School of for

Manufacturing

Engineering

his helpful supervision

and guidance during the course of this project.

I would like to express

my

gratitude to Dr.

A.W.

Shahid Director Of Scientific Studies & Research Centre, DAMASCUS, SYRIA, for his kind support and encouragement.

would

also and J.

like to acknowledge help Walsh of the and Mr.

the

technical Mr. L. in

collaboration MaCarthy, Mr.

following: G.

Toyrrell

Airmotive Ireland; Mr. G. EOLAS; Mr.

Dardes and Mr.

M. Fleming of I. Hooper

T. Walsh, Mr. J.

Treacy and Mr.

the workshop technicians in the School.

Finally, I would like to lent support

thank all my friends who t and encouragement while the thesis was

being prepared.

VII

LIST OF FIGURES Figure No Page

Welding

processes

defined

by

American

Welding

27

Society ( AWS). 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Oxyacetylene welding (OAW). Shielded metal arc welding (SMAW). Gas metal arc welding (GMAW). Gas tungsten arc welding (GTAW). Resistance spot welding (RSW). Resistance seam welding (RSEW). Submerged arc welding (SAW). Explosion welding (EXW). Friction welding (FRW). Ultrasonic welding (USW). Laser beam welding (LBW). Electron beam welding (EBW). Different types of strain gauges. The assembly drawings of the clamping dies. The bottom piece of the die. The top piece of the die. The drawing for build-up welding specimen. The drawing for crack repairing specimen. The drawing for tensile testing specimen. Illustration sketch for the specimen's axis. The hardness variation across specimen Al, 0.5 mm from the surface. 28 29 30 31 32 33 34 35 36 37 38 39 40 64 65 66 67 68 69 111 112

VIII

LIST OF FIGURES Figure No 23 The hardness variation across specimen A 1 , from the surface. 24 The hardness variation along the for specimen A 1 . 25 Thehardness variation across specimen A2, 0.5 mm from the surface. 26 The hardness variation across specimen A2, from the surface. 27 The hardness variation along the for specimen A 2 . 28 Thehardness variation across specimen A3, 0.5 mm from the surface. 29 Thehardness variation from the surface. 30 The hardness variation along the specimen for specimen A3. 31 Thehardness variation across specimen A4, 0.5 mm from the surface. 32 The hardness variation across specimen A4, from the surface. 33 The hardness variation for specimen A 4 . 34 Thehardness variation across specimen A5, 0.5 mm from the surface. 35 Thehardness variation across specimen A5, 2.5 mm 125 124 along the specimen axis, 123 2 mm 122 121 axis, 120 across specimen A3, 2 mm 119 118 specimen axis, 117 2 mm 116 115 specimen axis, 114 2 mm
113

Page

IX

LIST OF FIGURES Figure No from the surface. 36 The hardness variation across from the surface. 37 The hardness variation along the specimen axis, 127 specimen A5, 4.5 mm 126 Page

for specimen A 5 . 38 The hardness variation from the surface. 39 The hardness variation from the surface. 40 The hardness variation from the surface. 41 Thehardness variation along the specimenaxis, for specimen A 6 . 42 The hardness variation from the surface. 43 The hardness variation from the surface. 44 The hardness variation from the surface. 45 Thehardness variation along the specimenaxis, i for specimen A 7 . The hardness variation from the surface. 47 The hardness variation from the surface. across specimen A8, 2.5 mm 137 across specimen A8, 0.5 mm 135 across specimen A7, 4.5 mm 134 across specimen A 7 , 2.5 mm 133 across specimen A 7 , 0.5 mm 132 131 across specimen A6, 4.5 mm 130 across specimen A 6 , 2.5 mm 129 across specimen A6, 0.5 mm 128

46

136

LIST OF FIGURES Figure No 48 The hardness variation across specimen A8, 4.5 mm from the surface. 49 The hardness variation along the specimen axis, 139 138 Page

for specimen A8. 50 The hardness variation across specimen Bl, 0.5 mm from the surface. 51 The hardness variation across specimen Bl, 1.5 mm from the surface. 52 The hardness variation for specimen B l . 53 The hardness variation across specimen B2, 0.5 mm from the surface. 54 The hardness variation across specimen B2, 2.5 mm from the surface. 55 The hardness variation along the specimen axis, 145 144 143 along the specimen axis, 142 141 140

for specimen B2. 56 Comparison between the hardness variation for the two different depths, for specimen A 1 . 57 Comparison between the hardness variation for the two different depths, for specimen A 2 . 58 Comparison between the hardness variation for the two different depths, for specimen A3. 59 Comparison between the hardness variation for the two different depths, for specimen A 4 . 60 Comparison between the hardness variation for the 150 149 148 147 146

XI

LIST OF FIGURES Figure No three different depths, for specimen A 5 . 61 Comparison between the hardness variation for the three different depths, for specimen A6. 62 Comparison between the hardness variation for the three different depths, for specimen A7. 63 Comparison between the hardness variation for the three different depths, for specimen A8. 64 Comparison between the hardness variation for the two different depths, for specimen Bl. 65 Comparison between the hardness variation for the two different depths, for specimen B2. 66 Comparison between specimens thickness. 67 Comparison specimens thickness. 68 Comparison specimens thickness. 69 Comparison specimens thickness. 70 Comparison specimens between B1 and the B2 hardness which variation have for 160 between A4 and the A8 hardness which 1 variation have for 159 between A3 and the A7 hardness which variation have for 158 between A2 and the A6 hardness which variation have for 157 A1 and the A5 hardness which variation have for 156 155 154 153 152 151 Page

different

different

different

different

different

XII

LIST OF FIGURES Figure NO thickness. 71 Comparison between the specimens length. 72 comparison between the specimens length. 73 Comparison between the specimens length. 74 Comparison between the hardness variation for 164 A5 and A7 hardness which have variation for different bead 163 A2 and A4 hardness which have variation for different bead 162 Al and A3 hardness which have variation for different bead 161 Page

specimens A6 and length. 75 Comparison

A8 which have different for bead

between the A2

hardness have

variation for different bead

165

specimens Al and width. 76 Comparison

which

between the A4

hardness have

variation for different bead

166

specimens A3 and width. 77 Comparison specimens width. 78 Comparison specimens A7 width.

which

between the A5

hardness

and A6 which have

variation for i different bead

167

between the and A8

hardness which

variation for

168

have different bead

XIII

LIST OF FIGURES Figure No 79 Illustration sketch for strain gauges position the specimen's surface. 80 Illustration direction. 81 The distribution of the residual axis, for specimen A3. 82 The distribution of the residual axis, for specimen A3. 83 The distribution of the principal residual 173 stress Sy along X 172 stress Sx along X 171 sketch toshow the strain in X 170 on 169 Page

stresses 84

along X axis, for specimen A3. stress Sx along X 174

The distribution of the residual axis, for specimen Bl.

85

The distribution of the residual axis, for specimen Bl.

stress Sy along X

175

86

The

distribution

of

the

principal

residual

176

stresses along X axis,for specimen B l . 87 The distribution of the residual strain along X 177

axis, for specimen Al. 88 The distribution of the residual strain along X 178

axis, for specimen A3. 89 The distribution of the residual strain along X 179

axis, for specimen A 5 . 90 The distribution of the residual strain along X 180

axis, for specimen A 7 . 91 The distribution of the residual strain along X 181

XIV

LIST OF FIGURES Figure i No I axis, for specimen B l .

i

Page

92

The distribution of

the residual

strain

along X

182

axis, for specimen B2. 93 The distribution of the residual strain along X 183

axis, for specimens Al, A3, A5, and A7. 94 The distribution of the residual strain along X 184

axis, for specimens Bl and B2.

XV

LIST OF PLATES

Plate No 1 2 3 4 5 6 7 8 9 10 11 Electric furnace. Tensile testing machine. Hardness tester. Optical microscope. Digital strain indicator. Clamping die. Build-up welding specimen. Crack repairing specimen. Metallurgy specimen. After welding, to measure the residual stress. The metal microstructure before applying heat

Page

54
55

56 57 58 59 60 61 62 63 104

treatment, for specimen A 8 . 12 The metal micorstructure before applying heat 105

treatment, for specimen B2. 13 The metal microstructure after heat treatment (1), 106

for specimen A8. 14 The metal microstructure for specimen B2. 15 The metal microstructure after heat treatment (2), 108 after heat treatment (1), 107

for specimen A8. 16 The metal microstructure for specimen B2. 17 The tensile specimen after the test. 110 after heat treatment (2), 109

XVI

CHAPTER 1

INTRODUCTION

1.1

WELDING

(HISTORICAL AND TYPES)

More join small

than gold

2000 years ago, boxes which

welding was were made

used

to

by pressure

welding lap joints. the Egyptians and area

During the iron age it appears that other learned middle people to weld in the Eastern of iron

Mediterranean together.

pieces

During the

ages different works have However, it

been seen which were welded by hammering. was not until the early know it today two was by

19th century that welding as we During this the the

was discovered and used. of welding and the were

period, first

types

discovered, was by

acetylene

second

production of an arc between two carbon electrodes using a battery. The period of 1877 to 1903 provided a great discoveries pertaining to welding. During

number of

this period gas welding and cutting and arc welding with the carbon arc were developed and resistance welding

became a practical joining process.

IN electrode introduced

1892 was

the

arc

metal

process and in

using a

metal

discovered

1900 Strohmeyer Great Britain.

a coated metal electrode in

Meanwhile, the resistance including seam

welding process was developed During the

welding and spot welding.

period from about 1900 to

1918 the oxyacetylene welding

and cutting process together with the carbon arc welding and metal electrodes maintenance introduced, arc welding used In process with lightly for covered and was

were work.

primarily 1920

repair welding

Automatic

during the 1920s various different types of

welding electrodes were developed and used for different kinds of metals.

During discovered Submerged

1930s the tungsten using atmospheres

inert gas welding of argon

was

and helium. 19 30s and

arc

welding was used in the late

early 1940s.

In 1948 gas shielded metal arc welding was In 1950s the Co2 was used as an

successfully developed. inert gas. and

Electroslag welding process was used in 1958 for the

electro-moulding process was used in 1959 diesel engine blocks. which is very was invented by

fabrication of welded arc welding process,

The plasma to gas

similar

tungsten 1957.

arc welding

Robert Gage in which uses a

The electron beam welding process,

focused beam of electrons chamber,

as

a heat source In a vacuum In the last

was developed in the late 1940s. gained

few years the process has for welding,

widespread acceptance recent

its popularity is increasing since

developments have allowed it to be used without any need for the vacuum chamber. is laser welding, also. it has The newest of welding processes been used for cutting metals be

Additional welding processes and methods will

developed and as the need arises they will be adapted to metalworking requirements.

The recognizes processes.

AMERICAN 12 major

WELDING headings

SOCIETY for

(AWS)

[1 -

4]

welding and allied diagram for these

Fig.

1 shows a block Figs.

welding processes. of welding

2 to 13 show different types different

processes which are used to weld

kinds of metals.

1.2

ADVANTAGES AND DISADVANTAGES OF WELDED STRUCTURES

The advantages of welded structures are:

High

joint

efficiency:

The joint efficiency is the fracture strength of a

defined as the percentage of

joint to the fracture strength of values

the

base plate.

The

of joint efficiency of welded joints are

higher

than riveted joints, it can be as high as 100%.

2 - Water and air tightness: A welded structure is ideal for situation which require water and air tightness such as submarine hulls and storage tanks.

3 - Weight saving: The weight of a hull structure can be reduced as much as 10 - 20% if welding is used.

4 - No limit on thickness: It is very difficult to rivet plates that are more than 2 inches thick. In welded

structures there is virtually no limit to thickness that may be employed.

Simple

structure design:

In

welded

structures,

members can be simply

butted together or fillet welded.

In riveted structures, complex joints are required.

Reduction

in

the

fabrication a

time:

welded

structure

can be fabricated in

short period of time

and be less costly than riveted structures.

The problems with welded structures are:

1 - Difficult to arrest fracture: Since the crack starts to propagate in a welded structure, it is very difficult to arrest it.

Possibility with

of

defects: types of

Welds

are

often including

plagued porosity,

various

defects

cracks, slag inclusion,etc.

3 - Sensitive to

materials:

Some

materials

are more

difficult to weld than others.

Lack

of

reliable NDT techniques:

Although

many

non-destructive testing methods have been are in use today, some are completely

developed and satisfactory in

terms of cost and reliability for specific application only.

5 - Residual stress and distortion: uniform heating result during after welding, welding,

Because of the nonresidual stress and which may lead to

distortion

cracking and mismatching.

1.3

CRACK IN WELDED COMPONENTS

Residual stresses contribute to weld cracking. The restrained contraction tensile of welded structures during

cooling sets up

stresses

in the joint and may which is

cause one of the most serious of weld defects, crack. Weld cracking will occur

during manufacturing

operation

of the weldment or shortly after the weldment Cracking may occur in the weld deposit,

is completed.

in the heat affected zone, It is either of the gross naked eye

or in both of these regions. type, which is visible to the or is visible

and is termed macrocracking, in

only under the microscope, microcracking

which case it is termed Cracking that occurs

or microfissuring.

during the solidification

of the weld metal is known as

solidification cracking or hot cracking. Cracks may form in the heat melting cracking. affected zone this of dueto is the liquidation known of low

components,

as liquidation

Embrittlement

parent metal or heat

affected zone may result in subsolidus or cold cracking. In solidification cracking there are two necessary the and

preconditions

for the occurence of cracking during the metal must lack ductility,

weld thermal cycle? the

tensile stress developed as a result of contraction

must

exceed

the

corresponding

fracture

stress.

