Professional Documents
Culture Documents
WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, NOVEMBER 2008
Sponsored by the American Welding Society and the Welding Research Council
ABSTRACT. When the steel grade or carbon and low-alloy steels, the higher the More accurate welding procedures for
composition is unknown, the measure- preheat temperatures required (Ref.1). unknown steel grades can be developed by
ment of oxygen-cut surface maximum However, when the combined carbon and oxygen cutting the unknown steel at ambi-
heat-affected zone (HAZ) hardness can low-alloy contents are relatively high (5% ent or room temperature using standard
be an aid in developing or confirming re- maximum total content) for steels, the through-thickness oxygen-cutting set-
liable welding procedures. If the chemical nearly complete (90%) martensite trans- tings, by removal of the oxide scale from
analysis of a carbon or low-alloy steel is formation temperature for that steel can the oxygen cut surface and by making a
not available or is not practical to obtain, be below the preheat temperature and small or shallow hardness measurement
weld repair or new fabrication welding of subsequent interpass temperatures. If the on the steel to obtain the maximum hard-
a component made of an unknown grade preheat and interpass temperatures are ness of the oxygen-cut surface. Note that
of steel in the field or in the shop is haz- high relative to a low 90% martensite large indentation hardness measure-
ardous. A sequence of field or shop oxy- transformation temperature for that steel, ments, such as a 10-mm-diameter Brinell
gen-cut surface hardness measurements is substantial retained austenite in the HAZ impression, are not recommended be-
recommended to help ensure the success can occur. When the weldment cools, re- cause the maximum hardness of an oxy-
of this type of weld repair or fabrication. tained austenite can transform to marten- gen-cut surface is just below the thin (usu-
These procedures are for multibead weld- site to produce high residual tensile ally 0.004-in.-deep) decarburized layer
ments of cast and wrought steel compo- stresses and an increased probability of de- below the oxygen-cut oxide scale. This
nents more than 25 mm (1 in.) in thickness layed cracking. For example, the measured method is not presented to replace weld-
but do not take into account weld joint as-quenched hardness of steel, the re- ing procedures that take into account steel
complexity or hydrogen relief. The devel- ported 90% martensite transformation joint size and complexity or hydrogen re-
opment of minimum preheat tempera- temperature (M90), and the calculated car- lief where the steel grade, certified com-
tures and maximum interpass tempera- bon equivalent (CE) listed in Tables 1 and position, or check composition of the steel
tures was demonstrated by a Welder 2 were taken from actual data reported in is available. For example, weld repair of a
Training & Testing institute (WTTI) test Ref. 2. The grades of steels listed in Tables critical component that has failed in ser-
of the maximum oxygen-cut surface heat- 1 and 2 show that higher low-alloy compo- vice and cannot be immediately replaced
affected zone (HAZ) hardness of three sition content and higher carbon content with a spare component could rely on an
unknown grades of steels. (higher CE) result in higher as-quenched ambient oxygen-cut and maximum surface
hardness and a lower M90 temperature. hardness determination of potential re-
Introduction Steel grades listed in Tables 1 and 2 that are pair weldability. When the steel grade or
difficult to weld include AISI 4340, 1050, composition is unknown, the determina-
Although the weld applications of the 6150, 8660, and 4360. tion of oxygen-cut surface maximum HAZ
enclosed methods presented and dis- hardness can be an aid in developing or
cussed can be applied to new carbon and confirming reliable welding procedures.
low-alloy steel fabrications, these methods KEYWORDS These procedures do not apply to code-
are usually applied to weld-repair applica- welded steel applications where code-re-
tions and broken components provided Carbon Equivalent lated weld repairs are required. For exam-
that these are not components that re- Carbon Steel ples of code welding requirements, see
quire code weldments. In general, the Hardness Equivalent Refs. 3–7.
higher the carbon and alloy contents of HAZ
Low-Alloy Steel Experimental Procedures
R. W. HINTON is with R. W. Hinton Associates,
Center Valley, Pa., and R. K. WISWESSER is with
Martensite Transformation
Unknown Steel Grades In order to demonstrate the method of
Welder Training & Testing Institute (WTTI), Al-
lentown, Pa.
obtaining hardness equivalent (HE) weld-
WELDING RESEARCH
Fig. 1 — Line graph from least-squared fit of 90% martensite trans- Fig. 2 — Line graph from least squared-fit of 90% martensite trans-
formation temperatures vs. Jominy bar as-end-quenched Brinell hard- formation temperatures vs. carbon equivalents (CE) (Tables 1 and 2).
