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HOW TO WELD
fully austenitic stainless steels
How to weld fully
austenitic stainless steels
Thanks to their excellent properties, high-alloy fully austenitic steels
(also referred to as super austenites or super austenitic steels) are
used for most applications where requirements are severe.
The prime diference between fully austenitic steels and
more conventional stainless steels is corrosion resis-
tance. However, mechanical properties can also difer
signifcantly. This is primarily due to fully austenitic
steels having high chromium, nickel, molybdenum
and, in certain cases, nitrogen and copper contents.
The extremely good corrosion properties give fully
austenitic steels a wide feld of application in the most
demanding environments.
These steels have good weldability and can be wel-
ded using all common welding methods. However,
compared with low-alloy austenitic steels, more care
is needed when handling and welding fully austenitic
steels.
Chemical compositions
Table 1 gives the chemical compositions of parent
metals (plate, strip, pipe, etc.) and recommended fller
metals.
The fully austenitic stainless steels 254 SMO, 4529
and 4565 are alloyed with nitrogen. In addition to nitro-
gen, 4565 also has around 6% manganese. Alloy 28 and
904L are alloyed with around 1 1.5% copper.
Nickel base alloys are normally used for welding
254 SMO, 4529, 4565 and 654 SMO. In some cases (e.g.
where transpassive corrosion may arise), welding
should be with an iron base alloy, e.g. Avesta P54.
This can also be used when welding 4565.
Uses
Process equipment in the chemical industry
Equipment for bleaching paper pulp
Flue gas cleaning
Heat exchangers
Desalination plants
Sea water systems
Ofshore (oil and gas)
Applications in the pharmaceutical industry
1)
Hot-rolled plate, cold-rolled plate, bars, pipes, pipe ftings and fanges.
2)
MIG, TIG and SAW wire.
3)
EN ISO 3581, EN ISO 14343, EN ISO 17633, EN ISO 14172, EN ISO 18274.
4)
AWS A5.4, AWS A5.9, AWS A5.22, AWS A5.11, AWS A5.14, AWS A5.34.
2
Table 1: Chemical compositions parent and fller metals, typical values
Parent metal EN ASTM C N Cr Ni Mo Other
Plate
1)
725LN
Alloy 28
904L
254 SMO

4529
4565
654 SMO

1.4466
1.4563
1.4539
1.4547
1.4529
1.4565
1.4652
S31050
N08023
N08904
S31254
N08926/N08367
S34565
S32654
0.01
0.02
0.01
0.01
0.01
0.02
0.01
0.12

0.20
0.20
0.45
0.50
25
27
20
20
20
24
24
22.3
32
25
18
25
17
22
2.1
3.5
4.3
6.1
6.5
4.5
7.3

Cu 1.0
Cu 1.5
Cu
Cu
Mn 5.5
Mn 3, Cu
Filler metal EN
3)
AWS
4)
C N Cr Ni Mo Other
MMA 254 SFER
383
904L
P12-R bas
P625
P54
P16
25 22 2 N L R
27 31 4 LR
20 25 5 Cu L
Ni Cr 21 Mo Fe Nb
Ni Cr 22 Mo 9

Ni Cr 25 Mo 16

E383
E385
ENiCrMo-12
ENiCrMo-3

ENiCrMo-13
0.03
0.02
0.02
0.02
0.02
0.02
0.02
0.14

0.35

25.0
27.0
20.5
21.5
21.5
25.5
23.5
21.0
32.0
25.0
Bal.
Bal.
25.5
Bal.
2.5
3.7
4.5
9.5
9.5
5.0
15.5
Mn 2.5
Cu 1.0
Cu 1.5
Nb 2.2, Fe < 3
Nb 3.5, Fe < 1.5
Cu 0.8
Nb < 0.1
Wire
2)
254 SFER
904L
P12
P12-0
Nb
P54
P16
25 22 2 N L
20 25 5 Cu L
Ni Cr 22 Mo 9 Nb
Ni Cr 22 Mo 9

Ni Cr 25 Mo 16

ER385
ERNiCrMo-3
ERNiCrMo-20

ERNiCrMo-13
0.02
0.01
0.01
0.01
0.02
0.01
0.13

0.35
22.0
20.0
22.0
22.0
26.0
25.0
22.0
25.5
Bal.
Bal.
22.0
Bal.
2.2
4.5
9.0
9.0
5.5
16.0
Mn 4.5
Cu 1.5
Nb 3.6, Fe 1
Nb < 0.1, Fe 1, W 2.8
N 0.35
Nb < 0.1, Fe 1
FCW P12 ENiCrMo3 0.02 21.5 Bal. 9.0 Nb 3.3, Fe 1
4 5
Figure 1: Microstructure of, respectively, plate and weld metal with high content of secondary precipitates.
Microstructure
The chemical composition of fully austenitic steels
gives a structure that is entirely austenitic in the solu-
tion heat-treated condition. Fully austenitic steels may
contain traces of secondary precipitates (sigma phase),
but the contents are, generally speaking, very low and
do not signifcantly afect mechanical properties or
corrosion resistance.
When welding fully austenitic materials with high
molybdenum contents, there is a tendency towards
molybdenum segregation and secondary precipitates.
These have a negative efect on both corrosion resis-
tance and mechanical properties. Consequently, nickel
base alloys with a high molybdenum content (e.g. P12,
P625, P16, etc.) should be used for welding.
Secondary precipitates can also arise if the material
is exposed to temperatures between 600 and 1,000C.
Hence, unnecessary exposure to these temperatures
must be avoided. Consequently, to minimise the risk
of precipitation, welding must be with low added
energy (heat input). Welding methods associated with
high heat input, e.g. submerged arc welding (SAW),
require more care than do, for example, MMA, FCAW,
MIG and TIG. Please also see under Heat input.
Additionally, there is an evident risk of secondary
precipitates if the weldment has to undergo subse-
quent heat treatment. Please also see Hot working
and Heat treatment (pages 7 and 14).
Provided that the welding, hot working and heat
treatment recommendations are followed, the negative
efect is small.
Figure 1 shows the microstructure of a cold-rolled
plate and a weld metal with a high content of secon-
dary precipitates.
Mechanical properties
Nitrogen alloyed fully austenitic steels are characterised
by high strength (yield and tensile). The mechanical
properties of fully austenitic steels that are not nitrogen
alloyed (e.g. 904L) are equivalent to those of austenitic
standard steels. Table 2 shows typical mechanical pro-
perties of parent and weld metals.
The high tensile strength means that the fatigue pro-
perties are also very good. However, fatigue strength
is highly dependent on the components shape. The
fatigue properties of welded joints are also clearly
inferior. Welding method and joint type are of great
signifcance. A TIG welded joint generally has consi-
derably beter properties than one made using a
submerged arc. Austenitic steels have very good
ductility and can be used at low temperatures (down
to 196C).
Avesta Weldings P12-0
Nb
fller metals give a weld
metal that has very good impact strength. Nonethe-
less, tensile and yield strength are on the limits of
what is required of the parent metal.
Avesta P54 gives a high strength weld metal, but
elongation and impact strength are somewhat lower
than they are for P16.
Corrosion properties
The high content of alloying elements gives fully
austenitic stainless steels outstandingly good resis-
tance to most types of corrosion.
As shown by table 3 and diagrams 1 and 2, resis-
tance to general corrosion is very good.
904L, which is alloyed with copper, has especially
good properties in phosphoric and sulphuric acid.
This is one of the few stainless steels that can with-
stand sulphuric acid up to 35C at concentrations
from 0 to 100%.
Steel grade Corrosion rate, mm per year
4404
904L
254 SMO
654 SMO
> 6
0.47
0.27
0.06
Table 3: General corrosion in pickling acid* at 25C
* 20% HNO
3
+ 4% HF.
4 5
Steel grade/
fller metal
Min. values
1)
(EN) Typical values, pure weld metal
P H C MMA MIG TIG SAW FCW
725LN/254 SFER
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
196C
250
540
40
60