The

mechanical solidus are

properties of the metal in the region of the therefore cracking. and important In may in relation cracking to may

solidification

general, occur

occur for many reasons weldment is completed. are the main reasons

years after the stresses the

Restraint and residual for weld cracking

during

fabrication of a weldment. several factors one of

Weld restraint can come from the most important is the

stiffness and rigidity of the weldment itself. factor deposit, the weld rapidly. can occur. involved is the rapid cooling of

Another the weld and

if the base metals being joined are cold is relatively small it

will cool extremely cracking

So shrinkage will occur quickly and Another reason for

cracking is the content

of carbon and other elements in the base metal, when the weld is made metal. with higher carbon or high is alloy base melted and The alloy

During

welding the base metal

mixed with the electrode to produce the weld metal. resulting content, and weld metal have a higher carbon and

giving it a

higher strength but low ductility ductility

as it shrinks it may not have sufficient

to cause plastic occur. Another In

deformation and therefore cracking may factor is the hydrogen pickup the heat affected zone of in the

weld metal.

the base

metal,

the presence of hydrogen in the

arc

atmosphere

will cause it to be absorbed in the molten metal. As the metal cools it will reject the hydrogen and if there is

sufficient restraint, cracking will occur.

1.4

RESIDUAL STRESS IN WELDING COMPONENT

Due to thermal

local

heating occur

during

welding, and

complex residual

stresses

during

welding

stress is developed after

welding.

Thermal stress and High

residual stresses cause cracking and mismatching. tensile residual stresses in

areas near the weld cause

fracture under certain condition.

Many

techniques

have

been

used

for

measuring

residual stresses in metal. for measuring residual

The most widely used method in weldments is the

stresses

stress relaxation technique in which the residual stress is determined by measuring the elastic strain when a

specimen is cut into pieces or a piece is removed.

In gages are

most

cases

electrical

or

mechanical strain strain relaxation.

used for measuring this

There are many ways to section the specimen to determine

residual

stresses.

Some techniques plates,

are

employed

to

determine the stress in

while others are used

in cylinders, tubs,...etc.

The

main

disadvantage of the

stress

relaxation

technique is that it is destructive testing.

1.5

MEASUREMENT OF RESIDUAL STRESS IN WELDED COMPONENTS

Many residual

techniques stresses in

have

been

used There

for are

measuring different

metal.

available techniques for measuring residual stress which can be classified in four main groups.

1 - Stress relaxation techniques.

2 - X - Ray diffraction techniques.

3 - Techniques by use of stress - sensitive properties.

4 - Cracking techniques.

The stress relaxation principle that strains the

techniques are based on the unloading are

created during material has

elastic even when deformation. residual material. It

undergone plastic to determine of the

is therefore without

possible the

stress

knowing

history

In

Ray diffraction have

technique

the

elastic

strains in the metals that

crystalline structures by

can be determined by measuring the lattice parameter X - Ray diffraction. metal in the

Because the lattice parameter of a state is known or can be

unstressed

determined separately,

elastic strains in the metal can

be determined non-destructively without machining. X-Ray diffraction crystalline techniques materials are applicable only to small

having randomly

oriented

grains. Most metals fall into this category.

The stresses

technique

for

determining

the

residual the

by stress sensitive technique is based on

principle that when stresses exist in the metals some of the physical or mechanical properties, such as the

10

propagation changed.

speed However,

of

shear

waves

and hardness,

are been

none of this techniques have

developed beyond the laboratory stage.

The cracking technique developed to determine stress involves close observation

the

of cracks caused in

the specimen due to the stress, by Hydrogen or stress corrosion.

the crack being induced

1.6

POST WELD HEAT TREATMENT

Stress

relief

heat treatment is defined

as

the

uniform heating of a structure at a suitable temperature, holding at this temperature for a predetermined by uniform cooling. period

of time, followed heat

Stress relief critical

treatment is usually performed below the

temperature range.

The

temperature

and

time

for

post

weld

heat

treatment depend on the type of material. The percentage relief of internal stresses is dependent on the material type, reached composition, during or yield strength. The temperature a

the stress relief heat treatment has

greater effect in relieving

stresses than the length of

11

time

the

specimen near

is held at that the critical

temperature. is

The more

temperature

temperature

effective in the removal of residual stress.

When a thermal stress relief treatment is employed to reduce residual stresses, other important must be taken into consideration such properties as the

microstructure, tensile and impact strength. Thus, it is necessary to select a desirable temperature that will develop the

properties in the material, while at the same

time providing the maximum stress relief.

1.7

STRAIN GAUGES

The developed USA. Caltec

electrical

resistance

strain

gauge

was

in the late 19 30s, independently Ruge at MIT

by two researchers in the of each other, Simmons at strain gauge

Working and

developed a

consisting of a length of so that changes in

wire glued to the test object on the surface were

lengths These

transferred to the

wire.

length changes caused

alterations in the resistance of the wire which could be measured by comparatively simple electrical circuitry.

12

Modern strain gauge works exactly in the same with strain being detected by

way

measuring the resistance the

variations caused by changes in the gauge length of wire. having The strain gauge can

be very small and compact influence

negligible mass to exert a minimum of They

on the measuring object. the

can be easily mounted on electrical

test specimen, usually by cementing the circuits required

detection changes changes familiar in is

to measure the very small Measurement of by such

the gauge resistance. comparatively

uncomplicated

using the

Wheatstone bridge, employed resistance or

when suitable compensation self compensating gauges allows a very

circuits are used. The

strain

gauge

economically priced the actual cost

measuring

system to be made, where as to be

per gauge is often so low

virtually of no consequence. Gauge costs are no longer a hindrance to the use of strain gauges, cemented in their hundreds on a structure, to analysis of the solve any particular stress instead based had on been

task by actual multiple measurements, laborious from calculation procedures,

extrapolation

a few measurements, that

used previously.

13

Typical include aircraft, vehicles.

well known application for strain strain

gauges

experimental

and stress measurement on

boats, cars, and other form of transportation Strain gauges are also used for the for example pressurized is

measurement of stress in larger structures, apartment containers, buildings bridges, and office etc. blocks,

dams,

The strain gauge

an important laboratory implement used for pure research and as a design tool in the development stages of many

machines and structures.

Modern strain gauges are thin metal

often

made by etching a In recent

foil rather than using a wire.

years semiconductor strain gauges have become available, which are more sensitive than the wire and foil Fig. 14 shows different types of strain gauges. gauges.

1.8

REVIEW OF PREVIOUS WORKS

Different

studies

and investigations

have

been

carried out to evaluate the effect of various parameters on the residual stress, and the effect of stress relief

14

on the metal papers

composition

and

properties.

A number of on

reported the effect of vibrational treatment as a new method which

the residual stress advantage.

has some

In the

reference [5] the results of a of vibratory stress

study relief

towards process it low

application

instead of the heat treatment. as a method of applying frequency vibrations in

The author described low amplitude, to

controlled metal

components

obtain

dimensional stability and This

control machining tolerances. It is an economical, stress and is metallurgical

process has many advantages. method of

fast and convenient used during

reducing causing

processing without

changes, movements, oxidation or scaling.

vibratory

relief

system

consists an

of a small to

electrically

operated

vibrator,

accelerometer

transmit the degree of vibration to a resonance readout, a motor control to speed up or slow down the rate of

vibration,

and r.p.m readout and an ammeter. The author

mentioned the advantages and limitations of this process of treatment, and reported that most applications which

15

require

vibration take 10 to 20 min and use an

average

of 1/2 kw of power and the typical frequency range is 20 to 90 Hz.

The eliminated

application

of the

vibratory

process has

68 percent of the thermal stresses developed assuring dimensional stability with the

during welding,

same degree of accuracy.

Olenin

et

al on

[6]

have studied the

effect

of

vibration treatment especially when

reducing

the residual stresses or the

the heat treatment can not be used too was large. Inthis paper

when the work piece is residual stress relief form

determined on specimens of 300 mm long, 20-40 mm

St3 steel in the wide,

of sheets

and 2 mm thick.The reduction in

residual stress

was 50-55% and the duration

of vibrational treatment in

the optimum conditions was 20-25 min.

Thomas

[7]

gave

a general

ideaabout

using

vibration method for stress method as Meta Lax. In

relieving.

He called this this

this paper he described

method and how it works. most kinds of the

This process is applicable to copper and copper

metals except

16

alloys. process.

He

also

outlined

the

advantages

of

this

Keller [8] also described the vibration method

and their advantages.

Another work has

been

carried

out

by Merun and

Olenin [9] to show that electrohydraulic treatment makes it possible to reduce the residual welding stresses by

50 - 70% for specimens produced from low carbon steels.

Paper two in

has most

been written by common types of

Candeland [10] of

to

report the undertaken

heat treatment structures,

the fabrication

welded

preheat and post weld heat

treatment .He discussed both

of these heat treatments and the various techniques used throughout the world.

Bmankirski properties for 5520-69] under

[11] welded

has investigated the joint on

mechanical

20K sheet plate [GOST properties (2)

40 mm thick.

He has compared this (l) initial

three

conditions,

condition,

tempering [heating temperature 625+10C, h rs, cooling in air], [which was

holding time 2

and (3) after vibration treatment frequency of

carried out at the resonance 20-25

24-32 Hz for a time of out by manually.

min]. Welding was carried that tempering

The result detected

17

reduced yield strength and hardness but increased impact toughness. Vibration loading resulted in slight

increase of strength and reduced ductility.

In

reference

[12] the

author

investigated

the

mechanical strength and fracture mechanics of [Crack Tip Opening Displacement] of the welded base joints. metal He used

Submerged Arc Welding, steel

was a modified mm

TT St E 3 6 , the initial plate thickness was 60

and a wire electrode of type S3 was used. The welds were examined in the as welded state and after stress relief

annealing (570C for 2.5 hr). The investigation involved comparison between the tensile strength, yield strength, hardness, and before and impact energy for the plates and pipes The paper also has

after heat treatment. characteristic

discussed the

of the heat affected zone

in the welded component.

Another investigation al [13] for

has

been done by Suzuki,et of weld residual

evaluating the effect fracture toughness in

stresses on (HAZ),

heat affected zone toughness

and the effect of notch acuity on HAZ pressure vessel

of the reactor classl].

steel [Sa 533 Grade B,

The investigator used three sizes of specimens

18

and two different types

of

post

- weld heat treatment He studied the

(1/4 hrs at 600 C and 40 hrs at 600C).

fracture toughness for all the above situation.

Adoyan,et al [14] used a

new

form of specimen to

assess the effect of welding technology and all types of external loading on the distortion of the structure. The author steel used a ring shape element which was made of for many as of different 250 C to range 600C of of heat St3

treatment hrs. The by low

temperatures efficiency temperature

for 3

stabilisation

dimensions

heat treatment (250C) of that the residual in

in distortion caused stresses high isalmost

by the relaxation identical with

achieved

temperature

tempering (600C).

Research at the dealt with the

University of

of Tennessee [15] has Cr-Mo steels and

weldability

determined the stress Cr-Mo 12Cr,

relief cracking susceptibility of

alloys ranging in composition from 2.25Cr, IMo to 2Mo,using 51 mm thick of the plate. material of The author

investigated [Si,P,C,] and

the effect the

composition

temperatures

post welding heat

treatment on the stress relief cracking susceptibility.

19

In post weld

reference [16] the results of investigation on treatments of steel pressure vessels were

reported. The author described the conditions of applied heat treatment French, according U.S, to different regulations all

[Dutch,

Japan]. which

He also mentioned

other kinds of treatments

are possible to affect

stress relief in pressure vessels.

Another study has been al

undertaken

by Bosansky,et (Nb) and

[17] to investigate the effect of Niobium

the influence of Molybdenum function

(Mo) on weld toughness as a Different

of stress relieving heat treatment. and

percentage of Niobium with different conditions

without Molybdenum with heat treatment

of stress relief

(different temperature and coaling time) were looked at, and good result was obtained for heat treatment at 580C for 1 hr. Hardness measurements and Electron microscopy

were used to define the difference between all the above conditions.

Zubchenko,et al temperature and time and

[18]

investigated

the effect of welded

conditions on l5Kh2NMFA

hardening

joints in l5Kh2MFA

steels

and of their

relaxation resistance.

The author also investigated the

20

effect of temperature and heating time on the relaxation process Different of residual stresses temperatures into the in heat were treatment. and the the

reheating looked

used,

investigator

relation

between

chemical composition and the time duration.

Nedjeljko [19, preheating

20]

investigated

the

effect of the

and stress relieving heat treatments on The preheating

micro alloyed steel.

temperatures were temperatures

150 C and 300C, and the stress relieving were 450CC, 550C, and 650 C. show that better

The results of the tests are not

mechanical characteristics

achieved with preheating and annealing process. investigation effect of [21] has been carried out to relieving heat

Another the the for

study on used

stress

treatment

metallurgical

structure

for low alloy steel

pressure vessels.

Evans relieving

[22]

investigated

the

effect

of stress C-Mn

on the microstructure and properties of deposits using

as welded metal and Mn.

different content of C been used,

16 different metal deposits have relieved

all specimens were stress To

at 580C for 2 h rs. treatment

evaluate the effect of stress relief heat

21

the

investigator

examined

the

metallographic tensile

and

mechanical impact].

properties

[hardness,

strength,

Evans Silicon,

[23,

24]

also

studied

the

effects

of

Sulphur of

and Phosphorus on the C-Mn steels.

microstructure kinds of

and properties

Different

testing have been done to evaluate the effects of Si,P,S on [hardness, tensile structure] strength, by changing 0.90%], Heat the impact content and of

metallography

those elements Si [0.20 and P [0.00 7 - 0.040%]. above

S [0.007 - 0.046%], treatments was have been

applied and all the

testing

carried out on

specimens before and after heat treatment.

An investigation [25] to

has

been

done low

by Glover,et al alloy steels

assess reheat cracking for Test specimens

using Vinckier test. range of

were made from a thick,

different materials,

all about 50 mm

and different length of the length of A crack

specimens were used to evaluate with different was heat input and

composition.

microscope

used

to define the

structures and evaluate the grain size.