ness. (Table 1).
ing procedures proposed herein, three known steel samples. shallow, small hardness indentations on
grades of steel billets saw cut to 1-in. A welding instructor, with student ob- the oxygen-cut surface.
lengths. Accurate checks of chemical com- servers, oxygen-cut one sample from each After a number of shallow, small in-
positions of these three billets are listed in of the three grades of steel at ambient dentation hardness measurements were
Table 3. The hot-rolled AMS 6414 (modi- 1 temperature to produce two half pieces of made on the first surface, other shallow
fied AISI 4340) steel billet had 4 ⁄2-in. smooth 1-in.-thick steel. The oxygen-cut (0.004-in.-deep) grinds were made with a
square cross sections. The as-cast ASTM oxide scale on the surface was lightly flat grinder and additional hardness mea-
A36 and ASTM 616 Grade 60 billets had ground away. The oxygen-cut half-sample surements were made and tabulated.
5-in. square cross sections. These billet with a parallel uncut surface was placed in These hardness results were correlated
samples were “cold-stamp” identified as a Rockwell hardness tester. Rockwell A between the maximum oxygen-cut HAZ
A, B, and C and sent to the Welder Train- hardness was measured using a 60-kg load hardness converted to Brinell hardness
ing & Testing Institute (WTTI) as un- with a diamond Brale indenter to produce (Ref. 8) and the chemical carbon equiva-
(a, b, c) Reported compositions for carbon equivalents, maximum water-quenched end of bar hardness and 90% complete martensite transformation temperatures were
taken from Ref. 2. Steel compositions from Ref. 2 are listed in Table 2.
(d) CE = C+ (Mn + Si)/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15. Compositions from Ref. 2.
(e) CE = (end-quenched maximum BHN hardness equivalent) HEQ = (BHN-44)/667.
(f) M90 = 510°C - 0.45 (maxium as-end-quenched BHN).
(g) Minimum preheat temperature (PH) = 450°C √(HEQ–0.42) From Ref. 2 data.
(h) No metallurgical preheat was necessary to retard the HAZ cooling rate because the HEQ was below 0.47. A surface heat to 200°F to remove surface moisture is
recommended.
WELDING RESEARCH
Fig. 3 — Line graph from least-squared fit of carbon equivalents and Fig. 4 — Line graph from least-squared fit of carbon equivalents
Jominy bar as-end-quenched Brinell hardnesses (Tables 1 and 2). (CE) and maximum oxygen-cut HAZ Brinell hardnesses (Table 4).
lent for each grade. hesitation will produce a large prior austen- is to weld, especially at ambient tempera-
The same WTTI welding instructor ite grain size near the melted surface, will tures because of HAZ cooling rates. For
welded the three steel grades that were dissolve most of the carbides in this hot example, AISI 1020 (0.20% carbon con-
V-grooved from 1-in.-thick samples using zone, and upon rapid cooling as the oxy- tent) welds can be welded without preheat
the welding procedures, including inter- gen-cut goes further will transform this hot except to dry the surface of moisture with
pass and preheat temperatures, from the zone to martensite. Cooling transforma- a surface preheat of 200°F. In contrast,
correlation of maximum oxygen-cut tion diagrams for a variety of steels are AISI 1050 (0.50% carbon content) steel is
HAZ hardnesses and carbon equivalents. shown in Ref. 9. Similar HAZ behavior of difficult to weld and requires a relatively
The maximum interpass temperature base steel occurs when heated to a near- high preheat temperature throughout the
from the maximum oxygen-cut HAZ melting temperature near the molten weld base steel to reduce the cooling rate and
hardness was determined from the corre- metal except a lower cooling rate and lower potential hardness in the HAZ of the base
lation of Jominy bar as-quenched hard- HAZ hardness occurs when the base steel metal. A high preheat temperature re-
ness and 90% martensite completion is preheated prior to welding or during duces the hardness of the HAZ by reduc-
temperature (Table 1). multiple temper-bead welding. ing the cooling rate and the amount of
The basis for the correlation between hard martensite in the HAZ. The as-
maximum oxygen-cut HAZ hardness and Results water-quenched maximum hardness (Ref.
an estimate of weldability of the flame-cut 2) of various grades of steel subjected to a
steel with sufficient steel mass for cooling Steel Composition and Preheat Jominy bar end quench is listed in Table 1.
on either side of the oxygen-cut is the sim- for Welding In general, the Jominy bar as-water-
ilarity of the weld/base metal HAZ of this quenched maximum hardness is higher
same steel. A normal, smooth, oxygen-cut In general, the higher the carbon con- than the oxygen-cut surface maximum
through-thickness that progresses without tent in a steel, the more difficult the steel hardness of the same steel. The longer
(a) Compositions reported in Ref. 2 in percent by weight. Silicon contents were not reported except for 4360 (0.67 Si modified).