440
660
32
55

440
650
35
180
130

904L/904L
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
196C
220
520
35
60

220
530
35
60

240
530
35
60

400
565
34
70
50
340
570
38
130
100
410
610
35
180
130
350
560
36
100

254 SMO/P12
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
196C
300
650
40
60

300
650
35
60

320
650
35
60

480
730
37
90
70
480
750
42
170
150
490
740
37
130
110
460
730
41
80

460
750
40
75
45
254 SMO/P12-0
Nb
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
70C
300
650
40
60

300
650
35
60

320
650
35
60

380
630
36
240
220
440
670
41
220
210
400
630
36
120
110

4565/P16
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
40C
420
800
30
90

420
800
30
90

420
800
30
90

550
780
35
60
40
470
700
33
120

510
760
43
135

480
720
37
65
60

654 SMO/P16
R
p0.2
(MPa)
R
m
(MPa)
Elongation A
5
(%)
Impact strength (J)
+20C
40C
430
750
40
60

430
750
40
60

430
750
40
60

550
780
35
60
40
470
700
33
120

510
760
43
135

480
720
37
65
60

Table 2: Mechanical properties parent and fller metals

1)
P = hot-rolled plate, H = hot-rolled coil, C = cold-rolled coil.
100
80
60
40
20
254 SMO

654 SMO

904L
4404
4404
0 10 20 30 40 50 60 70 80 90 100
H
2
SO
4
%
4565
100
80
60
40
20
0 2 4 6 8 10
HCI %
254 SMO

654 SMO

904L
4404
Temperature, C
Diagram 1: Isocorrosion curves, 0.1 mm per year, in pure sulphuric acid.
Temperature, C
Diagram 2: Isocorrosion curves, 0.1 mm per year, in pure hydrochloric acid.
6 7
Table 4: Pitting resistance equivalent
Steel
grade
4404 4439 2205 904L 2507 254 SMO 4565 654 SMO
PRE 25 33 35 35 43 43 46 56
Critical pitting temperature (CPT), C
Diagram 3: Typical piting temperatures (CPTs) in 1M NaCl as per
ASTM G150, measured in the Avesta cell. Test surfaces were wet
ground to 320 mesh. CPT varies with type of product and surface.
CPT min./max.
Parent metal
CPT min./max.
Welded joint
0
20
40
60
80
100
4
4
0
4
2
5
4

S
M
O
2
5
0
7
9
0
4
L
2
2
0
5
Resistance to piting and crevice corrosion is prima-
rily determined by chromium, molybdenum and nitro-
gen contents. A simple way of assessing the resistance
to piting is to calculate the piting resistance equivalent
(PRE): PRE = %Cr + (3.3 x %Mo) + (16 x %N).
Table 4 gives the PRE values for some common
stainless steels.
In this connection, the critical piting temperature
(CPT) is a beter way of ranking stainless steels. Dia-
gram 3 shows the piting corrosion resistance in both
parent metal and a welded joint that has been brushed
and pickled.
There are many ways of measuring CPT. The
diagram shows CPT measured in the Avesta cell
(ASTM G150), an accelerated test that has no direct
correspondence with real operating conditions. How-
ever, it is a good tool for ranking steels.
Chloride content and temperature greatly afect
corrosion resistance. Diagram 4 shows the highest
operating temperatures at which various stainless
steels can be used at diferent chloride contents.
The diagram is general and factors such as welding
defects, oxide flms, contamination and pH value all
have a great impact on fnal results.
The high strength of the nitrogen alloyed fully aus-
tenitic steels also means that resistance to stress cor-
rosion is very good. Thanks to the low carbon content,
intergranular corrosion is rarely a problem.
For the most part, the corrosion resistance of a
welded joint is slightly lower than that of the parent
metal. This is primarily due to: the temperature cycle
undergone by the weld and the heat-afected zone
(HAZ); the shape of the weld surface; and, the conta-
minants and defects generated in welding. To achieve
the best conceivable corrosion resistance, both the
weld reinforcement and the plate should have even
and clean surfaces. Weld metal and HAZ must be
pickled afer welding. Please also see the Pre-weld
cleaning and Post-weld cleaning sections (pages
12 and 15).
Detailed information is given in Avesta Finishing
Chemicals brochures, at www.avestafnishing.com
and in Outokumpus corrosion handbook.
80
70
60
50
40
30
20
100 10,000 100,000
Cl
-
ppm
p = pitting corrosion (solid line) c = crevice corrosion (dashed line)
1,000
904L c
254 SMO

c
4404 c
4404 p
2205 c
2205 p
904L p
254 SMO

p
Diagram 4: Diagram of the risk of piting corrosion and crevice corrosion
afecting high-alloy stainless steels at diferent chloride contents and
temperatures.
Temperature, C
6 7
Working
Cold working of fully austenitic steels is possible
using conventional methods such as bending, pressing
and stretch forming. Fully austenitic steels have very
good ductility and, in many respects, 904L is similar to
1.4301/304 and 1.4401/316 while 254 SMO, 654 SMO,
4529 and, in particular, 4565, harden considerably
more and faster under deformation. This, in combina-
tion with inherent high strength, means that high press
forces are required. Springback is also considerably
greater than with, for example, 1.4401.
Spinning of, for instance, end plates requires high
deformation forces to give full plastic deformation.
The weld metal is subject to stringent requirements
and, as the parent metal is very strong, there is a risk
that the weld metal will crack during spinning. Con-
sequently, the weld metal must be as free from secon-
dary precipitates as possible and it is extra important
that welding is carried out correctly. This applies
especially to SAW. A process in which spinning and
heat treatment are executed in steps may ofen be
necessary.

Hot working, if required, must be performed at the
temperatures given in table 8 (page 14). To reduce the
quantity of precipitates, the workpiece should under-
go solution heat treatment afer hot forming. Provided
that hot working is carried out at a temperature of
at least 1,100C and the component is cooled rapidly
thereafer, subsequent heat treatment is not necessary
for 904L.

Machining (e.g. drilling, turning and milling) of
austenitic steels is generally considered to be more
difcult than it is for low-alloy steels. This very much
also applies to fully austenitic materials. Nonetheless,
provided that the right tools and right parameters are
used, all sorts of machining can be carried out with
good results.
Filler metal
As already stated, fller metals of the nickel base type
should be used for welding fully austenitic materials.
Allooy 28 and 904L are exceptions. They are to be wel-
ded with a fller metal of a matching composition. In
certain cases, 254 SMO and 4565 can be welded using
an iron base alloy, Avesta P54. Filler metal recommen-
dations are given in table 5.
MMA welding of 254 SMO and 4529 can be car-
ried out with two alternative fller metals, P12-R (Ni
22 Cr 9 Mo Nb Fe / ENiCrMo-12) and P625 (Ni 22 Cr
9 Mo Nb / ENiCrMo-3). The diference is that P12-R
has a lower niobium content than does P625. Niobium
increases the tendency towards secondary precipitates.
In its turn, this can lead to hot cracking in the weld
metal. Thus, P12-R is slightly less sensitive than P625.
However, in environments with high working tem-
peratures (over 400C), P625 is a beter option because
the higher niobium content gives superior structure
stability here.
Welding of, in particular, thick workpieces in 254
SMO and 4529 can be carried out using P16. Generally
speaking, this gives a less crack prone weld metal than
P12/P12-R and P625.
MIG, TIG and submerged arc welding of 254 SMO
and 4529 is normally carried out with P12 (Ni 22 Cr 9
Mo Nb / ENiCrMo-3). P12-0
Nb
, which is niobium free,
is an alternative fller metal. It gives a weld metal that,
in principle, is completely free from secondary preci-
pitates. The ductility of MIG and TIG weld metals is
extremely high.
P16 (Ni 25 Cr 16 Mo / NiCrMo-13) is normally used
for welding 4565, but the iron base alloy P54 can also
be used. However, impact strength and elongation are
somewhat lower than they are with P16.
654 SMO must be welded with P16 fller metal
(Ni 25 Cr 16 Mo / NiCrMo-13).
Autogenous welding (i.e. without a fller metal) is
not to be recommended because the microsegregation
in the weld metal during cooling leads to lower ducti-
lity and greatly reduced corrosion resistance. The sole
exception is where a complete solution heat treatment
can be carried out afer welding.