22

Lieurade [26] summarized in his paper the of residual stresses and the fatigue strength. stress

effects

ratio after welding on of

He also mentioned the effect

heat treatment on the fatigue strength.

An investigation [27] has been undertaken to study the effect of stress relieving on the fatigue property

for cruciform welded joint. were produced

Two welded plate cruciforms In the treatment

from Grade 250 steel.

the specimens were slowly and were held at

heated to approximately 580C for 8 hrs. The

that temperature that stress

results indicated fatigue

relieving influence the joints.

performance of fillet welded cruciform

Another investigation [28] has been carried out to study the effect of stress relief on the fatigue strength The specimens are of

high strength steel. welded applied from with has

box sections welds process. the were An

15 mm thick plates and groove the Submerged Arc

improvement relief.

been noted as a result of

stress

Vachav,et al

[29]

investigated

the correlations

23

between

the structural characteristics of welded joints steels and their mechanical

in the Ferritic/Austenitic

properties after thermal and mechanical loading.

Lamb,et al [30] have studied the residual stresses * in two stainless steel surfaces melted by laser. The stresses were measured by X-Ray diffractometry over a

range of depths and they defined the stresses after heat treatment. Higuchi,et al [31] studied the weld and repair

through half bead method conventional

they compared it with the An investigation has been

repair method.

done by Karjalainen,et al stresses It seams

[32] to evaluate the residual measurement. of

in welding from Barkhousen noise possible to evaluate the

distribution

residual stress using this method. But the determination of exact magnitudes of Debabrata and residual stress seems difficult. the

Bhattacharya [33] have investigated time on the

effect of normalising but-welded joints

hardness for steel welding condition.

under identical has been

Another investigation [34] to determine

done

by Watkins,et al Cracking (SSC)

Sulfide

Stress

resistance of welded repairs to wellhead equipment. They studied the effect of hardness and stress relief heat

treatment on (SSC).

24 r t f The results show that there is a tensile stress at a specimen surface and by applying the heat treatment (500C for 1 hr) the residual stress is minimized to about 50 MN.m-2 without any adverse metallurgical effects.

In

reference [35] investigation was undertaken to stress relieving in reclaimed and peening. steel and the after on the

study the residual built-up The

welding of steel castings by investigated three types

hammer of

author

evaluated surface peening. the

the distribution of residual stresses on and across the thickness before and

They also described the effect of peening Fick and Rogerson [36] studied

hardness.

variations in toughness between the root and sub-surface regions of some multipass effect of the welds. Their study shows the the thermal

electrode composition and

ranges on the toughness;

they also described the effect Farrar,et al [37] have relieving on fracture

of stress relief heat treatment. studied the effect of stress

properties. The steel weld metals containing 1.0% Mn and 0.08% C, the post weld heat treatments were at 625C for 4 hrs. The investigation revealed the effect of stress redistribution of the carbon. Another

relieving on the investigation

[38] has been done to study the effect of rupture strengths of dissimilar

stress relieving on the

metal welds (Ferritic and Austenitic).

25

1.9

PRESENT WORK AND ITS OBJECTIVES

The effect of

objective post weld and

of

this project is to heat treatment on

study the

the metal Steel

microstructure AISI 410

properties for high Chromium component. Another object,

welded

is

to

determine the magnitude and distribution of the residual stress for the same kind of welded components.

To reach these heat treatment was

objectives, two types of post weld carried out. for Stress relaxation

technique also was employed

measuring the residual

stress, as described fully in Chapter 2.

In Chapter 3 results of discuss these results. The work

these studies. final Chapter

Chapter 4 gives a

conclusion of the present further work.

and recommendations for

26

gas mciai arc welding -pulsed i c '- short circuiting arc g * i t u n g it t n arc a U r t - pulsed V C plasm arc M i U i n g /aided mai al aie 9 n * ftlud arc w fM in g submerged arc - series ll onnc hydrogen e ld m g bare malal arc aid ing carbon arc aid in g . -anrelded - im electrogas elding flu corad arc raiding

(M A W yM AW P SMAW S frTAW C^AW P f AW SMAW sw u w (A W S AHW IM A W CAW CAWG CAW S CAW T EGW FCAW

coertruuon elding cold aiding . .. drHuuon aiding ... explosion weMmg forge elding friction aiding . . . hot pressure raiding ro* aiding........ ultrasonic aiding .
<H> sotdanng lu m a c a soldering ind uctio n soldering m frered soldering n o n soldering re s ilie n c e soldering torch aoldann^ a r a e d d e rm g

CEW CW DfW EXW fOW fRW MPW now usw

OS FS IS IRS INS RS IS WS

Fig. 1

Welding Society

FW flath weMang high frequency raaralanca welding MFRW P tW parcuaawn waKVig RPW projection w a M n g . rsew raaiatanca aaam welding R SW raaiatanca apot welding uw upaat walding

.. .

. .

an a c e ty la n oa ya ca tyla na o n y h y d ro g tn praaauia g a t

c u llin g w e ld in g w ip in g w e ld in g

A AW OAW OHW PGW

arc t n " t block b ra ro g diffusion txapng d braiing

f\OW b r u i n g

AB
B8

O F6
DB F IB FB IB IRB RB

furnace b a i ( induction braxmfl inf farad braim g raaiatanca baim g torch braung tw in carbon arc braiing

TB
TB

aK carbon arc culling carbon arc cultmg gaa matal arc cutting ga* tungsten arc cutting metal arc cutting plaama arc cutting Shielded matal arc cutting

AAC C AC GM AC G TA C M AC PAC SM AC

electron b a a 0 cwnmg laaar beam cutting

EBC IB C

processes ( A W S )

defined

by American

Welding

OXVGEN
r e g u l a t o r

AND GAUGES

W ELD IN G ROD

N > 0 0

O IR E C TIO N OF W ELD IN G

Fig. 2

O x y acetylene welding (OAW).

fU fC TR O D C M O L O C PI

e l e c t r i c a l

WE

10

M ETAL

WLOIWG CIRCUIT

{ '

| POWER SO U R CE

t o
VO

| |

. . .

---------

T
E l

E L E C T R O O E W IR E

F L U X (O A S

ARC

SLAG

'*^1 M O L T E N P U D O L E M E T A L

4-

M O TIO N OF ELECTRODE

1 '*

Fig. 3

Shielded metal arc welding (SMAW).

f LOW M E TE R

REGULATOR

O J
o
H IG H PRESSURE S H iE L O i N G G A S

M O V E ME N T

W ELD

M ETAL

Fig. 4

Gas metal arc welding (GMAW).

PRESSURE r t C G U lA T O P a n d Plo w m e t *a

W E l OING

C F / / / / / / / / * 3

SHI L O l N G G A S CVLINOtR

C L C T R i C P O W E R iN

H IG H PRf SSURE S H I f L O l N d t; A S L O W P R t SSURfc S H IL D IN G G A S

MO V tM r NI

Fig. 5

Gas tungsten arc welding (GTAW).

SECONDARY

TRANSFORMER

Fig. 6

Resistance spot welding (RSW).

SECONDARY W IN O IN G
p n e u m a tic o r

H V O R A U L IC C V L IN D E R O L L IN O C L C C T R O O I

TRANSFORM ER

A l l M i TAL ST A T IO N A R Y W i LO

P R IM A R Y W IN O IN G

j'
co
LO | | W 6 L P IN O CUWWCNT l 0 VM T * A ,t P R S S U P O W E R IN

E j ,A s e M e T A L
W El O NUGGET

P O W E R IN

E lE C TR IC IT V FLOW

WE L O M E T A L

Fig. 7

Resistance seam welding (RSEW).

ifCTRooe
FEED M EC H A N IS M

ELECTR O DE

REEL

VACUUM PICK UP O F UNUSED FLUX

co

S ID E V I E W O F W E L D

Amc

E N D V IE W O F W E L D

base

m e ta l

ARC

PUDOLE

e l e c tr ic a l

W E L O I N O PO W E

M ELTEO FLUX

PLUX TRAVEL

MOVEMENT

P O W E R IN

ELECTR O DE

Wm

9LAQ

Fig. 8

Submerged arc welding (SAW).

PROTECTIVE
lA A ftlC M

' SWi T C H O ETO NATO R LEAOS ELEC T (C A L CO N T HOL M ETAL POW C SOURCE

EX P LO S IO N
x p lo s iv c

EX P LO S IV E CO

m o tio n

en
BU P FC* M A TE R IA L B PUWt IN L E A O S

JO IN T

OASE M E T A L

rriT l V fiD M E T A L

M O LTEN M ETAL

Fig. 9

Explosion welding (EXW).

S TA TIO N A R Y CHUCK R O TA TIN G CHUCK AND

P N E U M A TIC OR H YD R A U LIC
c y l in d e r

//
\) *
'

LYWHflL

4
rs

i1

ASE M E T A L

MOVEMENT

o\

00

W(LO ARCA
M OLTEN M ETA L

P O W E R IN

Fig. 10

Friction welding (FRW).

POWER SUPPLY
ELEC TR O N IC

Fig. 11

Ultrasonic welding (USW).

SAFETY SHUTTER

LASER R ESER V O IR

D IR E C TIO N A L M IR R O R

UJ

0 0
REF L E C T I N G LASER L IG H T (S IN G LE W AVELENGTH! WE L O

LASER BEAM

FLASH LAMP

WELD

Rye

r o d

M IR R O R S

BASE M E T A L

Fig. 12

Laser beam welding (LBW).

IN S U LA TO R

E L E C TR O N BEAM

W VOR KP iE CE A IR I N L E T O P T IC A L V IE W

'L A M E N T AS ANOOE

MOVEMENT

VACUUM

F IL A M E N T

W E L O E D BASE M E TA L VACUUM BYPASS VALVE COLUMN VALVE L IG H T FOR O P TIC S

M O LTEN M ETAL

O P TIC A L V IE W IN G SYSTEM

E N D V IE W O F W E L D

M A G N E TIC LENS

D EF LE C TIO N C O IL

WORKPIECE
'M E T A L B E IN G W ELDEDI

5VSTEM

TO V A C U U M

WORK CARRIER

Fig. 13

Electron beam welding (EBW).

39

Delta rosette

Stacked g rid 9 0 rosette

T w o elem ent 90 grid

H e rrin g b o n e g rid

Fig. 14

Different types of strain gauges.

40

CHAPTER 2

EXPERIMENTAL EQUIPMENT & TEST PIECE PREPARATION

2.1

EQUIPMENT

2.1.1

ELECTRIC FURNACE

In this work a Lenton Laboratory Electric Chamber Furnace, series ECF1200, was used. The working 13

temperature

is up to 1200C.

It is operated from a

amp, 230 - 250 volt, single phase A.C. power supply.

The 20 3 mm deep.

chamber

size is 101 mm high, rating

127 mm

wide, Plate 1

Maximum power

is 2.0 kW.

shows this electric furnace.

2.1.2

TENSILE TESTING MACHINE

The

tensile

testing

machine

was

an

Instron

Universal Testing of

instrument model 4204, which consists separate

a loading frame and a control console as

assemblies. The frame has a load capacity of up to 50 kN and is designed for testing materials in either tension

or compression.

41

The basic operation of the instrument consists of selecting a load cell for a particular testing

application, head within in

mounting the load cell in the moving cross the loading frame, then setting can the be

specimen measured. testing, plate 2

position

so that an applied load is held by

The specimen

grips for tension

or is table - mounted for compression testing, shows a photograph of the machine and its

accessories.

During

a test, results are displayed as

tracked

values of load, extension and strain or, after a test,as stored break and peak values of these parameters. cross head during The

action of the moving return, button provided on the cycle) switches may or

a test (stop, by push

be controlled automatically

manually by the

functions

by limits panel. applied load

These functions may be based or strain, or to a

extension

specimen break detection.

2.1.3

HARDNESS TESTER

A micro hardness tester hardness of the specimens.

was

used to measure the capable of

This tester is

measuring three kinds of

hardness

- vickers, knoop and

42

scratch

hardness

- by changing the only

diamond

indenter.

However, for this project was employed.

vickers hardness method hardness

The tester is accompanied by a calibration and

test plate for

a set of loads varying

from 5g to 300g. These loads are chosen according to the thickness of LEITZ the 2. test piece; the tester type being of the

MINILOAD

Plate 3 shows a photograph

hardness tester. In this work a load of 100 g have been used. 2.1.4 OPTICAL MICROSCOPE

An entirely used, which

new

metallograph

Reichert MeF3 was It has a

had the following facilities. binocular

convenient position of

body with inclination It provides 6 all types of It

angle of 32 and viewing height of 420 mm. nosepieces objectives. to make it suitable for

There are four step magnetic changers.

has reticule insert. The MeP3 has low coaxial coarse and fine controls which are easily accessible and a

rotatable mechanical stage with coaxial controls.

A 4x5 Camera is built-in into the MeF3 Microscope and an additional is also 35 mm camera provided. The with automatic film

transport supplied

Microscope

is also changing

with an automatic control system for

43

from one camera to time. The

the

other

with display of exposure frame

MeF3 is provided with an illuminated focussing purpose using

projection for tube with

the binocular It is

automatic

brightness

regulator.

supplied with a Rotoscope resolution screen.

projection device with a high mirror

A 100 Watt Halogen lamp and high power

house for use with are built into it. (22 and to

lamps of up to 450 Watt large visual is also

A Macrodual zoom system for 175 mmj imaging for both It

specimens observation

photography is provided.

supplied with a Varicode

projection system for luminous

measuring bars with numbers or reticules for both visual observation and photography. A photograph of this

device can be found on plate 4.

2.1.5

TIG WELDING MACHINE

A FILARC TIG 350D was used to execute all welding needed in this work. The current for this machine

ranges from 4 - 350 A. providing FILARC proper

This machine has water hoses for for the welding torch. The gas

cooling

TIG welding machine is also supplied with a

cable to provide the protective inert gas environment.

