Materials Behavior

Basic Regions of a Weld

Fusion Zone: area that

is completely melted

Heat-Affected Zone:
portion of the base metal
not melted but whose
mechanical
properties
and microstructure were
affected by the heat of
the joining process

Base Metal

Fusion Weld
Zone

Fig : Characteristics
of a typical
fusion weld zone
in oxyfuel gas
and arc welding.

Composite Zone Concerns

Grain Structure

(a)

(b)

Fig : Grain structure in (a) a deep weld (b) a shallow weld. Note
that the grains in the solidified weld metal are perpendicular to
the surface of the base metal. In a good weld, the solidification
line at the center in the deep weld shown in (a) has grain
migration, which develops uniform strength in the weld bead.

Solidification of
Weld metal
Solidification begins with formation of columnar
grains which is similar to casting
Grains relatively long and form parallel to the
heat flow
Grain structure and size depend on the specific
alloy
Weld metal has a cast structure because it has
cooled slowly, it has grain structure
Results depends on alloys ,composition and
thermal cycling to which the joint is subjected.
Pre-heating is important for metals having high
thermal conductivity

Weld Beads

(a)

(b)

Fig : (a) Weld bead (on a cold-rolled nickel strip) produced by a

laser beam. (b) Microhardness profile across the weld bead.
Note the lower hardness of the weld bead compared to the
base metal.

Heat affected Zone

Heat effected zone is within the metal itself

Properties depend on:

Rate of heat input and cooling
Temperature to which the zone was raised
Original grain size ,Grain orientation , Degree of prior
cold work

The strength and hardness depend on:

how original strength and hardness of the base metal
was developed prior to the welding.
Heat applied during welding which Recrystallises
elongated grains of cold worked base metal.

Weld Quality
Welding discontinuities can be caused by inadequate
or careless application
The major discontinuities that affect weld quality are
Porosity
Slag Inclusions
Incomplete fusion and penetration
Weld profile
Cracks
Lamellar tears
Surface damage
Residual stresses

Cracks
Cracks occur in various directions and various
locations
Factors causing cracks:
Temperature gradients that cause thermal stresses in
the weld zone
Variations in the composition of the weld zone.
Embrittlement of grain boundaries
Inability Of the weld metal to contract during cooling

Cracks

Fig : Types of cracks (in welded joints) caused by thermal stresses that
develop during solidification and contraction of the weld bead and
the surrounding structure. (a) Crater cracks (b) Various types of
cracks in butt and T joints.

Cracks
Cracks are classified as Hot or Cold.

Hot cracks

Occur at elevated temperatures

Cold cracks

Occur after solidification

Basic crack prevention measures :

1.Change the joint design ,to minimize stresses
from the shrinkage during cooling
2.Change the parameters,
sequence of welding process

procedures,

the

3.Preheat the components to be welded

4.Avoid rapid cooling of the welded components

Cracks in Weld Beads

Fig : Crack in a weld bead,

due to the fact that the
two components were
not allowed to contract
after the weld was
completed.

Perils of Welding Free-Machining Steels

Solidification cracking
due to impurity
elements

Sulfur, phosphorus,
boron

Impurity segregation at
weld centerline creates
low ductility area

Combines with shrinkage

stress to cause cracking

Manganese Can Prevent Solidification

Cracking

Manganese combines with sulfur to form MnS

particles
Use a filler metal with higher manganese to absorb
sulfur

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Residual Stresses:
Caused because of localized heating and cooling
during welding, expansion and contraction of the
weld area causes residual stresses in the work
piece.

Effects:
1.Distortion,Warping and buckling of welded parts

2.Stress corrosion cracking

3.Reduced fatigue life

Distortion after Welding

Fig : Distortion of parts after welding : (a) butt joints; (b) fillet
welds. Distortion is caused by differential thermal expansion
and contraction of different parts of the welded assembly.

Stress relieving of welds :

Preheating reduces problems caused by
heating the base metal or the parts to be
welded

Heating can be done electrically, in furnace or by OAW

torch and for thin surfaces by radiant lamp or hot air
blast.

Some other methods of stress relieving :

Peening, hammering or surface rolling