Table 5: Filler metals
Steel grade MMA MIG TIG SAW FCW
725LN 254 SFER 254 SFER
Alloy 28 383
904L 904L 904L 904L 904L (P12-PW)
254 SMO

P12-R Bas, P625, P16, P54 P12, P12-0

Nb
, P16, P54 P12, P12-0
Nb
, P16, P54 P12, P12-0
Nb
, P16 P12-PW
4529 P12-R Bas, P625, P16, P54 P12, P12-0
Nb
, P16, P54 P12, P12-0
Nb
, P16, P54 P12, P12-0
Nb
, P16 P12-PW
4565 P16, P54 P16, P54 P16, P54 P16
654 SMO

P16 P16 P16 P16

8 9
Welding methods
All conventional welding methods such as MMA,
MIG/MAG, TIG, SAW, FCAW, plasma and laser can be
used to weld fully austenitic steels.
Property requirements, positional weldability and
productivity usually determine the choice of welding
method.

MMA welding is an excellent method, particularly
for position welding, single-sided welding and where
access is limited. Avesta Welding has a wide range of
covered electrodes for fully austenitic steels:
Avesta AWS EN Position
254 SFER (-17) R All positions
383 AC/DC -17 R All positions
904L-3D -17 R All positions
904L-PW -17 R Position welding
P12-R -15 B All positions
P625 -15 B All positions
P54 -15 B Flat
P16 -15 B All positions

Welding with rutile-acid electrodes (-17/R) is pos-
sible using both alternating and direct (DC+) current.
However, direct current always gives beter welding
results. To give a weld metal with as low an oxygen
content as possible (and thereby minimum oxides
and inclusions), all nickel base alloy electrodes have a
basic coating (-15/B). The weldability of basic electro-
des is, generally speaking, somewhat poorer than that
of rutile-acid electrodes. Direct current (DC-) must
always be used when welding with basic electrodes.
A short arc is to be used for welding. This gives the
best stability and reduces the risk of nitrogen pick-up.
The later can lead to pore formation and increase
surface oxidation.

MIG welding (which, as it is ofen carried out with an
active component in the shielding gas, is really MAG
welding) is a particularly good method for welding
sheet metal up to around 6 mm thick. Welding is usu-
ally from two sides, but sheet metal (< 4 mm) can be
welded single-sided with a root backing.
A pulsed current is best for welding, but a spray arc
can be used in some cases. Drop transfer is conside-
rably more sedate and more controlled with a pulsed
arc. The opportunity for position welding, especially
vertical-down, is thus very great. The advantage of
spray-arc welding is the higher deposition rate. Howe-
ver, arc stability is lower and, because the weld pool
is relatively large, position welding possibilities are
limited.
The MIG method is especially suited to robot or
automated welding in all positions.
Welding is normally with a pulsed arc and wires of
1.00 or 1.20 mm in diameter.
Arc stability varies greatly between not only diferent
arc types and steel grades, but also between diferent
welding machines.

Figure 2: TIG welding with Avesta P12.
8 9
TIG welding is normally used for thin materials (up
to around 4 mm), especially when joining pipes in all
welding positions. The method is also highly suitable
for welding single-sided root beads (both with and
without root backing). Subsequent beads can then be
welded using a method with a higher deposition rate.
Welding is normally with wires of 1.60 or 2.40 mm in
diameter.

Submerged arc welding of fully austenitic steels is
associated with certain difculties, but can certainly
be carried out if the conditions are right. The problem
with fully austenitic steels and SAW is the relatively
high heat input, which increases the tendency to form
secondary precipitates. If present in sufciently large
quantities, these can cause hot cracking or solidifca-
tion cracking during welding. The risk increases with
heat input and the materials thickness (the degree of
restraint). To minimise the risk, welding should be
with as litle restraint as possible and the minimum
conceivable heat input (max. 1.5 kJ/mm). Please also
see the Defects section (page 16).
Regardless of this, productivity is high and the end
result is a weld with a very fne fnish. Furthermore,
the work environment with SAW is considerably bet-
ter because both fume generation and radiation are
minimal.
SAW must be with a basic agglomerate fux such as
Avesta Flux 805 and a wire diameter of no more than
2.40 mm (max. 3.2 mm with 904L).
Flux cored arc welding (FCAW) is suitable for mate-
rial thicknesses above approximately 2.5 mm. Thanks
to the slag that is formed, positional weldability is
very good. When FCW is used, the arc and weld
pool are protected by both the slag and the shielding
gas. Drop transfer is even and fnishes are extremely
smooth and fne. For welding 254 SMO and 4529,
there is Avesta FCW P12-PW fux cored wire. This is
an all-round wire for all welding positions. It is also
used for overlay welding and welding 904L.

Laser, laser hybrid and plasma welding are high
productivity methods that are very suitable for fully
austenitic steels. However, as previously stated, if a
fller metal is not used, the workpiece must be heat
treated afer welding.
Laser hybrid is a particularly interesting method. It
combines keyhole welding (laser) with arc welding
(MIG/MAG, TIG or plasma). The method ensures a
high productivity process that, thanks to the fller
metal and the low heat input, preserves metallurgical
properties.
Table 6 gives typical welding parameters for several
diferent types of joints.
Figure 3: Welding with fux cored wire (FCW).
10 11
Method Steel grade Shielding gases
MIG 904L, P12, P12-0
Nb
,
P54, P16
Ar + 30% He + 1 3% CO
2

Ar + 30% He + 1 2% O
2
TIG 904L, P12, P12-0
Nb
,
P54, P16
Ar, Ar + 1 5% H
2
+ 10 30% He or
Ar + 2N
2
+ 10 30% He
FCAW P12 Ar + 16 25% CO
2
or 100% CO
2

Plasma 904L, P12, P12-0
Nb
,
P54, P16
Plasma: Ar + 5% H
2
or
Ar + 20 30% He + 1 2%N
2
Shielding gas: Ar or Ar + 5% H
2
or
Ar + 20 30% He
Root pro-
tection
904L, P12, P12-0
Nb
,
P54, P16
90% N
2
+ 10% H
2
or Ar
Table 7: Shielding gases for MIG, TIG, FCW and plasma
Shielding gases
MIG welding is best with a three-component gas
Ar + 30% He + 1 2% O
2
or 2 3% CO
2
. The oxygen
and carbon dioxide here serve as arc stabilisers. An ad-
dition of 30 50% helium is advantageous. It increases
arc energy which, in turn, increases weld pool fuidity
and enables higher welding speeds. Pure argon can
also be used. The gas fow is typically 15 l/min.
An addition of 0.03% NO (nitrogen monoxide) is good
not only from the environmental viewpoint (reduced
ozone emissions), but also because it has a positive ef-
fect on arc stability.