44

This

welding machine is fitted to carry the water cooler,

gas

bottle and optional tank

comprising plastic

with a pump, well able to cool a torch employed at temperatures. Water cooling lines pass

high welding

under the power source,

away from any circuitry.

In this work the current range was about 65 to 75 A, and Argon gas was employed to protect the welding.

2.1.6

DIGITAL STRAIN INDICATOR

Digital this work.

Strain

Indicator V/E -20A was Digital Strain

used

in

The V/E

-20A

Indicator is

designed primarily for use with resistive type of strain gauges or strain gauge in the structure. devices to determine the strain and

The V/E -20A has a high accuracy

is an automatic instrument microstrain channels.

capable of measuring -+19999

in two ranges of -+1999 and -+19999 with 10

When

the

strain

gauge

and

the

resistor

are

connected to this instrument, the digital board of this

direct reading appears on Plate 5 shows a

instrument.

photograph of the Digital Strain Indicator.

45

2.2

TOOLS AND MATERIALS

2.2.1

CLAMPING DIES

Clamping dies were used for two purposes; to clamp the second welding, during type of specimens

first,

to execute the the the specimen residual and

the second purpose was to hold machining process to measure

stresses.

This clamping die consists of two pieces

the specimen were mounted between them to provide a good matching during welding and machining. Fig. 15 shows

the assembly drawings for this die.

The bottom

piece

of

this

die has

a circular Fig.

groove as a pilot for mounting the specimen on it. 16 shows the bottom piece of the die.

The piece. was

top

piece is

quite similar to was

the

bottom

The specimen (which

clamped by four bolts) Fig. 17 shows the

fixed between those two pieces. die. Plate

top piece of this

6 shows a photograph of

the top and bottom pieces.

46

2.2.2

STRAIN GAUGES

CEA - 06 - 125 UR - 120 Rosette strain gauges and CEA - 06 - 125 UN - 120 used single strain gauges have been this work.

to determine the residual stresses in are a general used purpose in

These strain gauges constant strain

family of

gauges The

widely

experimental

stress analysis. encapsulated grid

gauges

are supplied with a fully coated integral

and exposed copper heavy lead

solder tabs to which directly.

wires may be soldered

The resistance of this gauge is 120 +- 0.4 %

Ohms. Normal gauge factor is 2.04 - 0.5 % .

2.3

SPECIMEN PREPARATION

Two main types of specimens were used. type was for and weld build-up thicknesses. with The different

The first lengths,

widths,

second type is for the

welding of simulated cracks of different thicknesses. The chemical composition of this steel is : 0 15% r 1^00% Mn, 0.040% P, 0.030% S, 1.00% Si, and 11.5-13.5% 2.3.1 BUILD-UP WELDING SPECIMEN PREPARATION

In preparing a specimen produce a circular

it was first machined to In the

shape of diameter 75 mm. specimen

central location of this

a slot has been made

47

of

different

lengths (20, The

and 40 depth

mm)

and

different

widths (10, and 20mm). for

of this slot is 3 mm mm thick

6 mm thick specimen's,

and 1.5 mm for 3

specimen's. Fig. 18 shows the drawing of this specimen.

After

machining,

build-up welding was done into

by

filling the deposit metal of this specimen.

this slot in the middle this

Plate 7 shows a photograph of

specimen before and after build-up welding.

2.3.2

CRACK REPAIRING SPECIMEN PREPARATION

This specimen consists of two similar parts, each part having together a semi-circular shape, which when placed mm diameter. about the

produce

a circular shape of 75

Between those two parts there is a very thin gap, 0.2 mm, to simulate the crack. Fig. 19 shows

drawing of this specimen.

After machining, to fill the

welding

passes have been done around this gap

deposit metal into and this

between the two parts of

specimen.

Plate 8 shows

a photograph of this specimen before and after welding.

48

2.3.3

STRAIN GAUGE PREPARATION

In order to obtain the best results from a strain gauge, it is surface of important the to prepare the gauge and the to be

specimen to which the gauge is

attached.

To prepare the specimen surface,

an area

larger

than the installation was smoothed with fine grade emery paper of a fine sand blasting to provide a sound bonding surface. cleaner; used. a Then the for area was degreased with a solvant cleaner was

this purpose a PCB solvant

Finally the specimen surface was neutralised with Tissues were used for this

weak detergent solution. The final

operation.

cleaning was immediately prior to

the installation of the gauge.

After preparing location for

the

specimen

surface a desired determined. After

the strain gauge was of adhesive

that a short length

tape

was placed over

about half of the gauge tabs. Then the gauge backing and the specimen surface was coated with a thin layer of

Cyanoacrylate adhesive. 1 minute to dry. Then

The adhesive was held for about the strain gauge was placed in

its desired location and reasonable pressure was applied

49

to ensure that the the

assembly

was firmly in place.

Then any

gauge was covered with Polyethylene to prevent

external effect which might happen to the strain gauge.

2.4

TEST PROCEDURE

In addition to approaches

preparing

those specimen, the

other proper

have been followed to establish

procedure for this series of experiments.

2.4.1

WELDING PROCEDURE

After the specimen has been machined as mentioned before, the a TIG welding method has been used to produce For both

welding which was required in this work. specimens (build up

these types of repairing

welding and crack used as a

specimens),

Argon gas has been

shielding gas to protect during the welding.

the welding zone from any harm Ampere.

The Amperage was 65 to 75

Electrode E410 was used, as the specimen material.

which has the same composition

The build-up welding by

specimen

has been produced lengths and

filling the slots of different widths, which have been machined in

depths,

the specimens.

50

Different

passes and layers have been employed to have

fill

this slot; 4 and 8 passes mm

been used for 10 and 20 mm

width, 2 and 4 layers have been used for 3 and 6 The crack repairing the slit specimen

depth. by

has been produced two halves.

filling

between

those

Photographs 7 and 8 show after welding.

different specimens before and

2.4.2

MICROSTRUCTURE AND HARDNESS TESTING PROCEDURE

To

evaluate the microstructure and the slices

hardness

of these specimens,

of 5 mm width have been cut Then the perpendicular ground. After that a At

from the middle of the specimen. face of the metallurgy surface has been

lab has been used to polish this

face.

first, however, before polishing this face, the specimen was surrounded by BAKELITE by using the thermoplastic

instrument. was

After that,

different grades of polishing specimen was At

employed.

Then the surface of this

treated with acid. this

Finally it was washed and dried.

stage the microstructure and the hardness started. Photograph 9

testing

have been

shows the specimen

after machining encapsulated in the BAKELITE.

51

2.4.3

TENSILE TESTING PROCEDURE

For

determining

the tensile strength

of

these

different specimens, before weld heat treatment, a

and after applying the post special standard shape of

tensile specimen was machined by following the guideline in German Standard (DIN) [39], for the tensile test specimen. Fig. 20 shows a drawing

2.4.4

THE STRAIN MEASURING PROCEDURE

As mentioned above, evaluate the magnitude

strain and the

gauges were used to distribution of the

residual stresses.

To ensure a good result, the surface Then by

of the specimen was cleaned with solvant cleaner. the strain gauge was spreading and on Silicone the fixed at the correct place,

the adhesive on the back of the strain surface of the specimen. After

gauge that a to

rubber

was used to cover the strain gauge

protect it.

After the strain the

gauge

was

fixed, the first or to

initial reading has been taken by connecting it strain indicator. Then

the digital

the piece of the

52

specimen containing the strain gauge was machined to get the second after the reading. strain Photograph gauges 10 shows the specimen fixed and after

have been

machining the pieces of gauge.

specimen

containing the strain

2.4.5

POST WELD HEAT TREATMENT PROCEDURE

Two different types of have been applied to

Post

weld heat treatment the effect of heat

evaluate

treatment on the hardness

and tensile strength and also

to study their effect on the microstructure.

The specimens have been sectioned and machined as described above, In the then the heat treatment was applied. specimen was and (as In the kept

first type of heat treatment the

left for 30 min at 316C, then for 30 min at 427C, 2 hrs at 546C and kept to coal in the industrial furnace,

prescribed in the second

recommendations). the specimen was

type of heat treatment,

for 2 hrs at 760C and kept recommendation) [40].

to coal in the furnace (AWS

53

PLATE 1

ELEGTRIC FURNACE

54

r e sr,vG

55

PLATE3

HARDNESS TESTER

56

PLATE 4

OPTICAL MICROSCOPE

57

PLATE5

DIGITAL STRAIN INDICATOR

58

PLATE 6

CLAM PING D IE

59

PLATE?

BIULD-UP WELDING

SPECIMEN

60

PLATE 8

CRACK REPAIRING SPECIMEN

6 1

PLATE 9

METALLURGY

SPEGIMEN

62

PL AT E 10

AFTER MACHINING TO THE RESIDUAL STRESS

MEASURE

63

Fig. 15

The assembly drawings of the clamping dies. 64

o
.

CM
# i 1 P

< 2

ALL DIMENSION IN [m.m]. Fig. 16 The bottom piece of the die.

65

4 x 014 4H0LESCD85

all dimension

in

[m.m].

Fig. 17

The top piece of th die. 66

ALL DIMENSION IN [m.m].

? l 9 ' 18

Ths drawln9 for b u i l d u p welding specimen

67

i
T
ALL DIMENSION IN [m.m]

Fig. 19

The drawing for crack repairing specimen.

68

> > $

< <

ALL DIMENSION IN [m.m].

20

The drawing for tensile testing specimen.

CHAPTER 3

ANALYSIS OF RESULTS

3.1

EFFECT OF STRESS RELIEF HEAT TREATMENT

3.1.1

INTRODUCTION

In

order

to study the effect of microstructure heat of

stress

relief

heat treatment on metal two types of post

and properties, have been

weld

treatments for

applied. conditions been made, specimen.

Comparisons both

results

different have

before and after heat

treatment

for both

build-upi welding and crack repair

As

described before, were

in the first kind of

heat

treatment the specimens 30 min at 427C,

left for 30 min at 316C, this will be

and 2 hrs at 546C;

referred to as heat treatment (1). In the second type of heat treatment, the specimens were kept for 2 hrs at 760 C, which will be referred to as heat treatment (2).

70

3.1.2

METAL MICROSTRUCTURE

In

order

to study the effect of

stress

relief

heat treatment a number of

specimens have been prepared

to provide a good microstructural examination.

Both specimen,

types and

of crack

specimens repair

(build specimen)

-up have

welding been

investigated and conditions

comparisons of results for a number of kind

[after welding and before applying any after heat

of heat treatment; heat

treatment (1 ) and after The results

treatment (2)] have been carried out. microstructure

reveal that the all

in the welding zone for B2] have

types of specimens [A1 - A 8 ] and [B1 and the

the same microstructure for or after heat treatment).

same condition (before

In the first condition, applying any kind of heat

after welding and before treatment, the metal

microstructure consists of almost completely martensite. Plates 11 and 12 show photographs of the metal any

microstructure in the welding zone, before applying kind of heat treatment.

71

In treatment completely ferrite .

the (l),

second condition, the metal

after

applying

heat

microstructure

becomes of

tempered

martensite with low percentage

plates 13 and 14 show photographs of the metal in the welding zone, after heat

microstructure treatment (1 ) .

Finally, metal

after applying heat treatment (2), consists

the

microstructure

of tempered martensite, Plates 15 and 16 show in the welding

precipitated carbide and ferrite. photographs of the metal

microstructure

zone after heat treatment (2 ) . The photograph's magnification is X500 and X1000 as appears at the plates. 3.1.3 HARDNESS TESTING

it

A determine specimen's specimen's different

large the

number of readings have been variation at of the hardness depths

taken

to

across the from the

section

different

surface, and axes

along the specimen's

axis. The are

where the readings have been taken

shown in Fig. 21.

The specimens hardness

initial before

results heat

for the

build-up reveal

welding that the

treatment,

increases to the range of

490 - 510 HV in the

72

welding zone and the surrounding area, zone it decreases to about 260 - 270 HV. applying specimens, heat the treatment results (1 ) for

and outside this However same the after type of hardness

the that

indicate

becomes about 430 - 450 HV

in and near the welding zone

and outside the welding zone it decreases to about 250 270 HV. measured Similarly the variations for the same type of in hardness have been specimens after heat

treatment (2). decreases

The results

point out that the hardness

to about 300 - 3 30 HV in and near the welding zone it decreases to about 250 -

zone and outside the 265 HV.

Different demonstrate build-up the

diagrams effect of

have

been

plotted variables

to for

different

welding specimens [A1 - A 8 ], and crack

repair

specimens [Bl and B2]. See table. 1 and 2.

In Figs.

22 - 55 the

hardness

variation across

the specimen are presented for different depths from the surface and three along the specimen's axis for the above stress

conditions

(as welded specimen and after for both build-up

relief heat treatment) crack repair specimens.

welding and

73

Figs. specimen Al, specimen's

22 and 23 show the hardness variation for two surface

for

different depths: 0.5 mm from the (Fig. 22), and 2 mm from the

specimen's surface (Fig. 23).

Fig. specimen

22 shows that

the

hardness

for as welded of the

reaches

about 510 HV over about 9 mm specimen's axis,

welded zone from the

then it reduces

to about 265 HV over the next 6 mm. first type about of heat treatment,

After employing the the hardness becomes from

440 HV over about 7.5 mm of the welded zone it

the specimen's axis, then over the next 8 mm.

decreases to about 260 HV treatment

The second type of heat decreases

shows that the hardness

to about 3 20 HV over axis,

about 3 mm of the welded zone from the specimen's after that, it drops to about 255 - 260 HV.

Fig. condition

23 shows that

the

hardness

for the first

[before heat treatment], specimen's

is about 510 HV for

about 7 mm from the to about 265 HV.

axis, then it decreases treatment (1),

After applying heat to about about 260

the hardness decreases then it reduces to

440 HV for about 6 mm HV. In the third

74

condition, for about

the hardness 5 mm

becomes between 280 and 290 HV specimen's axis, then it

from the

decreases to about 250 HV.

