Defence Technology 14 (2018) 188e195

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Defence Technology
journal homepage: www.elsevier.com/locate/dt

Influence of welding consumables on tensile and impact properties of

multi-pass SMAW Armox 500T steel joints vis-a-vis base metal
Ambuj Saxena a, A. Kumaraswamy a, *, G. Madhusudhan Reddy b, Vemuri Madhu b
a
Defence Institute of Advanced Technology (DU), Pune 411025, India
b
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad 500048, India

a r t i c l e i n f o a b s t r a c t

Article history: In this investigation, comparative study of tensile and impact properties of multi-pass SMAW Armox
Received 29 October 2017 500T steel joints fabricated by austenitic stainless steel (ASS) and low hydrogen ferritic steel (LHF)
Received in revised form consumables vis-a-vis base metal was carried out. The tensile tests were conducted on computer
11 January 2018
controlled Walter þ Bai Ag UTM at a nominal strain rate of 103 s1. Subsequently, charpy impact tests
Accepted 18 January 2018
Available online 31 January 2018
were carried out on an instrumented Zwick-Roell test setup to obtain load vs. displacement and
maximum energy absorbed vs. displacement of the specimen. It was observed that, the joint efficiency of
weldment processed by LHF consumable was 41.7% and weldment processed by ASS was 30.6% of its base
Keywords:
Armox500T
metal indicating the influence of electrode consumable on tensile properties of the joints. On the con-
Multi-pass SMA welding trary, impact toughness of weldment processed by ASS was 20% more and weldment processed by LHF
ASS and LHF welding consumables was 12% less than that of base metal. Microstructural studies also revealed that, ASS can be considered as
Mechanical properties a candidate welding consumable for good strain hardening and toughness of the welding joint in impact
Microstructural characterization applications. However, LHF steel consumable is recommended for welding joints that requires higher
joint efficiency under tensile loading conditions.
© 2018 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction A number of welding processes are available to fabricate high

Armor steels are widely used in building civil and military
structures such as battle tanks, armored vehicles, helicopter com-
ponents etc. Armor steels possess high density with excellent
mechanical properties i.e. ultra-high strength and high hardness to
resist penetration against projectiles and shaped charge threats.
Armox 500T steel is one such quenched and tempered steel having
martensitic structure subjected to high loading rates in applications
such as ballistic impact, collision, detonation etc. [1e3]. Shielded
metal arc welding (SMAW) process is widely used for joining of
armor steel plates in the fabrication of turret and ship hulls, landing
gears, earth moving, mining equipment, mortar casings, armored
personnel carrier, cash in transit vehicle, patrol vehicle etc.
Quenched and tempered steel SMA weldments must be of good
quality especially when used for construction of combat vehicles in
military applications [4].
* Corresponding author. Department of Mechanical Engineering, Defence Insti-
tute of Advanced Technology (DIAT), Girinagar, Pune 411025, India.
E-mail address: akswamy@diat.ac.in (A. Kumaraswamy).
Peer review under responsibility of China Ordnance Society.
strength armor steel structures; however, SMAW is commonly used
for joining of thick steel sections due to less cost and easy avail-
ability of the equipment [5]. Austenitic stainless steel (ASS) and low
hydrogen ferrite (LHF) steel welding consumables (electrodes) are
commonly used for SMAW of quenched and tempered steels to
prevent hydrogen induced cracking (HIC), as they have higher
solubility for hydrogen in austenitic phase. Further, ASS consum-
able as filler metal is used in welding of heavy structures in ship
building, pressure vessels and heavy vehicles to obtain good impact
properties along with adequate strength. Magudeeswaran et al.
performed shielded metal arc welding (SMAW) and flux cored arc
welding (FCAW) using austenitic stainless steel (ASS) and low
hydrogen ferrite (LHF)steel welding consumables for joining of
quenched and tempered steels [6e9]. The weldments were used to
investigate the transverse tensile, impact and dynamic fracture
toughness properties and hydrogen induced cold cracking in
welding joints. Results revealed that, the joints fabricated using LHF
steel electrodes have superior transverse tensile properties and the
joints fabricated by ASS electrodes exhibited higher impact
toughness and superior dynamic fracture irrespective of welding
process used. In addition, ASS welds made out of FCAW process