TIG welding is usually performed with pure argon as
the shielding gas. A typical gas fow is 8 12 l/min.
The addition of around 30% helium markedly in-
creases arc energy and thus enables a 20 30% in-
crease in welding speed. An addition of 1 3% hydro-
gen gives a similar efect and is used particularly for
automated welding in tube/pipe manufacture.
Single-sided root beads must be welded with a back-
ing gas. This is normally the same as the shielding
gas. However, Formier gas (90% N
2
+ 10% H
2
) is an
alternative. This also provides good root protection.
A backing gas should also be used as early as tack wel-
ding and all the way up until weld thickness is at least
8 mm. Backing gas fow is typically 8 12 l/min.

FCAW is most suitably performed using argon with
an addition of 16 25% carbon dioxide as the shiel-
ding gas. A typical gas fow is 20 25 l/min.

Plasma welding is normally carried out with argon
or argon with an addition of hydrogen. Mixtures of
argon, CO
2
and N
2
are ofen used as the shielding gas.
Typical gas fows are 3 7 l/min for plasma and
10 15 l/min for backing gases.

Laser welding can be carried out with pure argon,
nitrogen, helium or mixtures of these gases.
Edge preparation
When welding stainless steels, meticulous edge
preparation and the correct choice of joint type are
important for good results. This applies even more
particularly to fully austenitic steels.
Because of the weld pools slightly poorer fusion
penetration and fuidity (compared with standard
austenites), the joint must be correctly designed to
give full penetration without risking burn-through.
The groove angle must be sufciently wide to allow
the welder full control of the arc, weld pool and slag.
A groove angle of around 35 (i.e. somewhat larger
than for austenitic standard steels) is to be recommen-
ded for manual welding.

General recommendations:
An X-joint can advantageously be used for plate
thicknesses above approximately 15 mm.
For plate thicknesses above approximately 30 mm,
a double U-joint is advantageous.
In single-sided welding, a root gap of 2 3 mm and
a straight edge of about 0 1 mm are recommen-
ded. For double-sided welding, the straight edge
can be increased to 1.5 2 mm.
Table 6: Welding parameters for several different types of joint
Method
Thickness
mm
Filler
Diameter
mm
Position
EN/ASTM
Bead
Current
A
Wire feed
cm/min
Voltage
V
Speed
cm/min
MMA 12 904L 3.25
4.00
PA (1G) Root
Cap
100 110
140 150
25 26
26 27
15 25
20 30
MMA 5 P12-R 3,25 PA (1G) Root/cap 105 115 25 27 20 30
MMA 20 P12-R 2.50
3.25
PF (3F) Root
Cap
55 60
70 75
23 24
23 24
6 8
6 8
MMA 10 P16 3.25
4.00
PA (1G) Root
Cap
95 100
120 125
25 27
26 27
15 25
20 30
FCAW 10 P12 1,20 PA (1G) Root
Cap
185 195
220 230
6.5 8.5
9.5 11.5
24 25
26 27
30 40
35 45
MIG 10 904L 1,20 PA (1G) Root/cap 200 220 6.0 7.0 28 30 30 40
MIG 5 P12 1,20 PA (1G) Root/cap 180 200 6.0 7.0 26 28 25 35
TIG 3 P12 1,60 H-L 056 (6G) Root/cap 45 55 10 11 2 6
TIG
SAW
16 P12
P12
1.60
2.40
PA (1G) Root
Cap
140 150
300 350
10 12
30 33
4 10
40 45
SAW 20 P12-0
Nb
2,40 PA (1G) Root
Cap
300 350
300 400
29 31
31 33
40 45
40 45
10 11
84
Edge preparation
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
1. I-joint One side TIG < 2.5 mm
No root gap
1)
2. I-joint Two sides SAW 6 9 mm
No root gap
2)
3. I-joint One side PAW 1 8 mm
4. I-joint One side MMA < 2.5 mm
D = 1.0 2.0 mm MIG
TIG
5. I-joint Two sides MMA < 4 mm
D = 2.0 2.5 mm MIG
TIG
FCW
6. V-joint One side MMA 4 16 mm
= 60
3)
MIG
C = 0.5 1.5 mm TIG
D = 2.0 4.0 mm FCW
7. V-joint Two sides MMA 4 16 mm
= 60
3)
MIG
C = 2.0 2.5 mm TIG
D = 2.5 3.5 mm FCW
8. V-joint One side FCW 4 20 mm
= 60
3)
against
C = 1.5 2.5 mm backing
D = 4.0 6.0 mm
9. V-joint Two sides TIG+ 3 16 mm
= 80 90 SAW
C = 1.5 mm
No root gap
1)
10. V-joint Two sides SAW 8 16 mm
= 80 90
C = 3.0 6.0 mm
4)
No root gap
11. V-joint Two sides PAW+ 6 16 mm
= 80 90 SAW
C = 3.0 4.0 mm
No root gap
1)
There must be a root gap when welding special grades.
2)
A ground groove, 1 2 mm deep and wide.
3)
The joint angle for special grades is 60 70.
4)
A root land of 5 mm and above may require the torch to be angled towards the direction of travel,
4)
see Width and depth in chapter 4.
D

D
C

D
C

C
C
M
Y
CM
MY
CY
CMY
K
Fig 2-4.pdf 06-10-30 14.24.40
85
Edge preparation
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
12. V-joint One side MMA 4 16 mm

1
= 45 FCW

2
= 15
C = 1.0 2.0 mm
D = 2.0 3.0 mm
13. V-joint Two sides MMA 4 16 mm

1
= 45 FCW

2
= 15
C = 2.0 2.5 mm
D = 2.0 2.5 mm
14. V-joint One side FCW 4 20 mm

1
= 45 against

2
= 15 backing
C = 1.5 2.5 mm
D = 4.0 6.0 mm
15. X-joint Two sides MMA 14 30 mm
8)
= 60
3)
MIG
C = 2.0 3.0 mm TIG
6)
D = 2.0 2.5 mm FCW
16. X-joint Two sides SAW 14 30 mm
= 80
C = 3.0 8.0 mm
4)
No root gap
3)
The joint angle for special grades is 60 70.
4)
A root land of 5 mm and above may require the torch to be angled towards the direction of travel,
4)
see Width and depth in chapter 4.
6)
Normally only for the first 1 3 runs. Followed by MIG, FCW, MMA or SAW.
8)
A thickness above 20 mm can be prepared as an asymmetrical X-joint.
D
C

2
D
C

D
C

C
C
M
Y
CM
MY
CY
CMY
K
Fig 4 ny.pdf 06-10-30 14.31.25
Figure 4: Examples of common joint types
84
Edge preparation
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
1. I-joint One side TIG < 2.5 mm
No root gap
1)
2. I-joint Two sides SAW 6 9 mm
No root gap
2)
3. I-joint One side PAW 1 8 mm
4. I-joint One side MMA < 2.5 mm
D = 1.0 2.0 mm MIG
TIG
5. I-joint Two sides MMA < 4 mm
D = 2.0 2.5 mm MIG
TIG
FCW
6. V-joint One side MMA 4 16 mm
= 60
3)
MIG
C = 0.5 1.5 mm TIG
D = 2.0 4.0 mm FCW
7. V-joint Two sides MMA 4 16 mm
= 60
3)
MIG
C = 2.0 2.5 mm TIG
D = 2.5 3.5 mm FCW
8. V-joint One side FCW 4 20 mm
= 60
3)
against
C = 1.5 2.5 mm backing
D = 4.0 6.0 mm
9. V-joint Two sides TIG+ 3 16 mm
= 80 90 SAW
C = 1.5 mm
No root gap
1)
10. V-joint Two sides SAW 8 16 mm
= 80 90
C = 3.0 6.0 mm
4)
No root gap
11. V-joint Two sides PAW+ 6 16 mm
= 80 90 SAW
C = 3.0 4.0 mm
No root gap
1)
There must be a root gap when welding special grades.
2)
A ground groove, 1 2 mm deep and wide.
3)
The joint angle for special grades is 60 70.
4)
A root land of 5 mm and above may require the torch to be angled towards the direction of travel,
4)
see Width and depth in chapter 4.
D

D
C

D
C

C
C
M
Y
CM
MY
CY
CMY
K
Fig 2-4.pdf 06-10-30 14.24.40
1. I-joint for single-sided MMA, MIG, TIG
and plasma arc welding. Suitable root
protection must be used for single-sided
TIG welding.





