WELDING OF STAINLESS STEEL

G. CHOWDHURY Prof. (Met)

STAINLESS STEELS
Stainless steels are iron-carbon alloys enough amount of Chromium (a minimum of 12.2%) to impart anti-corrosive property Anticorrosive in oxidising environments Not very suitable in reducing environments Property due to formation of passive impervious complex Iron-Cr Oxide film

CLASSIFICATION
Based on microstructure at room temperature stainless steels are classified in three major groups. STAINLESS STEEL Austenetic Martensitic Ferritic

RECENT USES OF STAINLESS STEEL IN INDIAN RAILWAY

S No Class of Steel C% Cr % Composition Ni % Others Application

409M (Ferritic)

0.08

10.5-11.75 -

Ti- 6 X C

304 (Austenitic)

0.08

18-20

8-12

301 (Austenitic)

0.15

16-18

6-8

M- 44 (Ferritic)

0.03

10.8- 12.5

Ti- 0.75 (Max)

Side wall & End wall of LHB Coach Side wall below window of EMU, Underframe & Side wall below window of All SSEMU Roof and trough floor of LHB Coach, trough floor roof and side panel above window of all SS EMU, Break pipe of EMU. Trough floor , vendor compartment deck sheet, inside panelling, partition wall, drivers cabin etc. of EMU Side wall , floor, Extension, Side Sil and Centre Sil of BOXN CR wagon.

Various Types of Stainless Steel Ferritic Stainless Steel

Very low carbon About 11-30% chromium. Micro structure contains ferrite Magnetic in nature Remains Ferritic from RT to MP Do not respond to heat treatment Prone to grain growth if heated above 9500C. Possess good ductility. Very good corrosion resistance property Suitable for low temperature use.

Various Types of Stainless Steel Martensitic Stainless Steel Higher amount of carbon (0.2% - 1.2%). 11-18% chromium Can be hardened by heat treatment Contains martensite in the micro structure Extensive usage because of resistance to: Wear Oxidation & Corrosion.

Various Types of Stainless Steel

Austenitic stainless steel Carbon 0.03% to 0.1% Chromium 18-30% & Nickel 5-20% By far the most important group wrt Tonnage of use Variety of application Many varieties with varying composition & properties are available in market.

Various Types of Stainless Steel

Austenitic stainless steel
Microstructure contains mainly austenite Sometimes ferrite is present in small amount Remains Austenite from RT to MP Non-magnetic Possess highest corrosion resistance of all Some grades have very good strength & Scale resistance at higher temperature. IS 9511 covers various grades of Ferritic, Martensitic & Austentic stainless steel plates, sheets & strips for common use.

Weldability of Stainless Steel

Basic problems in welding SS Low thermal & electrical conductivity High Co-efficient of expansion So, during welding SS exhibits Higher tendency of warpage Higher incidence of weld cracking Apart from these, SS welding has other problems related to different phase formations during the thermal cycle Relative weldability of different grades vary

COMPARATIVE PHYSICAL PROPERTIES OF STAINLESS STEEL & CARBON STEEL

Property Martensitic Ferritic Austenitic Carbon Steel

Thermal Conductivity Cal/sec.cm C/cm

0.059

0.049

0.033

0.104

Coefficient of Expansion m/m/C

11.2

11.2

18.2

13.2

Electrical Resistivity /cm

58

60

70

15

Melting Range C

1483-1532

1427-1510

1398-1454

1538

Weldability of Ferritic Stainless Steel Problems specific to Ferritic SS

Excessive grain growth

Sigma phase formation 475 embrittlement Sensitization or Weld Decay

Weldability of Ferritic Stainless Steel

Remedies: Excessive grain growth:
Restrict heat input, Restrict inter pass temperature 1500C

Weldability of Ferritic Stainless Steel

Sigma Phase Formation Slow heating/ cooling in the range of 500 9000C, formation of sigma phase Iron- Chromium inter metallic hard and brittle

Remedy Avoid slow cooling in that temp. range

Weldability of Ferritic Stainless Steel

475 embrittlement Slow heating on the range of 400 5400C Formation of chromium rich zone along certain crystallographic plane. Remedies A post weld heat treatment at 7900C i.e. below the grain coarsening temperature, followed by furnace cooling to 6500C, then rapid cooling to 4000 is beneficial. Matching filler wire or fully austenitic filler wire (25/20 type) may be used.

Weldability of Ferritic Stainless Steel

Sensitisation Slow heating/cooling or holding at temp. range of 700-9000C, Chromium Carbide precipitates along GB Depletion of chromium in neighborhood area. Corrosion resistance property of that area is destroyed or decayed Corrosion at GB in corrosive atmosphere. Also known as Weld Decay or Knife edge cracking

Weldability of Ferritic Stainless Steel

Remedies: To use extra low carbon steel To use stabilized base metal & electrode Solution treatment. For welding thin sheet using ductile Austenetic SS filler metal, preheating & post weld heat treatment is not generally required.

Weldability Martensitic of Stainless Steel

Least weldable amongst all stainless steel types Hardened HAZ susceptible to crack formation. Preventive measure * Preheating to 150-2500 C * Post weld heat treatment at 750-8000 C * Furnace cooling to 5900 C * Rapid cooling Matching filler wire,13Cr type or austenitic filler wire (23/12, 25/20 type) may be used. Welding of MSS is practically nil in Railways.