https://doi.org/10.1016/j.dt.2018.01.005
2214-9147/© 2018 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
 A. Saxena et al. / Defence Technology 14 (2018) 188e195
offered a higher resistance to hydrogen induced cracking. Datta
et al. [10,11] presented the weldability properties of ASTM A 537 C l.
1 pressure-vessel quality steel and 20 mm thick O SA 517 Gr. F steel
plates using single pass and multi-pass SMAW process respectively
with AWS A5.5 E11018 M (LHF) consumables. Results from previous
investigations reveal that, single pass welded joint was found to
possess adequate strength, impact toughness and meet the MSTS
requirements for ASTM A 537 C l. 1 steel and the impact toughness
of the parent material was superior to that of multi-pass weld zone
and heat affected zone (HAZ) at all test temperatures. Reddy et al.
[12,13] revealed in their investigation that, SMAW joint efficiency of
ASS filler metal deposits was found to be around 72% of its coun-
terpart high-strength low-alloy steel base metal. In addition, the
weld deposits exhibited good toughness and better ballistic per-
formance. Lakshminarayanan et al. [14] studied the effect of SMAW,
GMAW and GTAW processes on tensile and impact properties of
AISI 409 M grade steel using duplex stainless steel consumables.
They have observed that, GTAW ferritic stainless steel joints have
superior tensile and impact properties compared to SMAW and
GMAW joints. Bott and Teixeira [15] investigated the influence of
multiple post weld heat treatment (PWHT) on mechanical prop-
erties of quenched and tempered BS7191 Grade 450EM steel
(0.10 wt%C-1.08 wt%Mn) and its ferritic multipass SMA weldments
prepared by AWS E-9018 M type electrode. Results revealed that,
the base metal was affected by PWHTs and presented a brittle mode
of fracture and this tendency tends to increase with increasing
numbers of cycles. Further, the weld metal Charpy V-notch
toughness showed lesser reduction than the base metal after
extended PWHT.
From the above discussions, it is clear that, welding consum-
ables and welding processes have considerable effect on the per-
formance of quenched and tempered steel joints that are specially
used in military applications. Further, the data on tensile and
impact properties of multi-pass SMAW Armox 500T joints fabri-
cated by ASS and LHF welding consumables is seldom available in
the literature. In order to fill up this knowledge gap albeit partially
and in view of importance of this data in the design of structures,
the present investigation is oriented towards understanding the
effect of these consumables on transverse tensile and impact
properties of multi-pass SMAW Armox 500T steel joints in com-
parison with its base metal. Further, microstructural characteriza-
tion and fractographic analysis of test materials is also carried out
and feasibility of using LHF over ASS welding consumables for
joining of Armox 500T structures is suggested.
2. Experimental details
2.1. Welding of Armox500T plates e sample preparation
As received Armox500T steel was water quenched from 1273 K
and tempered in the range of temperatures 473e773 K. Prior to
quenching and tempering the steel was hot rolled at 1523 K. Test
plates measuring 150  200  25 mm were carefully machined and
butt-welded by shielded metal arc welding (SMAW) with five
welding passes using two different electrodes i.e. austenitic stain-
less steel (ASS) consumable and low hydrogen ferrite (LHF)as
shown in Fig. 1 (a). The welding process parameter details are given
in Table 1. Tensile test and charpy impact test samples were wire cut
from Armox500T steel plate in rolling direction (hereafter referred
to as base metal) and fusion zone of two weldments in the
configuration shown in Fig. 1(b). The smooth (un-notched) tensile
specimens as shown in Fig. 1(c) were prepared to evaluate yield
strength, UTS and ductility of joints. Notched tensile specimens as
shown in Fig. 1 (d) were prepared to evaluate notch tensile strength
and notch strength ratio of the joints. The geometry of charpy
189
impact test samples is as shown in Fig. 1 (e). Weldments produced
by low hydrogen ferrite (LHF) and austenitic stainless steel (ASS)
consumable electrodes are referred to as weldment-1 and
weldment-2 respectively. In order to ensure the repeatability and
consistency, three samples were tested for tension and impact as
described in the following sections.
2.2. Tension test
The tensile test samples as described under section 2.1 were
pulled to fracture at a nominal strain rate of 103 s1 on a computer
controlled Walter þ Bai Ag UTM. The load-extension data was
converted to engineering stress-strain andtrue stress-true plastic
strain (s-ε) data.
2.3. Charpy impact test
The Charpy impact test was performed on an instrumented
Zwick-Roell test setup. The experimental setup consists of anvils on
which the standard notched specimen (Fig. 1 (e)) prepared as per
ASTM, E23 [16] is freely supported and a pendulum with a mass of
30kg attached to a rotating arm pinned at the machine body. The
span length between the anvils was kept at 40mm.The released
pendulum hammer follows a circular trajectory and hits the test
specimen at the middle span at a striking velocity of 5.23 m/s thus
transferring kinetic energy to it. Energy losses due to bearing fric-
tion and air resistance have been ignored while calculating the
energy absorbed by the specimen. The impact test data was ob-
tained in terms of load vs. displacement as well as the maximum
energy absorbed vs. displacement of the specimen.
2.4. Microstructural characterization
The standard metallographic technique was used to prepare the
sample for microstructural characterization of test samples. Solu-
tion made of 1 gm picric acid, 5ml HCl and 100ml ethanol was used
for etching of base metal for 15s and weldments for 25s. Optical
microstructures were taken from semi-automatic microscope
(Make: Leica Microsystems) and back scattered SEM images (20kV
electron high tension) have been taken from Gemini SEM Sigma
(Make: Zeiss).
3. Results and discussion
3.1. Microstructural observations
The back scattered SEM image and optical micrograph of the
base metal, weldment-1 and weldment-2 are shown in Fig. 2(aeb),
Fig. 3(aeb) and Fig. 4(aeb) respectively. The chemical composition
(wt. %) determined by EDX method is given in Table 2. The detailed
microstructural observations from SEM and optical microscope are
given in the following sections.
3.1.1. Armox500T steel (base metal)
Back scattered SEM image of Armox500T steel (Fig. 2 (a)) in-
dicates tempered martensite lath in acicular form with coarse and
fine precipitate along with some grain boundaries. On the other
hand, the optical micrograph of Armox500T (Fig. 2 (b)) shows the
presence of columnar laths and blocks of laths. Pandey et al. [17]
and Li et al. [18] have highlighted that, mechanical properties are
structure sensitive and they vary with the amount and distribution
of phases like retained austenite with martensite. Therefore, in the
present work, micrographs with higher magnification were used
for closer identification of precipitation. Amount of retained
austenite will reduce the tendency of cracking. Further, the retained
190 A. Saxena et al. / Defence Technology 14 (2018) 188e195