Fig.

24 shows the

hardness

variation along the For the as

specimen's axis in the thickness direction.

welded specimen, the hardness varied between 490 and 520 HV, and between 425 and 440 HV after the first type and between of

heat treatment,

290 and 315 HV after the

second type of heat treatment.

Figs. 25 and 26 reveal the hardness variation for specimen A2, specimen's for two different depths: 0.5 mm from surface, (Fig. (Fig. 26). 25), and the

2 mm from the

specimen's surface,

Fig.

25 shows that the hardness before any

kind

of heat treatment is about it

505 HV for about 15 mm, then After heat treatment (1) 440 HV for about 13.5 mm, In the third condition,

decreases to about 260 HV. to

the hardness is decreased then

it becomes about 255 HV.

the hardness decreases to 320 HV for about 11 mm then it reduces to about 250 HV.

75

Fig. 26 reveals that the hardness is about 505 HV for about 13 mm before heat to about 260 HV. treatment and it decreases hardness

After heat treatment (1) the HV for about

decreases to about 440 reduces 300 and

11.5 mm, then it between then it

to about 255 HV. 320 HV after

The hardness becomes heat treatment (2),

decreases to about 250 HV.

Fig.

27 shows the hardness

variation along

the

specimen axis in the specimen [A2].

thickness direction,

for the same hardness is

Before heat treatment the HV. After heat

between 480 and 520 becomes between 415

treatment (1) it after heat

and 440 HV.

Finally

treatment (2) it is HV.

decreased to the range of 300 - 325

Figs.

28

and 29 show for two

thehardness different (Fig. 28),

variation

across specimen A3,

depths: 0.5 mm and 2 mm from

from the specimen's surface, the specimen's surface,

(Fig. 29).

Fig.

28

reveals that the hardness before to about

heat

treatment is increased from

500 HV for about 9 mm

the specimen's axis,

then it reduces to about 265

76

HV.

After first kind about

of

heat treatment about 8 mm, After

the hardness that it

becomes

455 HV for

after

decreases to about 260 HV. hardness

heat treatment (2), the mm,

is diminished to about 310 HV for about 6

then it decreases to about 250 HV.

Fig.

29 reveals that the hardness, in the first

condition is increased to about 500 HV for about 8.5 mm, after that it decreases to about 265 HV. After heat

treatment (1) the hardness to about

is decreased to about 450 HV In

7.5 mm, then it reduces to about 260 HV.

the third condition, the hardness decreases to the range of 300 - 310 Hv for about 6 mm, after that it becomes

about 250 HV. I

Fig.

30 shows the

hardness

variation along the

specimen's axis in the thickness direction, for specimen A3. and In the first condition 505 HV. the hardness is between 490

And it is decreased to the range of 445 (1). is Finally, decreased after heat to become

455 HV after heat treatment treatment (2 ) the hardness

between 300 and 310 HV.

77

Figs. across

31 and

32

show

the

hardness

variation 0.5 mm

specimen

A4, for two different depths: (Fig. 31),

from the specimen's surface, the specimen's surface,

and 2 mm from

(Fig. 32).

Fig. 31 reveals that the hardness before any kind of heat treatment is becomes about 505 HV for about 16 mm, then it is

265 HV.

After heat treatment (1) it

decreased to about 440 HV for about 14 mm, after that it diminishes to about 260 HV. hardness decreases to In the third condition about the

become

310 HV for 10 mm,

then it drops to about 250 HV.

Fig. condition is

32 shows that about

the

hardness

for the first then it the mm,

495 HV for about 15 mm,

reduces to about 265 HV. hardness

After heat treatment (1),

is decreased to about 435 HV for about 13 about 260 HV.

after that it drops to

After the second

type of heat treatment, the hardness decreases to become about 310 HV for about 10 about 250 HV. mm, then it is decreased to

78
I

Fig.

33 reveals the hardness variation along the thickness direction, for specimen is

specimen axis in the A4.

Before any kind of heat treatment the hardness It (1).

between 495 and 505 HV. HV after heat treatment

becomesbetween 435 and 445 In the third condition the

hardness is decreased to the range of 300 - 310 HV.

Figs. 34 - 36 show the specimen specimen's specimen's A5,

hardness variation across 0.5 mm 2.5 from the

fordifferent depths: surface, surface, (Fig. (Fig. 35), 34),

mm from the from the

and 4.5 mm

specimen's surface,

(Fig. 36).

Fig. 34 reveals that the hardness before any kind of heat treatment is about the 265 specimen's axis, HV.After to heat 490 HV for about 10 mm from about

after that it decreases to (1) the

treatment

hardness is mm from the

decreased

about 440 thenit

HV forabout 8 diminishes to

specimen's axis, After

about 260 HV.

heat treatment (2),

the hardness becomes between after that it decreases

290 and 310 HV for about 10 mm, to about 255 HV.

79

Fig.

35 shows that the hardness before employing

the heat treatment is about 490 HV for about 8.5 mm from the specimen's axis, after that it reduces to about HV. to In the second condition, about 265

the hardness is decreased the HV. specimen's After heat about

435 HV for about 7.5 mm from it becomes about 260

axis,

then

treatment

(2 ), the hardness diminishes to become

300 HV for about 6 mm from

the specimen's axis, then it

is decreased to about 255 HV.

Fig.

36

shows

that

the

hardness

before heat

treatment is increased to about 490 HV for about 8.5 mm, after that it decreases treatment (1) to about 265 HV. After heat 435 HV for

the hardness becomes about to 260 HV. the

about 7.5 mm, then it drops the second kind of heat

Finally, after hardness is

treatment 295

decreased to the range of

- 300 HV for about 6 mm,

then it reduces to about 255 HV.

Fig. the specimen

37 shows that the axis The in the hardness

hardness variation along direction, for

thickness is between

specimen A 5 .

490 and 510 HV After heat

before employing any kind of heat treatment.

80

treatment between (2),

(1 ),

the

hardness

is

decreased to become treatment

435 and 445 HV.

Finally, after heat

it is decreased to the range of 300 - 310 HV.

Figs.

38 - 40 show the hardness variation across 0.5, 2.5, and 4.5 mm from the

specimen A 6 , for depths specimen's surface.

Fig.

38 revealsthat the hardness HV for about

before

heat

treatment is about 500

17.5 mm from the

specimen's axis, after that it decreases to become about 265 HV. decreased After to heat treatment (1), the hardness is it

about 450

HV for about 15.5 mm, then After heat treatment the range of 310 - 320

reduces to about 260 HV. hardness decreases to

(2), the HV for

about 13 mm, after that it becomes about 255 HV.

Fig.

39 shows that the

hardness,

in the first

condition, is increased to about 500 HV for about 14 mm, after that it decreases to heat become about 265 HV. After about

treatment (1 ), the hardness is decreased to

450 HV for about 13 mm,

then it drops to about 260 HV.

81

After

heat treatment (2), the hardness is diminished to

about 310 HV for about 11 mm, after that it decreases to about 255 HV.

Fig.

40

reveals

that

the

hardness,

before

employing any kind of heat treatment is about 500 HV for about 13 mm, then it reduces to about 265 hardness HV. After

heat treatment (1 ), the 445 HV for about 11 mm, HV. Finally, after heat

is decreased to about

after that it becomes about 260 treatment (2), the hardness is then

decreased

to become about 310 HV for about 10 mm,

it reduces to about 255 HV.

Fig.

41 shows the

hardness

variation along the for the same

specimen axis in the thickness direction, specimen, A 6 . The results reveal

that the hardness is

between 495 and 505 HV before employing any kind of heat treatment. decreased After heat treatment (1), the hardness is And after

to become between 440 and 450 HV.

heat treatment (2), it is - 315 HV.

decreased to the range of 305

The hardness variation three different depths, 0.5,

across

specimen A7,

for the

2.5, and 4.5 mm from

specimen's surface, are plotted in Figs. 42 to 44.

82

Fig.

42 shows

that

the

hardness,

before

applying any kind of heat about HV.

treatment is about 505 HV for

10 mm, after that it is decreased to to about 270 After heat treatment to (1),the hardness mm, is it

diminished

about 450 HV for about 8 HV. After the

then

decreases to about 260

second type of

heat treatment, the hardness reduces to the range of 300 - 315 HV for about 7 mm, after that it becomes about 255 HV.

Fig.:

43 reveals that the hardness, about

before

any

kind of heat treatment is after

505 HV for about 8 mm, After

that it decreases to become about 270 HV. the

heat treatment (1 ), 450

hardness is decreased to about

HV for about 7 mm, then it reduces to about 265 HV. after the second becomes about type of heat treatment, the for about 5 mm,

Finally, hardness

300 -310 HV

after that it decreases to about 260 HV.

Fig.

44 shows

that

the

hardness,

before

employing any kind of about

heat

treatment,

is increased to to

505 HV for about 7.5 mm.

after that it drops

about 270 HV. decreased

After heat treatment (1), the hardness is

to about 450 HV for about 7 mm, after that it

83

reduces to about 265 hardness

HV.

In

the third condition, the then it

becomes about 300 HV for about 5 mm,

decreases to about 255 HV.

Pig.

45 reveals the hardness variation along the thickness direction, for the same

specimen axis in the

specimen, A 7 . The results point out that the hardness in the first condition decreased to the is range between 490 and 510 HV. HV after It is heat

of 440 - 455

treatment (1).

After heat

treatment (2),

the hardness

is decreased to become between 300 and 320 HV.

Figs. 46 - 48 show the specimen A8, for three

hardness variation across depths from the

different

specimen's surface, 0.5,

2.5, and 4.5 mm.

Fig.

46 reveals that the hardness, before

heat

treatment, is increased to about 510 HV for about 18 mm, after that it decreases to about 265 HV. the hardness After heat

treatment (1), HV

is decreased to about 450 260 HV.

for about 17 mm,

then it reduces to about

After heat treatment (2), the hardness is also decreased to about 310 HV for about 12 mm, then it diminishes to

about 255 HV.

84

Fig.

47

shows

that the hardness in

the

first

condition, is about 510HV for about 15.5 it decreases to about 265HV. to

mm, after that

After heat treatment (1), about 440 HV for about 13 Finally, after heat

the hardness is decreased

mm, then it drops to about 260 HV. treatment (2), the hardness HV for about 11 mm, HV. is

diminished to about 305 255

after that it reduces to about

Fig. about

48 shows that the

hardness is increased to after that it reduces to

510 HV for about 15 mm,

about 265 HV. decreased to

After heat treatment (1), the hardness is about 440 HV for about 12 After mm, then it

diminishes to about 260 HV. the

heat treatment (2), HV

hardness is decreased to the range of 300 - 310

for about 10 mm, after that it drops to about 255 HV.

Fig.

49 reveals the hardness variation along the thickness direction, for the same in After

specimen axis in the specimen, A8.

The results show is

that the hardness,

the first condition heat

between 495 and 515 HV.

treatment (1), it is decreased to the range of 430 Finally, after heat treatment (2), it becomes

- 445 HV.

between 295 and 310 HV.

85

The following welding. Figs.

figures

results

for crack repair

50 and 51 reveal the hardness variation for two different depths from the

across specimen Bl, specimen's (Fig. 51) . surface,

0 .5 mm from the specimen's surface

50), and 1.5 mm from the specimen's surface (Fig.

Fig. reveal that applying any

50 and 51 show very similar results, the hardness, after welding is and

which before to

kind of heat treatment

increased

about 525 HV for about 4 265 HV. After

mm, then it decreases to about the hardness is

heat treatment (1),

reduced to about 460 HV for decreases to about 260 HV.

about 3.5 mm, after that it After heat treatment to (2),

the hardness is diminished

about 290 HV for about 3

mm, then it becomes about 250 HV.

Fig.

52 reveals the hardness variation along the thickness direction, for the same

specimen axis in the kind of specimen B l . is between 525 and 5 30 heat treatment.

The results show that the hardness HV before applying any kind of

After heat treatment (l), the hardness

86

is decreased to the

range

of

460

- 465 HV.

Finally, to

after heat treatment (2 ), the hardness is diminished become between 295 and 300 HV.

Figs.

53

and 54 reveal the for two

hardness

variation

across specimen B2, specimen's surface. (Fig. 54) .

different depths from the surface

0.5 mm from the specimen's

53), and 2.5 mm from the specimen's surface (Fig.

5 3 shows that the hardness, before applying I any kind of heat treatment is about 520 HV for about 6 mm, after that it decreases to about 265 HV. treatment (1), the hardness is After heat

Fig.

reduced to about 465 HV

for about 5 mm, then it decreases to about 260 HV. After heat treatment (2 ), the hardness is diminished to about

295 HV for about 3 mm, then it reduces to about 250 HV.

Fig.

54 reveals that the hardness, before

heat

treatment is about 525 HV

for about 5 mm, after that it

decreases to about 265 HV. After heat treatment (1), the hardness is reduced to about 465 HV for about 5 mm, then it decreases to about 260 HV. is Finally, after heat

treatment (2), the hardness

diminished to about 300

HV for about 3 mm, after that it becomes about 250 HV.

87

Fig.

55 shows the

hardness

variation along the for the same

specimen axis in the thickness direction, specimen B 2 . The results reveal that

the hardness is

between 515 and 520 HV, before applying any kind of heat treatment. After heat treatment (1), the hardness is Finally, to after become

decreased to the range of 460 - 465 HV. heat treatment (2 ), the hardness

reduces

between 295 and 305 HV.

In order to study variables width), hardness in and

the

effect

of

the different length, results and of the for

the specimen to compare

(thickness, between the

variation for the same kind of specimen, specimen's surface,

different depths from the of

a number

graphs have been plotted for both types of specimens and crack repair specimen). applying

(build-up welding specimen, The

first condition (after welding and before heat treatment)

any kind of comparisons.

has been chosen for these

Figs.