2. V-joint (t > 4 mm) for single and double-
sided MMA and TIG welding as well as
double-sided MIG and FCAW.




3. V-joint for SAW. So that full penetra-
tion is possible, the root bead must be
ground precisely.



4. In SAW, an X-joint is to be recommen-
ded where plate thickness exceeds 16
mm. Straight edge, 3 4 mm.



5. Edge preparation for pipe joints. TIG or
MMA welding is the most appropriate.




6. Half V-joint with full burn-through.
Single-sided welding requires TIG or
electrode for the root bead. In this type
of joint, the distance between tacks
should not exceed 150 mm. This is so
that shrinkage does not prevent full
burn-through.

7. Single-sided or double-sided U-joint for
welding thick sections, t > 30 mm.
The joint can advantageously be made
as a symmetrical or asymmetrical double
U-joint. Root welding is most suitably
carried out as a TIG or MMA weld fol-
lowed by SAW.
84
Edge preparation
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
1. I-joint One side TIG < 2.5 mm
No root gap
1)
2. I-joint Two sides SAW 6 9 mm
No root gap
2)
3. I-joint One side PAW 1 8 mm
4. I-joint One side MMA < 2.5 mm
D = 1.0 2.0 mm MIG
TIG
5. I-joint Two sides MMA < 4 mm
D = 2.0 2.5 mm MIG
TIG
FCW
6. V-joint One side MMA 4 16 mm
= 60
3)
MIG
C = 0.5 1.5 mm TIG
D = 2.0 4.0 mm FCW
7. V-joint Two sides MMA 4 16 mm
= 60
3)
MIG
C = 2.0 2.5 mm TIG
D = 2.5 3.5 mm FCW
8. V-joint One side FCW 4 20 mm
= 60
3)
against
C = 1.5 2.5 mm backing
D = 4.0 6.0 mm
9. V-joint Two sides TIG+ 3 16 mm
= 80 90 SAW
C = 1.5 mm
No root gap
1)
10. V-joint Two sides SAW 8 16 mm
= 80 90
C = 3.0 6.0 mm
4)
No root gap
11. V-joint Two sides PAW+ 6 16 mm
= 80 90 SAW
C = 3.0 4.0 mm
No root gap
1)
There must be a root gap when welding special grades.
2)
A ground groove, 1 2 mm deep and wide.
3)
The joint angle for special grades is 60 70.
4)
A root land of 5 mm and above may require the torch to be angled towards the direction of travel,
4)
see Width and depth in chapter 4.
D

D
C

D
C

C
Joint type 1
I-joint, t < 2.5 mm
D = 1.0 2.0 mm
Single-sided without root backing
I-joint, t < 4.0 mm
D = 2.0 2.5 mm
Double-sided with root grinding
Joint type 2
V-joint, t = 4 16 mm
= 60 70
C = 0.5 1.5 mm
D = 2.0 4.0 mm
Single-sided without root backing
V-joint, t = 4 16 mm
= 60 70
C = 2.0 2.5 mm
D = 2.5 3.5 mm
Double-sided with root grinding
Joint type 3
V-joint, t = 8 16 mm
= 80 90
C = 3 6 mm
No root gap
Joint type 4
X-joint, t = 14 30 mm
= 80 90
C = 3 4 mm
No root gap
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
28. Half V-joint One side MMA 4 12 mm
= 50 MIG
C = 1.5 2.5 mm TIG
6)
D = 2.0 4.0 mm FCW
5)
29. Half V-joint Two sides MMA 4 16 mm
= 50 MIG
C = 1.5 2.5 mm TIG
6)
D = 1.5 2.5 mm FCW
30. K-joint Two sides MMA 14 30 mm
8)
= 50 MIG
C = 2.0 2.5 mm TIG
6)
D = 2.0 4.0 mm FCW
31. Half V-joint
7)
Two sides MMA 4 16 mm
= 50 MIG
C = 1.0 2.0 mm TIG
6)
D = 2.0 3.0 mm FCW
32. Half pipe One side MMA 4 16 mm
= 45 MIG
C = 1.5 2.0 mm TIG
D = 1.0 2.0 mm FCW
88
Edge preparation
5)
Welding performed against ceramic backing (round type).
6)
Normally only for the first 1 3 runs. Followed by MIG, FCW, MMA or SAW.
7)
For openings such as manways, viewports and nozzles.
8)
A thickness above 20 mm can be prepared as an asymmetrical X-joint.

D
C
C
D

C
D

C
D
C
M
Y
CM
MY
CY
CMY
K
Fig 5 ny.pdf 06-10-30 14.40.27
Joint type 5
V-joint, t = 4 16 mm
= 50
C = 1.0 2.0 mm
D = 2.0 3.0 mm
Single-sided without root backing
Joint type 6
Half V-joint, t = 14 30 mm
= 50
C = 1.5 2.5 mm
D = 2.0 3.0 mm
Double-sided
Joint type 7
U-joint, t > 30 mm
= 10
R = 8 mm
C = 2.0 2.5 mm
D = 2.0 2.5 mm
Single-sided without root backing or double-
sided with root grinding
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
21. Fillet weld One or MMA > 2 mm
No root gap two sides MIG
A 0.7 x t TIG
FCW
22. Half V-joint One side MMA 4 16 mm
= 50 MIG
C = 1.0 2.0 mm TIG
6)
D = 2.0 4.0 mm FCW
23. Half V-joint Two sides MMA 4 16 mm
= 50 MIG
C = 1.5 2.5 mm TIG
6)
D = 2.0 3.0 mm FCW
24. Half X-joint One side MMA 14 30 mm
= 50 MIG
C = 1.0 1.5 mm TIG
6)
D = 2.0 4.0 mm FCW
5)
25. Half X-joint Two sides MMA 14 30 mm
= 50 MIG
C = 1.5 2.5 mm TIG
6)
D = 2.0 3.0 mm FCW
26. Fillet weld Two sides MMA < 2 mm
No root gap MIG
TIG
FCW
27. Fillet weld Two sides MMA 2 4 mm
D = 2.0 2.5 mm MIG
TIG
FCW
87
Edge preparation

t2
C
D
t1
5)
Welding performed against ceramic backing (round type).
6)
Normally only for the first 1 3 runs. Followed by MIG, FCW, MMA or SAW.
A
t1
t2

D
t2
t1
C
D
C
M
Y
CM
MY
CY
CMY
K
Fig 6 ny.pdf 06-10-30 14.38.48
86
Edge preparation
Joint preparations Table 7.1
No. and joint type Sides Method Thickness
17. X-joint Two sides MMA 14 30 mm
8)

1
= 45 MIG

2
= 15 TIG
6)
C = 1.5 2.5 mm FCW
D = 2.5 3.0 mm
18. X-joint Two sides SAW
9)
14 30 mm

1
= 45

2
= 15
C = 3.0 8.0 mm
4)
No root gap
19. U-joint Two sides MMA < 50 mm
= 10 MIG
R = 8.0 mm TIG
6)
C = 2.0 2.5 mm FCW
D = 2.0 2.5 mm SAW
10)
20. Double U-joint Two sides SAW
9)
> 20 mm
= 15
R = 8.0 mm
C = 4.0 8.0 mm
4)
4)
A root land of 5 mm and above may require the torch to be angled towards the direction of travel,
4)
see Width and depth in chapter 4.
6)
Normally only for the first 1 3 runs. Followed by MIG, FCW, MMA or SAW.
8)
A thickness above 20 mm can be prepared as an asymmetrical X-joint.
09)
TIG or MMA can be used for root runs. Grinding from the back. C = 3.0 mm.
10)
SAW can be used for fill and cap passes.