Weldability of Austenitic Stainless Steel

Most readily weldable amongst all SS No pre-heat or post weld heat treatments are generally required. However following problems are encountered Microfissuring or Solidification cracking. Sigma phase formation. Sensitisation or Weld decay

Weldability of Austenitic Stainless Steel

Solidification cracking Poor solubility of impurities like Phosphorus, Boron, Sulphur, Selenium, Silicon etc in austenite Segregate along GB during solidification GB becomes weaker Tendency to develop cracks i.e. microfissures under solidification stress. Remedy By producing some ferrite (4-5%) in the weld metal because of its ability to dissolve impurities. Weld Metal composition is balanced accordingly

Weldability of Austenitic Stainless Steel

Sigma phase formation

Similar to ferritic steel problem More significant as Cr is generally high Problem aggravates with high ferrite in WM & WM contains element like Mo, Si, Cb, Ti, Al
Sensitisation or Weld Decay Similar to ferritic steel problem Remedy Same remedy as discussed in case of ferritic SS

Nickel equivalent = %Ni + 30 x % C + 0.5 x %Mn Chromium Equivalent = % Cr + % Mo +1.5 into % Si+ 0.5 x %Nb

SCHAEFFLER

DIAGRAM

Du Long DIAGRAM

Welding of SS: Special Features

Welding Technique
Arc length is a significant factor SS welding Specially when rutile coated electrode is used As sealing is not as good as basic coated one Longer arc means more Chromium loss Tendency towards austenitic weld deposit More nitrogen pick up. Resulting in more Austenite formation.

Welding of SS: Special Features

Welding Technique

Shorter arc results in little chromium loss Favouring formation of delta ferrite in WM Dilution is also less.. Stringer bead leads to fast cooling Promotes ferrite formation in the weld metal That is why welding technique has great influence in SS welding.

Welding Processes
Shielded Metal Arc welding Gas Tungsten Arc welding Gas Metal Arc welding Submerged Arc welding Resistance welding (Spot, seam & projection) Flash Welding

Welding Process

SMAW

A great variety of covered electrode is available for welding of stainless steel. These are covered by specification IS 5206, AWS A-5.4. IRS M-28 Class M1-M6 for various applications. The covering is generally basic or rutile-basic. Recommended DC(+ve) polarity using rectifier Some electrodes are operable in AC also OCV of the equipment should be 70 V minimum. Welding can be done almost in all position.

Welding Process GMAW

This process uses DC reverse polarity using Argon or Argon/Helium shielding gas. Sometimes, Oxygen and/or CO2 are added to shielding gas improve the arc & penetration. A variety of filler metal is available. These are covered in AWS A 5.9. IRS-M-46, Class 6 & 7 covers MIG solid filler wire for Railway use. The proprietary shielding gas being used in RCF contains 90% Argon, 5% CO2 & 5% Oxygen.

Welding Process FCAW

Fluxcored Arc Welding is also used for welding of Stainless Steel. The process is similar to GMAW. Deposition rate is higher & superior weld metal quality is obtained. Filler wire is covered in AWS A 5.22. IRS-M-46, Class 6 & 7 covers MIG flux cored filler wire for Railway use.

Welding Process GTAW

Suitable for welding SS up to 6mm thick Beyond that, the process is uneconomical. Up to 2mm no joint preparation, no filler metal Above that, bevelling of the face with filler wire Filler metal is used manually from outside DCRP is used to remove chromium oxide. For low thickness AC power can also be used. Improved power source like Pulsed power source, Square Wave power source Potential problem is Tungsten inclusion and porosity in the weld metal.

TIG WELDING EQUIPMENT

Welding Process Resistance Welding

Spot, Seam & Projection Welding Extensively used for sheet metal welding normally up to 3mm No filler wire Heating through resistance in current passage Joined by pressure when reached plastic state Forces applied before, during & after the application of current Suitable for continuous production line

Welding Process Resistance Welding

Major variables are current, time & applied pressure. A proper balance to ensure proper fusion & avoid spitting. Surface preparation is not required except claning Due to very short time, HAZ is very less and defects like Sigma phase & Sensitisation not significant. Being used extensively in RCF for fabrication of LHB coach.

Welding Process Resistance Welding

In spot welding a nugget of weld metal is produced at the electrode site & used where leak tightness is not required. Seam welding is a variation of spot welding in which a series of overlapping nuggets are produced to obtain a continuos gas tight seam. Projection welding is similar to spot welding except the location is pre determined by a projection or embossment on one faying surface

VARIOUS RESISTANCE WELDING PROCESS

SEAM WELDER

SURFACE DEPRESSION AND NUGGET IN BY SPOT WELD

Cutting of Stainless Steel

Mechanical cutting i.e. shearing, machining etc. can be adopted during fabrication During maintenance Thermal cutting Oxy-Acetylene not suitable due to formation of Chromium Oxide Plasma Cutting & Metal Arc Cutting suitable Plasma cutting economical with smooth cut face Metal arc cutting uneven edge, needs grinding Cutting electrodes in class N1 of IRS-M-28