56

to

65 show

different

curves

which

represent the hardness

variation

across the specimens. particular 0.5, 2.5,

Each of these curves has been produced for a depth, 0.5 and 2 mm for specimens A1 - A4;

88

and

4.5

mm for specimens A5 - A 8 ; 0.5 and 1.5

mm

for

specimen Bl; and 0.5 and 2.5 mm for specimen B2. Each of these figures compares the hardness variations at

different depths of the same specimen.

Pigs. the

66 to 70 have

been plotted to demonstrate variation.

effect of the thickness on the hardness

Comparisons between similar in A8, thickness, (A1 and A5, been

specimens which differ only A2 and A 6 , A3 and A7, A4 and made at the depth of 0.5 mm

Bl and B2) have

from the specimen surface.

Different effect of the bead Comparisons have

curves have been plotted to study lengths on

the

the hardness variation. similar specimens

been made between lengths, The mm

which differ only in bead A4, A5 and A 7 , the

(A1 and A3, A2 and hardness from variation

A 6 and A 8 ). depth of 0.5

measured at surface.

the specimen shown in

The results of this comparison are

Figs. 71 to 74.

In order to study the effect of the bead width on the hardness variation, has different been made curves have been

plotted.

Comparison

between

similar A2,

specimens which differ only in bead widths,

(A1 and

89

A3 and A4, variation

A5

and

A6, at

A7

and

A 8 ).

The hardness mm from the

measured

the depth of 0.5

specimen surface.

The results

of these comparisons are

shown in Figs. 75 to 78.

3.1.4

TENSILE TESTING RESULTS

As

described

in

section

2.4.3,

after

the

specimens have been welded, produce standard tensile have been

these have been machined to Thfcsetests conditions,

testing specimens.

carried out for the above three kind of heat

before applying any

treatment and after

heat treatment (1 ) and (2 ).

This

testing

has

been done for both

to

determine

the

ultimate tensile strength

types of specimens,

(build-up welding specimens and crack repair specimens). i The ultimate results tensile reveal strength, that for the the magnitude of the first type of

specimens (build-up welding

specimen),

before applying

any kind of heat treatment is between 686 and 762 N/mm2. After heat treatment (1), strength is between the ultimate tensile tensile N/mm2. After heat

686 and 756

90

treatment (2 ), the ultimate

tensile

strength decreases

to the range of 649 - 706 N/mm2. These results are shown in Table 3.

In specimen). applying

the The

second type of.specimens ultimate tensile

(crack

repair before and

strength,

any kind of heat treatment is between 728

732 N/mm2. 7 33 and

After heat treatment (1), it becomes between N/mm2. After heat treatment (2), the

7 35

ultimate tensile strength

reduces to the range of 678 -

683 N/mm2. These results are shown in Table 4.

In this testing, to fracture zone. in

all

the

specimens were loaded outside the

and the fracture has occured Moreover, there is no

welding reduction

significant or near the

the area of the section in

welding zone.

This area extends Al, A4, and A3, A5, and A7; A6, B2. and A 8 ;

to

about

20 mm for specimens A2,

to about 30 mm for specimens about

and to

10 mm for specimens B1 two different

Plate 17 shows a photograph of

specimens, after they have been fractured.

91

3.2 THE MAGNITUDE AND DISTRIBUTION OF RESIDUAL STRESSES

3.2.1

INTRODUCTION

Stress determine residual the

relaxation magnitude

technique and the

has been

used

to

distribution of the specimens (build-up

stress

in both types of

welding specimens, and crack repair specimens).

The strain different axis as

gauges

positions shown the in

have been mounted on three i on the specimen's surface along X 79 which shows gauges a sketch on the

Fig. positions

illustrating

of strain

specimen's surface.

Some

difficulties due

have to the

been

experienced

in

attaching the gauges

small surface of the For this reason, the

specimen around the welding zone. testings have been made for

only those specimens which I have narrow welding zone (Al, A3, A5, A 7 , Bl, and B2).

To

determine

the

strain rosettes

in

different

orientations, strain gauge three

have been used and from each

different readings have been recorded

92

strain stresses

gauge

rosette.

After

that,

the

residual strain]

have been computed by using [stress,

formula given in the next section.

3.2.2

COMPUTING THE RESIDUAL STRESSES

From the specimen's surface

theoretical cannot that

approach act

[41],

stress at to gauge the is

surface so

perpendicular the

plane,

effectively

measuring a two dimensional strain system. in the X and follows : Y directions can be

The stresses [42] as

expressed

E ox -------l _ v2
} (l)

(ex + v.ey )

E
O y = -------(6y + V.6X )

1 _ v2

Where : ox = Oy = ex = The stress in X The stress in Y The strain in X direction. direction. direction.

93

y = The strain in Y direction. E v = The elastic modulus, = Poisson's ratio.

Often the directions

of

the

principal stresses

are not known in the practical measurement situation, so that it principal it advantageous to have expressions for the positioned

strains that refer to arbitrarily

axes as used in equation (2 ):

ea = ex .cos2a + y.sinza + rXy .sina.cosa

(2 )

The

equation defines the strain ea that the

at a

point,

where a is the angle axis

strain makes with the X and rXy is the 80). shearing The strain obtain

in arbitrary X - Y axes,

strain present at the point ea

(see Fig.

can be measured at three different angles to

three values for ea. Thus, three equations can be solved simultaneously to give ex , y, and rXy.

In out by three

this work, the measurements have been carried strain e2 / gauge and
3

employing values e^,

rosettes, to three

which give different

directions. Fig. 79 shows the three different directions of the strain gauges.

94

e is

measured by gauge 1 at a = 0

e 2 is measured by gauge 2 at a = 45
3

is measured by gauge 3 at a = -45

These measured

levels

can

be

substituted into

equation (2 ) to give ex , Ey and their direction referred to arbitrary axes, and rXy so that in terms of measured levels

1 = excos2(0 ) + EySlH2(00) + TXySin(0 0)cos(00)

e 2 = excos2(45) +

eySin2(45) + rXySin(45)cos(45)

(3)

e3 =

e x c o s 2(-45)

+ EySin2(-45) + rXySin(-45)cos(-45)

(emax min)

Further, to determine the principal strains 1 anc^ emin) anc^ the Principal stresses (cmax and
T^e principal (ex , Ey, strains and can in be determined by the following

substituting equation:

rXy)

emax = excos2ctp + EySin2Op + TXySinapCosap (4) 6min = excos2apl + eysin2apl + rxysinaplcosapl

95

Where:

c i p =' the angle with arbitrary axes,

that

the

principal

planes make This angle

and apl = ap +- 90.

can be determined by the following equation:

rxy tan2aD = 6x " ey (5)

The principal stresses can be determined by substituting 6max a r i < * emin the following equation:

E max = 1 - v2
(6 )

(emax + v em i n )

E
min = (emin + v,emax>

l - v2

96

3.2.3

THE RESULTS

As described above, are

three readings (]_, e 2> Then

e3) the

obtained from each strain gauge rosette.

magnitudes of ox and Oy, and the principal stresses have been computed at this location by using the above

equations.

As tested to

mentioned

before,

three

points the

have been residual

determine the distribution of

stresses along the X axis. results an

Before demonstrating all the how the

example will be described to show

results have been computed.

In

this example the residual stresses have 79.

been The

measured for specimen A3, at point 1, see Fig. results were as follows:

= 292 microstrain.

= 173 microstrain.

3 = 247

microstrain.

97

By substituting these values in equation (3):

ex = 292 microstrain.

Ey = 128 microstrain.

rXy = 74 microstrain.

By substituting ex and Ey in equation (l):

ox = 71.146 N/mm2.

Oy = 45.521 N/mm*.

By substituting ex , Ey, and rXy in equation (5):

dp = 9.3 0

By substituting

ex ,

Ey, rXy, and Op in equation (4)

smax = 289.3 microstrain.

Em in = 120.4 microstrain.

Finally, by substituting emax an< 3 min in equation (6 ):

max = 72 N/n 2

min = 44-2 N/mm 2

Fig. the residual This figure

81 shows a diagram for the distribution of stress ox along X axis, for specimen A3. central

shows that at about 25 mm from the zone, there

axis of the welded stress.

is negligible residual of 71

At a distance of 10 mm residual stress

N/mm 2 is obtained in the X direction.

Fig. the residual

82 shows a diagram for the distribution of stress Oy along X axis, for specimen A3.

Similar trend is observed as in Fig. 81.

Fig. the

83 shows a diagram

for the distribution of X

principal

residual stresses omax and om j _ n along A3. this figure

axis, for

specimen

shows a similar

results which obtained in Figs. 81 and 82.

99

Figs.

84

and

85

show

diagrams

for

the X

distribution of the residual stresses ox and Oy along

axis, for specimen B1 and again the maximum magnitude of the residual stress in the X direction was obtained 70 N/mm2. Outside the 25 to

be about

mm distance the

residual stress was negligible.

Fig. the principal

86 shows a diagram for the distribution

of

residual

stresses

omax and om ^n along X

axis, for specimen Bl. Similar trend is obtained in Figs 84 and 85.

Due

to

the small size of the specimens and gauge rosette,

the

high cost of the strain gauge

a single strain

has been used instead of the strain gauge rosette strain in one direction only to have

to measure the residual make

comparison between different specimens which

different variables.

In this situation e 1 = ex and the distribution of this parameter along the X axis has been specimens. I I t t 100 Diagrams have compared for

different

been

plotted to

illustrate 1these results, A 7 , Bl, 92.

for specimens A 1 ,

A3,

A5, 87 to

and B2. Those diagrams are shown

in Pig.

Different

curves

have been plotted in Pigs. acomparison

93

and 94 which represent results, for specimens

between the above

Al, A3, A5, and A7 (Fig. 93), and

for specimens Bl and B2 (Fig. 94).

101

Specimen No Al A2 A3 A4 A5 A6 A7 A8

L [m.m]
20

W [m.m] 10
20

T [m.m]

D [m.m ] 1 !

I ---20

!
i

xii.

40 40
20

10
20

I
i !

10
20

20

40 40

10
20

Table. 1 The different dimensions for build-up welding specimen.

1 Specimen No

T [m.m] 3 5

Bl B2 i

Table. 2 The different thickness for crack repairing specimen.

102

Tensile strength [N/mm2] Specimen before heat treatment Al A2 A3 A4 A5 A6 A7 A8

686

after heat after heat treatment (1) treatment(2)

688

657 652 653 649

688

689 694 696 709 725 739 762

686

695 700 724 747 751 756

698 713 706

Tabel. 3 shows the tensile testing results for build-up welding specimen.

Tensile Strength [N/mm2] Specimen before heat treatment 1 I B1 1 1 B2 728 733 732 735 1 1 678
I

after heat ! after heat treatment (l )jtreatment(2) i 683 1 1

Tabel. 4

shows the tensile testing results for crack repair specimen.

103

PLATE 1)

THE

M I C R O S T R C T URftL BEFORE TREATMENT, FR A8 ( x 500)

H EA T

MARTENSITE

104

PL ATE 12

THE MI OROSTRUCTURAL EFORE HEAT TREATMENT, F0RB2 (X 5

0 0

MARTENSITE

105

PLATE 13

THE Ml CROS TRUCTUR a L HEAT TREATMENTC1),

AFTER

FOR A 8 (X500)

PLATE 14

THE MIGROSTRUGTURAL AFTER HEAT TREAT M E N T C I), FOR B2

(x500)

TEMPERED

M A R T E N S IT E -

FERiTTE

TEMPERED PRECIPITATED CARBIDE

10 8

M A R T EN SIT E

PLATE 1 5 THE MI GRQSTRU g TUR A L

m
I m

I N J v .

o
O

n O
7)

AFTER

00

PLATE 16

THE HEAT

MI CRO STRUCTURAL TREATMENTS),

AFTER FOR B 2

(X 500)

109

PLATE

17

TENSILE

SPECIMEN

Al

110

(1 ) FOR SPECIMEN (2 ) FOR SPECIMEN

B1 B2

CRACK

REPAIRING

SPECIMEN AXIS

(2 ) FOR

SPECIMEN A 5 - 8

(1) >

B U IL D -U P WELDING
iI L O l D (2 ) * i n

SPECIMEN 1

Fig. 21

Illustration sketch for the specimen's axis

111

DISTANCE
Fig. 22

PR OH

THE

SPEC I HEN

AXIS

Cm. m:i

The hardness variation across specimen Al, 0.5m.m from the surface.

I) I S T A N C E :

PR OH

THE

S P E C I H E I'I ' S

AXIS

Cm. iti

Fig. 23

The hardness variation across specimen A 1 , from the surface.

2m.m

6 00

'viSO

1-*- before heat treatment 2-*-after heat treatment(l) 3-*after heat treatment(2) X
^ X

i'. 0 0

;r

l i f t 1

______

2
ISO 1 * .

/ >
\ \

\ \
\
\

400

3 S 0 (-

.3

\
t

/
V
i . ^ w
.'.V f"! l'

K \
\ \
s*

200

S DISTANCE

10 FROH THE

1 .b SPECIMEN

20 S AXIS

25 E ! in. m i

30

Fig. 25

The hardness variation across specimen A2, 0.5m.m from the surface.

DISTANCE
Fig. 26

PR OH

THE

SPEC I HEN

AXIS

Cm. m ::i
2m.m

The hardness variation across specimen A2, from the surface.

A R D w

118

Fig. 28

The hardness variation across specimen A3, 0.5m.m from the surface.

Fig. 29

The hardness variation from the surface.

across

specimen A3, 2m.m

6 00
1 before heat treatment 2 after heat treatment(l) 3 after heat treatment(2)
w -...

SS0

/'
soo TT

4S 0

/:

"\
\

400

H
350

/
300
' + H .. A .

K
i *

2S0 h

o
d :i: s t a n c

IS

i::

F R OH

SPEC I

h i 3

>I < "

oX
i t i .

i n .

Fig. 31

The hardness variation across specimen A4, 0.5m.m from the surface.