2
C
D

1
D
C
R
t

C
R

2
C

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Fig 7_Fog NYTT.pdf 06-11-01 15.03.40
12 13
Pre-weld cleaning
To ensure good weldability and reduce the need for
post-weld cleaning, all joint surfaces, and the surfaces
adjoining these, must be thoroughly cleaned before
welding. Dirt, oil and grease must be removed using,
for example, a cleaning agent such as Avesta Cleaner.
All rough edges, etc. must be carefully removed by
gentle grinding.
Oxides, paints and primers must be meticulously
removed, not only in the joint, but also in the 50 mm
from the joint edges.

Tack welding
So that shrinkage during welding does not prevent
full burn-through, precise tack welding is extremely
important. For metal thicknesses up to 6 mm, tack
length should be 10 15 mm. This should be increased
to 20 25 mm for thicker workpieces. A suitable dis-
tance between tacks is 150 200 mm.
In single-sided welding, the entire tack must be
ground away before welding. In double-sided wel-
ding, it is sufcient to grind away the beginning and
the end of the tack. A common alternative in single-
sided welding is the use of bridges or distance pieces.
These must be made of, and tacked using, matching
material. Note that gap width must be constant
throughout the joint.
Figure 5: Tack welding using distance pieces.
Starting and stopping
Striking and extinguishing the arc
It is very important to use the right technique when
striking and extinguishing the arc. As regards metal-
lurgical, mechanical and corrosion properties, each
start and stop is a critical area.
To avoid striking scars, the arc must always be
struck down in the joint. If, despite this, striking scars
occur, they must be meticulously repaired by grin-
ding, polishing and pickling or, in the worst cases,
repair welding.
In MMA welding, the arc must be extinguished
carefully by frst making several circular movements
in the centre of the weld pool. The electrode is then
to be moved slowly backwards 10 mm through the
weld pool before being gently lifed. If this is done too
quickly, crater cracks and slag inclusions may result.
Modern power sources for MIG and TIG welding
ofen have a so-called crater flling facility. This gives
smooth and controlled stops.
To remove any crater cracks and slag inclusions,
each start and stop must be carefully ground using a
suitable grinding disc.
Figure 6: Penetrant testing (PT) is a simple and highly visual way of
investigating weld metal quality as regards surface-breaking defects. At the
top, an approved joint where there are no indications of surface-breaking
defects. Below, a rejected joint where there are problems with both hot
cracks and end crater pipes.
12 13
Planning the welding sequence
Because it makes burn-through unnecessary, double-
sided welding is always to be preferred over single-
sided welding. To ensure full burn-through on the
last bead, the root side must be ground to clean metal.
A grinding disc not exceeding 2 mm in width is a
suitable tool.
If it is difcult to decide whether grinding has reached
the frst bead, penetrant testing (PT) can be used.
In double-sided MMA welding, electrodes with a
diameter of 3.25 mm (in some cases, even 4.00 mm)
can be used from the very start. Single-sided welding is
most easily carried out with root backing, but can also
be performed without. A 2.50 mm diameter electrode
must be used for the root bead and 3.25, 4.00 or 5.00
mm for flling the joint. Choice of electrode diameter is
determined by welding position. In certain cases (e.g.
pipe joints) single-sided welding without root backing
is required. TIG welding (diameter 1.60 2.40 mm) is
easiest for this.
As already stated, a backing gas must be used in TIG
welding. Single-sided welding without root backing
places high demands on even and thorough edge
preparation.

Root beads must satisfy three important requirements:
Correct metallurgy and structure (right root gap to
ensure sufcient quantity of fller metal).
Correct geometry (no root concavity, undercuting
or lack of fusion).
Best possible productivity (always in relation to
weldability).
Figure 8: Root bead correctly executed using TIG welding.
Figure 7: Root, fller and cap beads welded using Avesta P12-R basic
covered electrodes.
Figure 9: Grinding scars.

Filler beads must be deposited with the highest pos-
sible productivity. At the same time, structure and
mechanical properties have to be maintained. In most
cases, fll passes use the same fller metal as that used
in root passes. High productivity welding methods
may be economical for joint flling. Several common
choices are:
TIG root pass + MMA, MIG or SAW fll passes.
TIG root pass + SAW or FCAW fll passes.
Generally speaking, welding is carried out with the
highest possible heat input (max. 1.5 kJ/mm) that
is still consistent with maintained properties and
weldability. Visual inspection between the passes is
important.
Slag residues and severe welding oxide are to be
removed before depositing the next layer. Otherwise,
there is always the risk of slag inclusions being lef
behind. A suitable grinding disc must be used. To
avoid damaging adjacent surfaces (please see fgure 9),
grinding should be carried out with some care.
The cap bead is primarily intended to give the weld
good corrosion protection. Besides structure, surface
geometry can also play a critical role here. Undercut-
ting, unevenness, high reinforcements, gaps, etc. can
all have a negative impact on corrosion resistance.
Aesthetic considerations are ofen also important.
When using slag forming welding methods, weld
reinforcements must be cleaned of all slag residues.
14 15
Welding techniques
In the fat position, there should be no signifcant
weaving. In the vertical-up position, weaving of up
to 20 mm is advantageous. For the best control of arc
and weld pool, welding is normally carried out with a
torch or electrode angle of around 10 away from the
welding direction, i.e. backhand.
In submerged arc welding, the nozzle is not nor-
mally angled.
Distortion
Fully austenitic steels have a greater coefcient of
expansion than do low-alloy steels and duplex stain-
less steels. This means that distortion during welding
is also greater. Consequently, to reduce distortion,
tack welding has to be carried out precisely and the
welding sequence meticulously planned.
Preheating
Generally speaking, stainless steels (fully austenitic
steels included therein) must not be preheated before
welding. Welding is normally carried out at room
temperature. At lower temperatures, preheating to
a maximum of 50C is advisable. This drives of any
moisture that may otherwise lead to pore formation.
When welding castings, or where the workpiece is thick
or where restraint is high, preheating to a maximum of
100C may, in certain cases, be advantageous. In these
cases, a suitable preheating method is the use of electric
blankets or similar. The use of soot-depositing fames
can result in local carburisation. This reduces resistance
to intergranular corrosion.
Interpass temperature
Because fully austenitic materials are prone to inter-
metallic precipitates, the interpass temperature must
not be above 150C for 904L and 100C for other fully
austenitic materials.
Thermal conductivity is of the same order as for
austenitic stainless steels, i.e. considerably lower than
it is for low-alloy and carbon steels. This means that,
compared to carbon steels, it takes longer to reach the
correct interpass temperature. The cooling rate can be
increased by using compressed air. This is most suitably
directed at the back of the plate or the inside of the pipe.
Compressed air directed straight into the welded joint
presents the risk of contamination. Cooling can also be
accelerated by intermitent welding or using a correctly
planned welding sequence.
The interpass temperature must be measured. Some
form of thermometer or thermoelement is appropriate
for this. Temperature crayons seldom give good results
and must be avoided.
Heat input
To avoid intermetallic precipitates, the heat input
when welding fully austenitic materials must be kept
as low as possible without thereby giving rise to any
risk of lack of fusion, etc. One general recommenda-
tion is a maximum of 1.5 kJ/mm. However, the critical
upper limit depends very much on welding method
and the thickness of the workpiece. For example, MIG
is not as sensitive as SAW and a 5 mm joint is less
sensitive than a 20 mm joint.
Especially in automated welding, heat input is easy
to control.
{ }
Heat input =
U x I
k x
V x 1,000
U x I