Fig. 1. (a) Schematic of SMAW Joint, (b) Test Samples wire cut from Fusion zone, (c) Tensile test sample, (d) Notched tensile test sample, (e) Charpy impact test sample (All di-
mensions are in mm).

Table 1
SMAW welding process parameters.

Weldment-1: Low hydrogen ferrite (LHF) consumable electrode -AWS A5.1 E7018

No. of passes Filler material diameter/mm Current/A Voltage/V Welding speed/(mm$min1) Heat input/(kJ$mm1)

1 3.2 78 18 100 0.84

2 4 115 20 120 1.15
3 4 100 20 115 1.04
4 4 110 20 126 1.04
5 4 110 20 130 1.01

Weldment-2: Austenitic stainless steel (ASS) consumable electrode -AWS A5.4 E308-16

1 2.4 80 26 100 1.24

2 4 120 28 115 1.75
3 4 155 28 120 2.17
4 4 155 28 125 2.08
5 4 150 28 130 1.93

austenite may get transformed to bainite or martensite, which was
clearly observed in micrographs of parent materials. Further, opti-
cal micrograph is showing white etching wedge-shaped widman-
statten ferrite plates in a matrix quenched to martensite. These
plates are coarse (notice the scale) and etch clearly because they
contain very little substructure. It is evident through strain hard-
ening and uniformity in strain distribution as seen in Fig. 5.
3.1.2. Weldment-1 (processed using LHF consumable electrode)
Back scattered SEM image and optical micrograph of weldment-
1 (Fig. 3 (aeb)) indicatessound and clear welding jointwith no voids
and micro-cracks. Nucleation and growth tendencies are influenced
by chilling action of the parent metal and gives variable grain size
(dendritic size) within the weld. The microstructure of weldment-1
is mainly acicular ferrite associated with second phase containing
widmanstallen and bainite phase without martensite [10,19e21].
This type of microstructure containing large colony size and
oriented laths is undesirable in welding because it offers little
resistance to crack propagation [22e25]. Presence of low carbon
martensite clearly distorted by presence of C content i.e. the axial
ratio of its unit cell is almost unity. Under this condition, the system
tries to reduce its energy to the maximum level and hence the
phase separation occurs at the interfaces having similar atomic
spacing. Since, these phases cannot migrate to the grain bound-
aries; they get separated inside the grains. In addition, the acicular
ferrite microstructure (Fig. 3 (a)) also consists of small particles of
intergranular nucleated ferrite without any particular orientation.
Thus, the resulting small effective grain size and lack of orientation
makes acicular ferrite a desirable weld microstructure with excel-
lent mechanical properties compared to weldment-2 as described
in the following section.
3.1.3. Weldment-2 (processed using ASS consumable electrode)
Back scattered SEM image and optical micrograph of weldment-
 A. Saxena et al. / Defence Technology 14 (2018) 188e195 191

Fig. 2. Armox500T base metal (a) Back scattered SEM, (b) Optical micrograph.