Fig. 32

The hardness variation across specimen A4, from the surface.

2m.m

6 00
1 before heat treatment 2 after heat treatment(1) 3 after heat treatment(2) : K - jr Ni 4 (v i0 ir ' * 400
f

SS0

soo

3 iv i0

300

r" p~

2S0 200

^
-

~4 4

y~

10

1.5

20 :

O A..
a x is

30

DI STANOE
Fig. 34

FROH

T l i : : :

s p e c

:n ,

m. in ::i

The hardness variation across specimen A5, 0.5m.m from the surface.

Fig. 35

The hardness variation across specimen A5, 2.5m.m from the surface.

Fig. 36

The hardness variation across specimen A5, 4.5m.m from the surface.

6 00
1 before heat treatment 2 after heat treatment (l) 3 Rafter heat treatment (2)

SSO -

SOO

/
T -"*~

I2
t , . x < 4 S 0 ih * T f -% r w
r

T^-r- * * - "T Tr

400

3S0 \ \
\ f t .+ f * -K \

300 -

4 * . a M .. K .

\ i . / j 1 -fe . y.

2S0

200

s
in s t a n c e Fig. 38

10

1. s
the

20

Or ;*
f...

30

froh

spec:i:h e n ' s

axis

i::m . in ::i

The hardness variation across specimen A6, 0.5m.m from the surface.

FR 01*1 THE SPEC I HEN S A X I S Cm. m3

Fig. 39

The hardness variation across specimen A6, 2.5m.m from the surface.

6 00

SSO 5 00

' X

5 X *

1 before heat treatment 2 after heat treatment(l ) 3^after heat treatment(2)

ASO

400

\ \
3S0
i

< " i \ V '"\ *

-

300 p
^4, 25 0

' k \ . . .' O r * ti i | ........ J . p ii^ .t ...li I . j.. y wt j im - y ................... * * Y

2000

s
d is ta n c e

1.0

1.5
th e s p e c :i: h e n

20

* >r:;

A .. ..*

30

fron

'

a x i s

i::m . m

Fig. 40

The hardness variation across specimen A6, 4.5m.m from the surface.

Fig. 42

The hardness variation across specimen A7, 0.5m.in from the surface.

Fig. 43

The hardness variation across specimen A7, 2.5m.m from the surface.

DISTANCE
Fig. 44

FROM

THE

S PE C l I'lEN S A X I S

Cm. m3

The hardness variation across specimen A7, 4.5m.m from the surface.

6 00
1 before heat treatment 2 rafter heat treatment(l) 3 after heat treatment(2)

5S0 5 00
' t * .4 f f" 45 0 U t '

!
2 O O P ' X JL -n ~th' * w j \ J J . 1 ) '
...

400 350 300 r t * -

\ I

* * . -

T *

' V I I I I \ I \x

4.>

50 -

200 in s t a n c e

j. 0
fr

on

THE

S P E C :i: NEH ' S

AXIS

Cm, in"I

Fig. 46

The hardness variation across specimen A8 n m from the surface. ' u 'om' m

6 00

$f . {q _ /

1 before heat treatment 2 **after heat treatment (1) 3 after heat treatment (2 )

soo
t

450 '
400

/
v.

3 5 0 t-

1
j \

/
300 1 i'
2 SO VQ Q ' " ' 0

x \
T -4 .
T '

V \

\ V
* ni . ..^. 1

'U* ^3* i w T,~i.<yr3 ^ < B5y

i s

1.0

15

20 AXIS

25 Cm. m3

30

1 DI S T A N C E I" FROM T H E

SPE C I H E N ' S

Fig. 47

The hardness variation across specimen A8, 2.5m.m from the surface.

6 00

S50

SOO

t
'V .

l_*before heat treatment 2after heat treatment(l) 3-*-after heat treatment(2)

45 0
If

/
, ? t i f r . _ j k

400 35 0 -

\
X \ \^
f ! f .~ 7 i . .x .

300 f

.2 1 * k.

25 0

. , . . .\ v T- * *v u .i jgt __'Ml..7 W . . t .1 f f . 5_r^_ * *iL~. v

I \

^ r^rrEr.-^c:

. w ----

-Tf .if -- ..nr.. . -w. . ^

ri

1*

200q
S

i. o
Ron
th e

i. s
s p e c

20

25 AXIS i:m. m : : i

30

in

stano e

' I 'S

Fig. 48

The hardness variation across specimen A8, 4.5m.m from the surface.

A R D h i E s O
'..i

140 Fig. 50 The hardness variation across specimen B1 from the surface. 0 5 mm

Fig. 51

The hardness variation across specimen B2, 1.5 mm from the surface.

142

H A R D N

S S

H V
143
i r " i

DISTANCE

FR OH

THE

SPE C I HEN

AXIS

i:m. mil

Pig. 5 3

The hardness variation across specimen B2, 0.5 mm from thte surface.

144 Fig. 54 The hardness variation across specimen B2, 2.5 mm from the surface.

6 0 0 ------------------------------- !-------------

------ i

----T------------------------------- 1

i---------------------

SSO

(1 )AT A DEPTH OF 0.5mm ( 2 ) AT A DEPTH OF 2 mm

SOO

R
D h . i

4S 0

S
S

400

\ \ \\ \\ ' \ \ \ \y

\/
\ r .0 d

35 0

V
146

300

\\
1 , i

\ v

2 SO
----- 1 .... ...

200
0

------------ 1 ------------------------------ j _________________i

7 .

i .o r
o h

IS

20

{ .s . ' i n . i n .

30

in

stance

SPEC I HEN S A X I S

Pig. 56

Coparison between the hardness variation for the two different depths, for specimen Al.

1 * 1 R

D S S

V 147 Fig. 57 Comparison between the hardness variation for the two different depths, for specimen A2.

------------------ 1 ------------------------- 1 ------------------ 1 ------------- -----,------------------ 1 _ (D A T A DEPTH OF 0.5mm .

(2 ) AT A DEPTH OF 2 mm j . %

\\ \V A / - V w\ \ \V
10 15 i 20

i 25

3i

DISTANCE FROH THE SPECIMEN S A X IS Cm. m3

Fig. 58 Comarison between the hardness variation for the two different depths, for specimen A3.

6 00

550

(1 )AT A DEPTH OF 0.5 mm (2)AT A DEPTH OF 2 m m .

6 00 A R D
h i

\
450

S S

400

35 0
V 149

\
N V

300

250

200

1.0

20

A m S.*

DI S T A NO I
Pig. 59

R0H

THI::! SPEC I HEN

S AXIS

Cm. in3

Comparison between the hardness variation for the two different depths, for specimen A4.

Fig. 60

Comparison between the hardness variation for the three different depths, for specimen A5.

( D A T A DEPTH OF 0.5mm (2)AT A DEPTH OF 2 5 mm (3)AT A DEPTH OF4.5mm

I \ \ r
\

\
\
\

\
V

A
\

3 A
s

\ /
V

V
\
V

0
d :i: b t a n c h i :

:1.0

1 .5
tmiii : specim en s

:o
a x :i: s

O r::
t.., s.l

30

fr

on

| T I .H I .

Fig. 61

Comparison between the hardness variation for the three different depths, for specimen A6.

A R

D
w

S
S

152

DISTANCE
Fig. 62

FR OH T H E

SPEC I HEN

S AXIS

Cm. m i]

Comparison between the hardness variation for the three different depths, for specimen A 7 .

Fig. 6 3

Comparison between the hardness variation for the three different depths, for specimen A8.

Fig. 64

Comparison between the hardness variation for the two different depths, for specimen Bl.

6S0 6 00
A R D S 3
45 0

(1 ) AT A DEPTH OF 0.5mm'

.\ i\

(2 ) AT A DEPTH OF2 5 mm

i\
400 360

300

155

2S0

2 00
0

s
d :i: s t a n c

. 1 .o

1.6

20
S AX I S

30

ROH

THE

S PEC 1 HEN

Cm. mi

Fig. 65

Comparison between the hardness variation for the two different depths, for specimen B2.

A R D e

V < J 1 o \

Fig. 66

Comparison between the hardness variation for specimens A1 and A5 which have different thickness.

DISTANCE
Fig. 67

FROF

Comparison specimens thickness.

between the A2 and A6

hardness variation for which have different

Fig. 68

Comparison between specimens A3 and thickness.

the A7

hardness variation for which have different

159 Fig. 69 Comparison between specimens A4 and thickness. the A8 hardness variation for which have different

Fig. 70

Comparison, between specimens Bl and thickness.

the B2

hardness variation for which have different

< )0 0

sso
500

---w---^ N\ \\ v \\ 1 , s i
-

AT A DEPTH

OF 05mm

A
R

450

400
S

\ \ %
\ V \

/A1 /A3

350

V
300 250 200
0
-

\ \ T/ \\

161

%
__ -1 -------------- 1 -------------20
O< : s
i t i

*
i) :i: s t a n c
Fig. 71

1 -------------- L
10 R 0lY l

1.5

30

SPEC

!N S A X I S Cm.

Comparison between the hardness specimens A1 and A3 which have length.

variation for different bead

Fig. 72

comparison between the hardness specimens A2 and A4 which have length.

variation for different bead

R
D w e

V
163 Fig. 73 Comparison between the hardness specimens A5 and A7 which have length. variation for different bead

H A R D M s s

Fig.74

Comparison between the hardness variation for specimens A6 and A8 which have different bead length.

165 Fig. 75 Comparison between the hardness specimens A1 and A2 which have width. variation for different bead

ft

R D
hi

S s

H V

99t

d: i: S T A N C E

FROH

THE
between and

S P E C I! MEN
the

AXIS

Cm. m3
for

Fig. 76

Comparison widthmSnS A3

hardness have

variation

A4

whictl

different bead

A R D w 3 S

V 167 Fig. 77 Comparison between the hardness specimens A5 and A6 which have width. variation for different bead

Fig. 78

Comparison between the hardness specimens A7 and A8 which have width.

variation for different bead

BUILD-UP WELDING SPECIMEN

CRACK

REPAIRING

SPECIMEN

Fig. 79

Illustration sketch for strain gauges positions on the specimen's surface.

169

STRAIN

170 Flg. 80 Illustration sketch to show the strain in X direction.

200 180
160 140
tn <n
lu

120
100

<n
-_j

< Zi O tn L l) ( Y U :r i -

80 60 40

0
0

DISTANCE PROM THE SPECIMEN S AXIS [m m ]

Fig. 81 The distribution of the residual stress ox along X axis, for specimen A3.

TH E

RESIDUAL

STRESS

[N/mm

DISTANCE FROM THE SPECIMEN S AXIS [m m ]

Fig. 82 The distribution of the residual stress o alonq x axis, for specimen A3. Y

200
r iso

[N/mm STRESS THE RESIDUAL

160 140
120 100

80 60
40

20
0

10

15

20
[mm] !

25

30

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 83

The distribution of the principal residual stresses along X axis, for specimen A3.

THE

RESIDUAL

STRESS

ox

[N/mrn

DISTANCE FROM THE SPECIMEN S AXIS [m m ]

Fig. 8 4 The distribution of the residual stress ov along x axis, for specimen Bl.

DISTANCE FROM THE SPECIMEN S AXIS [m m ]

Fig. 8 5 The distribution of the residual stress oy along X axis, for specimen Bl. y

200

180
160

140
120 100

80 60 40
20
0

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 86

[mm]

The distribution of the principal residual stresses along X axis, for specimen Bl.

THE

RESIDUAL

STRAIN

[Microstrain]

10

15

20
[mm]

25

30

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 87

The distribution of the residual strain along x axis, for specimen Al.

THE

RESIDUAL

STRAIN

[Microstrain]

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 88

[mm]

The distribution of the residual strain alona x axis, for specimen A3.

THE

RESIDUAL

STRAIN

[Microstrain]

10

15

20
[mm]

25

30

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 89

The distribution of the residual strain along X axis, for specimen A5.

the

residual

strain

[Microstrain]

10

15

20
[mm]

25

30

THE DISTANCE FROM THE SPECIMEN AXIS

Fig. 90

The distribution of the residual strain along X axis, for specimen A 7 .

the

RESIDUAL

STRAIN

[Microstrain]

10

15

20

25

30

Fig. 91

THE DISTANCE FROM THE SPECIMEN AXIS [mm] The distribution of the residual strain along X axis, for specimen B 1 .

THE

RESIDUAL

STRAIN

[Microstrain]

THE DISTANCE PROM THE SPECIMEN AXIS Fig. 92

[mm]

The distribution of the residual strain along X axis, for specimen B2.

THE

RESIDUAL

STRAIN

[Microstrain]

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 93

[nun]

The distribution of the residual strain along X axis, for specimens Al, A3, A5, and A7.

THE

RESIDUAL

STRAIN

[Microstrain]

10

15

20
[mm]

25

30

THE DISTANCE FROM THE SPECIMEN AXIS Fig. 94

The distribution of the residual strain along X axis, for specimens B1 and B2.

CHAPTER 4

DISCUSSIONS

4.1

METALS MICROSTRUCTURE

The the

metal

microstructure

has been inspected in

welding zone for three different conditions [before

and after heat treatment (1) and (2)].

In the first condition, applying any kind of heat

after welding and before treatment, the Which metal means,

microstructure

is completely martensite.

that after welding has been completed,

the specimen has been

been cooled at room temperature and martensite has formed due to the fast cooling speed.

After microstructure percentage treatment. of The

heat becomes

treatment tempered due slow the to

(1),

the

metal with of leads low heat to

martensite this type rate and

feritte very of

cooling

transformation microstructure

martensite completely

the

metal

becomes

tempered martensite

with low percentage of feritte.