mm/s x 1000
= kJ/mm
U = voltage
I = current
V = speed
Welding method Factor, k
MMA, FCW, MIG/MAG 0.8
TIG 0.6
SAW 1.0
Although it is always desirable to optimise producti-
vity by increasing the welding parameters, this must
never happen if it would result in a too high heat
input.
Post-weld heat treatment
Fully austenitic stainless steels do not normally need
post-weld heat treatment. However, in certain situa-
tions, solution heat treatment may be necessary. Table 8
gives the recommended temperatures.
Heat treatment requires very precise control of both
time and temperature. It must only be carried out by
qualifed personnel using suitable equipment.
Type of treatment 904L 254 SMO 4529 4565 654 SMO
Hot forming** 1150 850 1200 1000 1150 850 1200 950 1200 1000
Solution heat treatment** 1060 1140 1150 1200* 1120 1180 1120 1170 1150 1200
Stress-relieving annealing 400 500 300 400 300 400 300 400 300 400
Pressure vessel approval 196 +400 196 +400 196 +400 (196) +400 RT +427***
Table 8: Recommended heat treatment
* So that material properties are not too seriously impaired, workpieces over 2 mm thick require quenching in water.
Thinner workpieces can be cooled quickly in air.
** As per EN 10088-2.
*** ASME Code Case 2195-1.
14 15
How to weld fully austenitic materials to
other materials
Welding fully austenitic steels to carbon or low-alloy
steels is best carried out using the same fller metals as
those for welding stainless steel to stainless steel.
However, in certain cases, Avesta P5 (309MoL) can be
a more economical alternative. This applies particular-
ly to thin workpieces (t < 10 mm) where the degree of
restraint and dilution are low.
Welding to other stainless steels such as EN 1.4301/
ASTM 304 or EN 1.4401/ASTM 316 is also entirely pos-
sible. It can be carried out with a fully austenitic fller
metal or, in certain cases, Avesta P5.
Welding to duplex stainless steels must be with a
suitable duplex or nickel base alloy. Please see table 9.
Because it gives rise to a risk of britle secondary
phases, it is important to minimise dilution when wel-
ding high-alloy materials to each other. Consequently,
this must be taken into account in the choice of joint
design and welding techniques.
Figure 10: Stainless steel pressure vessel for the petrochemical industry partly pickled.
Post-weld cleaning
Post-weld cleaning is critical in achieving fully satis-
factory corrosion resistance. Clearly enough, it is thus
an integral part of the entire stainless steel welding
procedure. Despite this, post-weld cleaning is not
always standard.
The method and extent of cleaning is determined
by the requirements imposed in respect of corrosion
resistance, hygiene and appearance.
Generally speaking, one basic requirement is that
defects, welding oxide, organic contaminants and
carbon steel contamination must be removed from
weld and parent metal surfaces. This can be done me-
chanically (grinding, brushing, polishing, blasting) or
chemically (pickling). An important rule of thumb for
grinding is to always fnish with polishing. The risk of
harmful grinding scars is otherwise very great.
The demonstrably most reliable method is a com-
bination of mechanical and chemical cleaning, i.e.
brushing with a stainless steel brush followed by
degreasing, pickling and passivation.
Avesta Finishing Chemicals has a complete product
programme for the pickling of stainless steel welds. It
comprises cleaning products, pickling pastes, pickling
sprays, pickling fuids and various items of equip-
ment. Fully austenitic steels are generally slightly more
difcult to pickle than are austenitic steels such as
1.4301 (304) and 1.4404 (316L). Thus, Avesta BlueOne
and Avesta RedOne, which are comparatively strong
pickling products, should be used.
Further details are available at www.avestafnishing.
com or can be obtained directly from Avesta Finishing
Chemicals.
Table 9: Suitable fller metals for welding fully
austenitic steels to other materials
Parent
metal
Recommended fller metal
254 SMO 2205 2507 316/304 Carbon
steel
904L P12 P12 2507/P100 904L/P5 P5/904L
254 SMO P12 P12 P16/P12-0
Nb
P12 P12
654 SMO P16 P16 P16 P16 P16
16 17
Defects
Apart from the risk of hot cracking, fully austenitic
steels are generally no more prone to defects than are
other stainless steels. However, certain factors require
special atention.
The high nitrogen content gives poorer penetration.
Arc stability, fuidity and arc control are somewhat
poorer than they are for austenitic stainless steels.
This applies particularly to 4565/EN 1.4565/ASTM
S34565, which has a high manganese content.
To avoid problems with poor penetration, slag
inclusions or pores, recommendations for joint
design and welding parameters must be followed
precisely.
Hot cracking (a classic problem for fully austenitic
materials).

During solidifcation, secondary precipitates form in
the weld metal. If the cooling rate is too low and the
heat input too high, these precipitates may collect and
form flms of late-solidifying phases at grain bounda-
ries. Under the infuence of the residual stresses al-
ways present in weld metal, the flms can crack. These
hot or solidifcation cracks form particularly at the
centre of the weld metal, where the stress is greatest.
Figure 11: Width to depth ratio.
Width
Depth
In workpieces of around 10 mm thick and upwards,
cracking can also arise when, in multilayer welding,
subsequent passes heat the underlying weld to a tem-
perature where precipitation can occur. Here too, flms
that may crack are formed.