Fig. 3. Weldment-1 (a) Back scattered SEM, (b) Optical micrograph.

Fig. 4. Weldment-2 (a) Back scattered SEM, (b) Optical micrograph.

Table 2
Chemical composition (wt. %) of test samples under investigation.

Material C Si Mn P S Cr Ni Mo N B Fe

Base metal 0.31 0.265 0.86 0.019 0.007 0.60 0.82 0.24 e 0.005 Balance
Weldment-1 0.06 0.58 0.85 0.017 0.012 0.04 0.03 0.015 0.018 e Balance
Weldment-2 0.05 0.51 1.18 0.018 0.06 18.03 9.45 0.04 e Balance
192 A. Saxena et al. / Defence Technology 14 (2018) 188e195
Fig. 5. (a) Engineering stress-strain and (b) True stress- True Plastic strain.
2 (Fig. 4 (aeb)) mainly composed of martensite and partially d-
ferrite phase. In general, coarse grained or mixed grain size struc-
ture obtained by fast heating and cooling in the weld region causes
the properties of the weld region to be completely different from
the properties of the parent metal.In addition, residual stresses are
developed in the weld region due to high hardness martensite
formation resulting from rapid cooling of the weld zone. The grain
size changes from coarse to fine with decrease in temperature.
Therefore, it is recommended to do annealing for stress-relieving
and recrystallization to increase the life of weld region
[11,22,26,27]. The amount of delta-ferrite was estimated using Cr
and Ni equivalents [26] of weld metal chemical composition. Cr and
Ni equivalents are found to be 22 and 10.5 respectively and based
on the Schaeffler diagram, about 20 (vol. %) ferrite was expected to
exist in the austenitic matrix.
3.2. Effect of welding consumables on tensile and impact properties
Tensile tests were carried out for base metal and weldments as
described under section 2.2. The load vs. elongation data was
converted to engineering stress-strain and subsequently true stress
vs. true plastic strain (s-ε) data as shown in Fig. 5 (a) and (b). The
strain hardening index, n was estimated using a relation s ¼ Kεn,
where K is strength coefficient, s and ε are the flow stress and true
plastic strain respectively. The tensile properties such as yield
strength, ultimate tensile strength, n, K, % elongation, notch tensile
strength, notch strength ratio and joint efficiency of base metal and
weldments are presented in Table 3. The UTS or in other words joint
efficiency of weldment-1 and weldment-2 was observed to be 41.7
and 30.6% of its base metal respectively indicating the influence of
electrode consumable used in SMAW welding process on tensile
properties of the test materials. During tensile test, all the speci-
mens (joints) were found to fracture in the weld region only. Thus,
it may be assumed that, the UTS data presented in Table 3 are
primarily the ultimate tensile strength of the welded joint. From
the comparison of results, it is noted that, the use of LHF steel
consumable for welding of test materials has enhanced the
Table 3
Tensile and Impact properties of test samples under investigation.
Material Yield strength/MPa UTS/MPa K/MPa n Elongation
/%
Base Metal 1268 1680 2563 0.12 14
Weldment-1 454 700 1185 0.15 28
Weldment-2 334 515 940 0.22 36
transverse tensile properties of the joints compared to ASS
consumable.
The microstructure of fusion zone of weldment-1 (Fig. 3 (a)) is
mainly acicular ferrite associated with second phase containing
widmanstallen and bainite phase without martensite [10,19e21].
Small interweaving ferrite plates formed within austenite grains
transforms during the cooling of low alloy steel weld deposits re-
sults in a good combination of strength and toughness. Therefore,
this is considered to be desirable structure in low carbon steels in
view of its commercial importance [28]. Weldment-1 with acicular
ferrite in which each lath is divided by high boundary angle dis-
playing fine grain size (typically 1e3 mm) [29] usually possesses
high tensile strength compared to weldment-2 as given in Table 3.
The microstructure of fusion zone of weldment-2 (Fig. 3 (b)) shows
skeletal d-ferrite in a plain austenitic matrix. Presence of high Ni
(9.45%)in weldment-2 balances the austenitic structure against the
formation of martensite [30].
The load-displacement curves obtained from the instrumented
charpy impact test are not smooth because of serrated oscillations
present in the data points. Therefore, data points were smoothened
by method of moving averages [31]. Load vs. displacement andE-
nergy vs. displacement curves are plotted as shown in Fig. 6 (a) &
(b) respectively. Results indicated that, in case of weldment-2, the
crack initiation at notch occurred before general yielding and in
case of base metal and weldment-1, the same occurred at the peak
load without general yielding. It is known that, Ni content in-
fluences the formation of austenitic phase (high impact toughness)
and reduction of the ferrite content (increased brittleness) in the
fusion zone compared toweldment-1 possessing very small content
of Ni (0.03%). It is evident from Table 3 that, impact toughness of
weldment-2 (9.45% Ni) is 20% more than its counterpart base metal
(0.82% Ni); on the other hand, impact toughness of weldments-1
(0.03% Ni) is 12% less than that of base metal.
3.3. Fractrography
SEM Fractrography images of Armox 500T base metal,
Notch tensile strength/MPa Notch strength ratio Joint efficiency Internal energy/J
/%
2200 1.30 e 56.91
900 1.28 41.7 51.16
637 1.23 30.6 67.66
 A. Saxena et al. / Defence Technology 14 (2018) 188e195 193