185

After heat treatment (2), the metal I microstructure consists of tempered martensite, ferrite, and precipitated carbide. This inspection demonstrates

that high temperature in heat treatment (2) and the very slow cooling rate, leads to this type of metal

microstructure. to separate

This slow cooling rate has given chance the carbide in and produce to ferrite the and

precipitated martensite.

carbide,

addition

tempered

These tempered improved

above results prove that the formation after heat treatment

of

martensite

(1) has hardness

the tensile strength and reduced the

in the welding zone by about 15 % when compared with the hardness significant precipitated would result the of under as welded was condition. the The most of the which [43]. the heat

observation carbide in

existence (2),

after heat treatment of

deterioration results show an

toughness that after

However, formation treatment

evidence carbide

the

precipitated

(2) has great effect on reducing the hardness

in the welding zone by about 40 % when compared with the hardness for as welded condition. The resulting hardness is only marginally metal. greater than the hardness in the decreased the

parent

However, this formation

186

tensile strength by tensile strength of

about the

10

% when compared with the under as welded

specimen

condition.

4.2

HARDNESS TESTING

The

hardness variation across the specimen

axis

has been measured for all at different

different types of specimens, for

depths from the specimen surface and [before

all three conditions

applying any kind of heat

treatment and after heat treatment (1) and (2)].

The welding produced has

results been

of

this testing a

show

that

after

completed,

hard

area

has been area

in and near the welding zone. measured from the

This hard

which has been

axis of the welding area

pass will be referred to as area (1), and the next

where the hardness has started decreasing to the edge of the specimen will be referred to as area (2).

Experimental results show that after welding hardness is increased to about 500 HV

the

in area (1), A3,

which extends between 8 and 10 mm for specimens A 1 ,

187

A5, A6, B2 .

and

A7;

between 15 and 19 mm for specimens A2, A4, to 5 mm for specimens B1 and

and A8; and between 3

After decreased

heat

treatment

(1), and

the

hardness

is area

to about 440 HV,

the width of this

[area (1)] is diminished by

about 1 to 2 mm.

After heat treatment to about 300 HV, and the

(2), the hardness is reduced width of this harder area

[area (1)] is diminished to about 3 to 5 mm.

Experimental area (2)

results

show

that the hardness in applying any

is between 265 - 270 HV before and about

heat treatment,

260 HV after heat treatment (2).

(1), and between 250 - 255HV after heat treatment These results demonstrate change in the that

there is no significant area of the welded

hardness in this three

component for all heat treatment).

conditions

(before

and after to the

This observation would apply 22, 23, 25, 26, 28, 29, 44, 46, 47, 48,

results shown in Figs. 34,

31, 32, 50, 51,

35, 36, 38, 39, 40, 42, 43, I 53, 54.

188

The results prove that

after

heat treatment (1)

the hardness in the welding zone is reduced by about 15% than that compared reduction is to the as welded condition. obtained by This heat

not as great as that These

treatment (2). from the

results coincide with the results tests which showed that the the

micro-structural has that been the

tempered martensite results emphasize

formed. large

Meanwhile, in

reduction

hardness after heat treatment (2) is in the welding zone where the resulting hardness is only slightly greater

than that of the parent metal and the hardness gradually reduced from area (1)to area show the (2). The results of heat

treatment (2) component

possibility of obtaining a welded in

with no significant variation in hardness

the specimen.

The

results of the hardness variation along that the

the

specimen axis, reveal all

hardness variation for before

different specimens is between 490 - 510 HV

applying any kind of heat treatment. And it is decreased to the range of 435 - 465 HV after heat treatment after heat treatment (2), (1).

Likewise,

the hardness is

189

reduced

to become between 290 - 320 HV. 30,

These

results

are shown in Figs. 24, 27, 55.

33, 37, 41, 45, 49, 52,

These results uniform along

show

that

the

hardness is about reduction of

the specimen axis

with a

about 15% in the hardness (1) and

after applying heat treatment (2) comparing

about 40% after heat treatment same

with the hardness for the

type of specimen before

applying any kind of heat treatment.

The

variation in the hardness has been from the

measured These

at different depths

specimen surface.

measurements have been made at two depths, 0.5 and 2 mm, for specimens that Al, A2, A3, and A 4 . The results show

the hardness is about the same in both situations, that hard area [area (1)] becomes

but the width of

smaller by about 1 to 2 mm at depth of 2 mm. The results of these measurements are shown in Figs. 56 to 59. Each

of these figures compare the hardness variation at depth of 0.5 and 2 mm for the same type of specimen.

In

specimens A5,

A 6 , A7,

and A8 the

hardness

variation has been measured at three different depths I from the specimen surface, at 0.5, 2.5, and 4.5 mm.

190

The results show that the all three

hardness is about the same at the

different depths, but that the width of [area (1)] reduces by about

hard zone depths

1 to 3 mm at

of 2.5 and 4.5 mm.

Also there is no significant variation at depths of 2.5 60 to

change between the hardness and 63. 4.5 mm.

These results can be seen in Figs.

In specimen Bl, the measured

hardness

variation has been The

for two different depths, 0.5 and 1.5 mm.

results show that there is

no significant change in the Fig. 64 shows a

hardness variation at these two depths. comparison between these results.

In

specimen B2 the hardness variation different depths,

has

been

measured for two

0.5 and 2.5 mm the

results show that the hardness is about the same but the width of the hard zone mm [area (1)] decreases by about 1 Fig. I 65 shows a comparison

in the depth of 2.5 mm.

between these results.

These

above results point out that the

hardness but

magnitudes are about the that the

same at different depths,

width of the hard zone [area (1)] is

greater

191

near the surface (at 1.5

depth

of 0.5 mm than at depths the

mm or more) due to the greater cooling rate at

top of the welded component.

Figs.

66 to 70 have

been

plotted

to study the hardness

effect of the thickness of the specimen on the variation. similar In these figures comparison

is made between the thickness.

specimens which differ only in

Theresults show that the area (1)becomes

hardness is about the same but the relatively thicker

greater in

specimens (A5, A6, A7, A8, and B2).

In terms of studying the effect of the bead width on the hardness variation, comparison between in similar

specimens which differ only carried out.

the bead width has been between The

In this comparison the difference mm from

the bead width were 5 results all for

the specimen axis.

show that there is no difference in hardness in but (A2, The area (1) extends by 2 to 4 mm A4, A6, and above A8) which have

these specimens, the specimens

greater bead widths. Figs. 75 to 78.

results

are shown in

192

Finally,

to study the effect of the bead length comparison between similar

on the hardness variation,

specimens which differ only in the bead length have been made. The results show that the hardness is about the

same but the width of the hard zone [area (1)] increases by upto 1 mm in the specimens which have greater bead Figs. 71 to 74 show these

lengths (A3, A 4 , A 7 , and A 8 ). results.

In these comparisons for parameters (thickness,

the effect of different length), the

bead width and

results prove that there is no significant difference in hardness variation and that there is only light

difference in the width of the hard zone.

4.3

TENSILE TESTING

Tensile testing has been carried out on different specimens, for three different conditions [before and

after heat treatment (1) and (2)].

Tables

3 and 4 show the tensile testing

results

for both types of specimens repair specimens). The

(build-up welding and crack results reveal that after

193

applying heat

treatment

(1),

the

tensile strength is

improved in most of these specimens when compared to the strengths treatment. of the specimens without any kind of heat

These results point out that heat treatment

(1) has a good affect in improving the tensile strength, which coincide with test and the results from the

micro-structural martensite strength.

the formation of the tempered in improving the tensile

hasa good effect

However,

the results

show

that the

tensile

strength is reduced after applying heat treatment (2) in all different types of specimens. These results are also substantiated by the of metallurgy test and the formation effect

the precipitated carbide has a deterioration strength.

on reducing the tensile made of

Comparison has been build-up welding

the tensile strength of the A1 and A 5 , A2

specimens,

and A 6 , A3 and A 7 , A4 and A 8 ,

which differ only in the thickness and the volume of the deposit strength metal. The results show that the tensile (A5, A6,

is greater in the thicker specimens

A 7, and A 8 ).

194

The

results also show that the tensile

strength

is slightly greater in widths (A2, A 4 , A 6 , and

specimens which have bigger bead A8).

Similarly,

the

tensile strength

is

slightly (A3,

greater in specimens which have larger bead lengths A 4 , A 7 , and A 8 ).

Comparison between crack repair specimens B1 B2 which differ only in the is no

and

thickness, shows that there tensile strength

significant difference in the The tensile strength

between them.

is only marginally

greater in specimen B1 than in specimen B2.

4.4

THE RESIDUAL STRESSES

As

mentioned have

in

the been

previous

chapter,

the

residual stresses (see show this Fig.

measured along the X axis the results stress in the

79) at three different points, value

that the greatest direction

of the residual

is about 72 N/mm2 at a point near specimen A3, and about 65

welding zone for

N/mm2 for

195

specimen in the

B1.

The residual stresses were not determined zone itself, which is expected to

welding

contain the greatest stress [42].

Figs. 81 to 86 show the distribution of ox and Oy and the principal the X residual stress omax and om ^n along which reveal

axis for two specimens A3 and Bl, stresses existed

that the residual and

as tensile stress,

the residual stresses decrease as the distance from

the welding zone increases.

The results of the residual stress

the

above

experiments show that the third

becomes negligible at

point along the X axis (near the edge of the specimen).

The above results show that the greatest value of the residual to stress be is about 72 N/mm2, to which the is

considered

small

compared

yield

strength of this type of metal which is about 350 N/mm2. However, in significant. In fatigue to loading indirectly such magnitude the may be

order

compare

relative

magnitude and distribution different

of the residual stresses for

specimens residual strains have been measured

by using a single strain gauge.

196

Different

diagrams

[Figs.

87 to 92] have

been

plotted to define the residual A5, A7,

magnitude and distribution of the

strains for these different specimens (Al, A3, Bl, value and for B2). The results show is that the near the

greatest

the residual strain residual

welding zone, and the

strains decrease as the

distance from the welding zone increases.

Comparisons between been made to demonstrate

these different results have the effect of different The in

variables of the specimens on the residual strains. results reveal that the residual strains are higher A7, and B2).

the thicker,specimens (A5,

Likewise, the

results show that the residual strains are higher in the specimens which have greater bead length (A3, and A5).

Figs. 9 3 and 94 show these results.

These

above comparisons prove that there in the

is

no

significant difference these different

residual strain between which have different

specimens

thicknesses and bead lengths.

197

CHAPTER 5

CONCLUSION & RECOMMENDATION

5.1

CONCLUSION AND RECOMMENDATION

This

project

gave

a good idea about

the

metal

microstructure of the all

welding

zone of AISI 410 metal in illustrated

different conditions. the

The results also

the variation in strength for

hardness

and magnitude of tensile different

all different specimens, in all

conditions.

On the basis of these the heat treatment (l) is

results it is apparent that more acceptable if the

mechanical strength is a critical parameter. However, the relatively higher hardness in the welding zone may not be desirable as distribution this may result in non-uniform stress this

in repaired zone.

The criticality of

variation in hardness may depend on the size and location of the repair in the component and also the type of

loading the component is designed for. strength is not critical then the

If the mechanical treatment (2)

heat

appears to be more desirable.

198

Before, however, any suggested further

final

recommendation can be is necessary. For

investigation

example, the relative impact resilience of as welded and i heat treated specimens need to be determined in order to suggest procedure the appropriateness of any heat treatment be

and also whether such heat treatment could

unnecessary for any size of weld repair.

On the present distribution was

investigation

the residual stress in a limited manner

determined only technique.

using stress relaxation gave

Such limited results near

only an indication of the magnitude of stress zone at locations transverse

the welding line.

to the weld

The stress variation around the weld line needs to

be determined in order to build a complete picture and to properly assess the effect of any constraint around the

welded zone. A better and accurate technique is to b p t use hole drilling method. The apparatus for this work technique

was not available for the

reported in this thesis. is

However, the apparatus has recently been procured and ready for use now.

The

following

may

be

concluded

from

this

investigation:

199

1 - The metal applying any

microstructure 'in the welding zone before kind of heat treatment is completely

martensite,

2 - The metal microstructure

becomes completely tempered

martensite after heat treatment (1).

After heat treatment (2), the metal of tempered

microstructure and

consists

martensite, ferrite,

precipitated carbide.

Harder zone exists in and near

the

welding

zone,

where the hardness is about 500 HV.

5 - The hardness the welding zone

is reduced

to

about 440 HV in and near

as a result of heat treatment (1).

6 - The hardness the welding zone

is decreased to about 300 HV in and near after applying heat treatment (2).

There is no significant change in the

hardness

in

area (2) after applying heat treatments (l) and (2).

200

There is no difference in the pattern depths,

of

hardness

variation at different

but the harder region is

wider near the specimen surface.

There is no significant change in variation in different

the

pattern but

of that in and

hardness

specimens,

harder region is wider for the thicker specimens, and those specimens which have greater bead widths

lengths.

10 - There is an improvement in the tensile strength after heat treatment (1).

11 -

The

tensile

strength

has

been

decreased

after

applying heat treatment (2).

12 - When the specimens have been tested for fracture tensile testing, the fracture

in

was outside area (1) in

all different specimens, for all different conditions.

13 -

The

results

demonstrate

that

there is a tensile

residual stress near the welding,

which decreases as the

distance from the welding zone increases.

201

14 - The highest value

forthe residual stress which is about 72 N/mma.

has

been recorded near thewelding zone

15- In all the the

experiments,

the

results emphasize that

stress value is about zero in the third point (25 mm

from the axis of the welding pass).

5.2

FURTHER WORK

In the next work the carried out :

following

points have to be

1 - Impact test should heat treated specimens.

be carried out on as

welded

and

- Residual stresses should be mapped around the welded

zone using more accurate hole drilling technique.

Effect

of

repeated

heat

treatment

should

be

evaluated.

- Effect of variation in heating / cooling rate should

be determined.

202

5 - Effect treatment.

of

the

variation

in

the

duration of heat

6 - Effectiveness of localised heat treatment.

Effect of weld size to specimen size ratio

on

the

residual stress.

203

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