(b) CE = C + (Mn + Si)/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15 in percent by weight.
(c) — Element not reported in Ref. 2.
(d) Element concentration is higher than maximum specified for AISI grade.
WELDING RESEARCH
Table 3 — Check Compositions and Carbon Equivalents (CE) of Steels A, B, and C Studied in This Investigation
(a) Carbon equivalent (CE) = C + (Mn + Si)/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15.
(b) Modified.
(c) Concrete reinforcing bar specification.
WELDING RESEARCH
steels based upon the measured maximum
oxygen-cut surface HAZ hardness. The
certified chemical compositions and CE of Table 5 — Maximum Hardness of Base Steel Heat-Affected Zone (HAZ) Next to Fusion Line
these three steels are listed in Table 3. The
Steel Maximum HAZ Hardness, DPH(a) (BHN) Next to Weld
maximum oxygen-cut surface HAZ hard- A 321 (304)
nesses determined are listed in Table 4. B 222 (212)
When the CE from Table 3 is plotted C 242 (230)
(Fig. 4) vs. the maximum HAZ hardnesses
for each steel listed in Table 4, the good
,least-squared straight-line fit is as follows: (a) Measured diamond pyramid hardness (DPH) or Vickers hardness using a 500-g load on a polished and
etched cross section (Refs. 8, 11).
WELDING RESEARCH
austenite to martensite after the com- cooled to below the M90 (399°F) tempera- edge of a manufacturer’s certified compo-
pleted weldment has cooled. Therefore, ture and the multibead weldment was sition of the steel to be weld fabricated or
buttering or predepositing first-bead weld completed. weld repaired, a product check of the
metal on the base metal joint surface at a Steel A represents medium-carbon steel’s chemical composition may not be
high preheat temperature should be con- steel with substantial low-alloy content practical. In the absence of a confirmed
sidered on large multibead weldments. (Table 3) and a hardness equivalent of steel grade identification, a welding pro-
After the base metal surface is weld over- 0.95. The difficulty in welding this type of cedure can be developed for this unknown
laid, cool to below the 90% Martensite steel is demonstrated by the higher pre- steel by measuring the oxygen-cut surface
transformation temperature of the base heat temperature requirement compared maximum heat-affected zone (HAZ)
steel to complete the weldment. with the lower M90 temperature require- hardness equivalent (HE), by estimating
Example 2. Procedure when the esti- ment. In general, a CE or HE value of 1.0 temperature of the 90% martensite com-
mated M90 temperature is below the pre- represents the practical maximum of pletion transformation (M90) using the
heat temperature for a HAZ hardness of weldability. same oxygen-cut surface maximum HAZ
600 Brinell is as follows: hardness, and by estimating the minimum
HE = (600 + 54)/ 769 = 0.85 Steel B: (255 BHN HAZ max) preheat temperature (PH) from the hard-
M90 = 510°C – 0.45 (600) = 240°C HE = (255 + 54)/769 = 0.40 ness equivalent (HE). These welding pro-
(464°F) M90 = 510°C – 0.45 (255) = 395°C cedures should not be applied to weld re-
PH = 450°C √ (0.85 – 0.42) = 295°C (743°F) pair code-welded steel components.