Fig. 6. (a) Load vs. Displacement and (b) Energy vs. Displacement.

Fig. 7. SEM Fractrography images of Armox 500T base metal.

Fig. 8. SEM Fractrography images of Weldment-1.

weldment-1 and weldment-2 are shown in Fig. 7(aeb), Fig. 8(aeb)
and Fig. 9(aeb) respectively. Fractrographic analysis of base metal
indicates that, the zone under the notch and the sphere along the
edges of the test specimen, only ductile dimple fracture mostly of
shear character was present. This type of failure mechanism in the
base metal is considered as trans-crystalline ductile. On the other
hand, fractrograph of weldment-1 shows mainly ductile fracture
with bimodal morphology (combination of coarse and fine dim-
ples) with pores and voids, whereas ductile fracture with uniformly
distributed dimples was observed in case of weldments-2.
4. Feasibility of LHF over ASS consumables for joining of
Armox 500T steels
The weldment-2 produced by ASS consumable has a duplex
microstructure consisting of delta ferrite in a plain austenitic ma-
trix (Fig. 4(aeb)) and weldment-1 fabricated by LHF consumable
produces an acicular ferrite structure (Fig. 3(aeb)). This acicular
194 A. Saxena et al. / Defence Technology 14 (2018) 188e195
Fig. 9. SEM Fractrography images of Weldment-2.
ferrite microstructure influences superior tensile properties i.e.
yield strength, UTS, strength coefficient, notch strength ratio and
joint efficiency as presented in Table 3 compared to weldment-2.
However, it is interesting to note that, weldment-2 showed supe-
rior impact toughness compared to weldment-1. Recent studies on
hydrogen induced cracking (HIC) of quenched and tempered armor
steel welds with LHF and ASS consumables [32] demonstrated that,
the measured diffusible hydrogen level in two consumables is
much lower than the maximum level permitted in the boiler
pressure vessel codes of the American Society of Mechanical En-
gineers [33] and further revealed that, there was no evidence of
delayed cracking (owing to HIC). Thus, the LHF consumables can be
accepted as an alternative to the conventional ASS consumables for
joining of Armox 500T steels particularly in defense applications.
5. Conclusions
1) The joint efficiency of weldment-1(processed by LHF) and
weldment-2 (processed by ASS) was observed to be 41.7 and
30.6% of its base metal respectively indicating the influence of
electrode consumable on tensile properties of the joints.
2) Impact toughness of weldment-2 (9.45% Ni) is 20% more than its
counterpart base metal (0.82% Ni); on the other hand, impact
toughness of weldments-1 (0.03% Ni) is 12% less than that of
base metal. This indicates that, Ni content influences the impact
toughness of test materials.
3) The failure mechanism in base metal was observed to be trans-
crystalline ductile. On the other hand, fractrograph of
weldment-1 shows mainly ductile fracture with bimodal
morphology with pores and voids, whereas in case of
weldments-2, ductile fracture with uniformly distributed dim-
ples was observed.
4) The feasibility study as described under section 4 indicates that,
the LHF consumables may be accepted as an alternative to the
conventional ASS consumables for joining of Armox 500T steels
particularly under tensile loading conditions. However, vice
versa is true for impact applications.
Acknowledgements
The authors are grateful to Vice Chancellor, DIAT (DU), Pune for
permitting to publish this paper in the journal. The authors are also
thankful to Director, DMRL, Hyderabad for extending the facilities
for conducting a number of experiments. Acknowledgements are
also due to scientists and technical staff of Armor division, Metal
Joining Group, DMRL, Hyderabad.
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