(563°F) PH: Since HE is less than 0.47, no
preheat except moisture removal was re- Acknowledgments
Use the preheat temperature to make quired.
the first-bead weld deposits on the base
metal (butter the base metal) and then The Steel B weld joint base metal sur- The Welder Training & Testing Insti-
drop the temperature to below the M90 face was heated to above 200°F to remove tute (WTTI) is gratefully acknowledged
temperature to complete the multibead surface moisture before welding. Inter- for its management, staff, and welding in-
weldment. pass temperature was not restricted be- structor’s participation in the application
cause the M90 temperature was extremely of these proposed welding procedures on
Welding Unknown Steels A, B, and C high at 743°F. three unknown steels. Laboratory Testing,
Inc. (LTI), provided the certified check
Steels A, B, and C were welded in 1- Steel C: (420 BHN HAZ max) chemical compositions of these three
in.-thick single-V multibead joints using HE = (420 + 54)/769 = 0.62 steels.
the hardness equivalent (HE), the M90, M90 = 510°C – 0.45 (420) =321°C
and the preheat temperature (PH) weld- (610°F) References
ing procedures determined from the mea- PH = 450°C √ (0.62 – 0.42) = 201°C
sured maximum oxygen-cut HAZ hard- (394°F) 1. Funderburg, R. S. 1997. Fundamentals of
nesses. The A, B, and C compositions and preheat. Welding Innovation. 14(2).
carbon equivalents (CE) are listed in Steel C was preheated to 400°F and 2. United States Steel Corp. 1966. I-T dia-
Table 3. During this study, WTTI staff and multibead welded. Maximum interpass grams. Isothermal Transformation of Austenite in
the welding instructor doing the work did temperature was kept below 610°F. a Wide Variety of Steels. 3rd Ed. U.S. Steel Corp.
not know the compositions or grades of Transverse cross sections of Steels A, 3. American Welding Society (AWS)
Steels A, B, and C. Therefore, this weld- B, and C weldments were saw cut, ground, D1.1/D1.1M:2006, Structural Welding Code —
Steel. Section 3.5.2. (Table 3.2). pp. 58 and 66.
ing exercise was a blind test of measuring polished, and etched to show the etched
4. American Association of State Highway
the proposed oxygen-cut surface maxi- structure of the weld metal HAZ and base and Transportation Officials (AASHTO)/AWS
mum HAZ hardnesses and welding to the metal. The maximum hardness of the D1.5M/D1.5: 2008, Bridge Welding Code. C-
following welding procedures. Composi- HAZs next to the weld metal was mea- 12.14 Preheat and interpass temperature con-
tion carbon equivalents (CE) and oxygen- sured via diamond pyramid hardness trol, p. 387.
cut surface maximum HAZ hardnesses (DPH) or Vickers hardness with a 500-g 5. American Society of Mechanical Engi-
are listed in Table 4 for Steels A, B, and C. load using the standard load to indenta- neers, ASME Boiler Code, 2007. Section VIII.
The following welding procedures were tion geometry described in Ref. 11 and Division Appendix R: pp. 597–598. Section IX,
based upon the measurements of flame-cut converted to Brinell hardness (Ref. 8). pp. 66, 67.
6. ASME Power Piping B31.1, 2004. Para-
surface maximum HAZ hardnesses and the The three base metal maximum HAZ
graph 131.4, pp. 80, 81.
corresponding carbon equivalents of A, B, hardnesses that were measured next to the 7. ASME Process Piping B31.3, 2004. Para-
and C steels. The following welding proce- weld interface are listed in Table 5. graphs 300.2; 330. Table 330.11. Appendixes
dure designs were as follows: The multibead weldments of steel sam- A328.4, K330.
ples A, B, and C were all sound and the 8. ASTM International, 03.01 E140 (Tables
Steel A: (679 BHN HAZ max) maximum weld HAZ hardnesses listed in 1 and 2): 2008
HE = (679 + 54)/769 = 0.95 Table 5 were reduced by the preheat tem- 9. ASTM International. 1977. Atlas of
M90 = 510°C – 0.45 (679) =204°C peratures used compared with the oxygen- Isothermal Transformation and Cooling Trans-
(399°F) cut maximum HAZ hardnesses listed in formation Diagrams. 1st Ed., pp. 380–420.
10. Engineering staff, Skoda, Pilsen,
PH = 450°C √ (0.95– 0.42) = 328°C Table 4. The application of this alternative
Czechoslovakia. 1990. Private communication.
(622°F) welding procedure design was demon- 11. ASM International. 1948. Metals Hand-
Since a preheat of 622°F would produce ex- strated by these results. book, 1st Edition, pp. 93–100 (Tables VI, VII,
cessive radiant heat on the welding person- VIII).
nel located at the weld joint site, Steel A Conclusion
was preheated to 550°F and the base metal
joint surface was welded (buttered joint In the absence of knowledge of the car-
technique). The buttered Steel A was then bon and low-alloy steel grade or knowl-