The risk of hot cracking generally reduces with:
Reduced heat input (max. 1.5 kJ/mm).
Reduced restraint.
The use of fller metals that do not contain niobium
(e.g. Avesta P12-0
Nb
and Avesta P16).
A good width to depth ratio, i.e. the width of the
weld must be around 1 to 1.5 times its depth (please
see fgure 11).
Using covered electrodes or TIG for root beads
(beads 1 3) when welding thick workpieces where
SAW is to be preferred.
Figure 12: Hot cracks in a weld surface (lef) and enclosed (right).
Figure 14: Weld surface, P12 MIG with poor arc stability. Figure 13: Root defect caused by incomplete penetration.
16 17
Repair welding
So that corrosion resistance is not impaired, all defects
must be repaired. Minor surface defects such as spat-
ter, slag and oxide islands can easily be remedied by
grinding followed by polishing using an at least 320
mesh disc. Note that a grinding disc intended for
stainless steel must be used. Afer polishing, conven-
tional pickling is to be carried out. Pickling paste is
most ofen the simplest alternative.
Defects must never be repaired by TIG dressing
(remelting using a TIG electrode). This has the same
efect as welding without a fller metal, i.e. there is
a risk of a high content of secondary precipitates in
the weld metal. If this occurs, ductility and corrosion
resistance will be lower.
Large defects and subsurface defects require heavier
grinding with a coarser grinding disc. Once the entire
defect has been removed (which can be checked by, for
example, penetrant testing), the ground area is to be fl-
led using a suitable method, most ofen MMA welding.
In-built defects in thick workpieces can be removed
by gouging with a plasma arc. Because of the resul-
tant carbonisation, carbon arcs should not be used.
The problem with both plasma and carbon arcs is the
powerful spater. If care is not taken, this can damage
adjacent surfaces. The later should be protected using,
for example, Masonite boards or chalk paint.
Afer gouging, the area must be ground before wel-
ding can start. Plasma gouging can be carried out at least
fve times with no negative impact on the parent metal.
3. The ground out area is repaired using a suita-
ble welding method (ofen covered electrodes).
Figure 15: Typical welding sequence in repair welding
1. Using a suitable grinding/cuting disc, the
defect is ground from the surface. To avoid un-
necessary grinding scars, be careful with the
surrounding areas.
2. Using a suitable grinding/cuting disc, the
defect is ground to a depth and width (width, min.
3 mm and depth, min. 10 mm) that is sufcient for
repair welding. To ensure that the entire defect has
been ground away, PT can be carried out.
4. The weld is ground fush with the plate. 5. Using a suitable polishing disc (at least 320
mesh), the surface is polished.
Measuring ferrite content
As can be judged from the name, fully austenitic steels
contain no ferrite. There is thus no reason to measure
or calculate the ferrite content.
Overlay welding
Overlay welding of carbon steel can be carried out
using all types of fller metals. Directly from the frst
layer, welding can be with a nickel base alloy (e.g.
P12) or 904L. Filler metals of the 309L or P5 type can
also be used as a frst layer. This is considerably more
cost-efcient.
Correctly executed, the overlay metal is extremely
resistant to corrosion.
All welding methods can be used. However, covered
electrodes, MIG and FCAW, where dilution is rela-
tively easy to control, most ofen give the best results.
SAW gives high productivity, but also high dilution.
Thus, it is extra important to use the correct parameter
setings.
Welding should be with as litle dilution of the
parent metal as possible. Welding parameters and
technique are of great importance. Dilution can be
minimised by building on the preceding bead and
avoiding directing the arc at the parent metal.
Table 10 gives examples of the chemical composi-
tion of the overlay weld metals resulting from various
methods and fller metals.
6. End with pickling.
18 19
How to weld fully austenitic steels of
similar compositions
In addition to the already described stainless steels,
there are many steel grades of a similar composition.
Table 11 gives some general recommendations
Table 11: How to weld similar fully austenitic steels
Method Filler Layer Chemical composition, % by weight
C Si Mn Cr Ni Mo Other
MMA 904L 1 0,022 0,89 1,38 20,1 23,7 4,0 Cu 1.2
904L 2 0,022 0,87 1,30 20,6 25,9 4,2 Cu 1.5
MMA P12-R 1 0,018 0,35 0,39 20,2 59,2 8,6 Fe 8.5
P12-R 2 0,016 0,36 0,35 21,8 63,0 9,1 Fe 2.8
FCW P12 1 0,017 0,6 1,4 22,0 12,0 8,4 Fe 3.8
P12 2 0,015 0,5 0,4 21,5 58,0 9,0 Fe 0.4
Table 10: Example chemical compositions
of overlay weld metals
Inspection and quality assurance
The rules that apply to structural steels apply also to
stainless steels. The following are some of the relevant
international standards:
EN ISO 5817, which gives guidelines on acceptance
levels for various defects in welded joints.
EN ISO 1560715614 and ASME IX, which describe
approval of welding procedures.
However, fully austenitic steels are used in applica-
tions where strength and corrosion requirements are
ofen very severe. There is thus every reason to be
extra careful from beginning to end. Welding oxide,
spater, striking scars and grinding scars must be re-
moved to achieve the correct corrosion resistance. For
the best fatigue resistance, the weld surface must be
even with no sharp edges.
Nondestructive testing is an integral part of the exa-
mination of welded joints. Suitable methods are visual
inspection, penetrant testing (PT), radiographic testing
(RT) and ultrasound testing (UT). In ultrasound
testing, it is important that surfaces are ground fat so
that defects such as pores and cracks can be reliably
detected.
Steel grade
EN ASTM
Recommended fller metal
Avesta Welding
1.4466 S31050 254 SFER
1.4563 N08023 383
1.4539 N08904 904L
1.4547 S31254 P12, P12-R
1.4529 N08926/N08367 P12, P12-R
1.4565 S34565 P16
1.4652 S32654 P16
Handling of fller metals
Stainless steel covered electrodes, fux cored wires
(FCWs) and fuxes can be prone to moisture pick-up.
Avesta Weldings consumables are supplied in packa-
ges that have been designed to resist moisture.
However, for the best possible results, the following
storage and handling precautions are still recommended.
Storage of unbroken packages: Covered electrodes,
FCWs and fuxes must be stored in their unbroken,
original packaging. Storage in opened packaging can
considerably shorten the products service life. Fol-
lowing the frst in, frst out principle, storage time
must be kept as short as possible. Covered electrodes
and fuxes should not be stored longer than 5 years.
The corresponding time for FCWs is 2 years.
Products that are over 5 (2) years old should be
redried before use.
Covered electrodes, FCWs and fuxes should not be
stored in direct contact with foors or outer walls.
Storeroom temperature must be kept as even as
possible ( 5C) and should not fall below 15C. The
relative air humidity should not exceed 50%.

Handling of opened packages: Electrodes that remain
unused at the end of a shif should be replaced in their
packaging and resealed. Alternatively, they can be put
in a warm heating cabinet at 60 70C. The relative air
humidity should not exceed 50%.
Flux that has not been used should be stored in a
heating cabinet at 60 70C.
If the relative air humidity is above 55%, FCWs should
never be lef unprotected for more than 24 hours.

Handling during welding: It is an advantage if
welding can be carried out at room temperature and
low relative air humidity. Covered electrodes, FCWs
and fuxes should be used at the same rate as they
are unpacked preferably within 24 hours. During
shifs, electrodes must be kept as dry as possible. If
the climate so demands, they should be kept warm
in a portable heat-retaining container or similar. One
alternative is to use smaller packs, e.g. half or quarter
capsules.

Redrying: Electrodes that have sustained slight
moisture damage can be redried for around 3 hours
at 250 280C. Heating and cooling must both be
gradual. Items should not be redried any more than 3
times.
Fluxes that have sustained slight moisture damage
can be redried for 2 hours at 250 300C.
FCWs that have sustained slight moisture damage
can be redried for 24 hours at 150C.
Procedures that have been approved for carbon steel
electrodes are also completely satisfactory for stainless
steel electrodes. This is because the later are not as
prone to moisture pick-up.

Recycling: Because they can be reused, lefover pro-
ducts and scrap are valuable. Wherever possible, pro-
ducts and packaging must be recycled in accordance
with local regulations.

18 19

Health and safety
The fumes and radiation given of during welding
can be hazardous to health. Spater, molten metal and
arcs can cause burns and fres. Furthermore, electrical
equipment is used. If it is not handled correctly, there
is the risk of electric shock. Thus, it is of the greatest
importance that welders and supervisors are aware of
all the potential dangers.
Ensure that ventilation is adequate and that the
welding site has an extractor system that removes
fumes and gases from the welders breathing zone.
When welding in confned spaces, use respiratory
protective equipment or a compressed air line
breathing apparatus.
The right to make changes without warning or notifcation is reserved. Great care has been taken to ensure that the contents of this publication are correct.
However, Bhler Welding Group Nordic AB cannot accept responsibility for errors or for information that is found to be misleading. Suggestions for, or
descriptions of, working methods or of the use, treatment or machining of products are for information only and Bhler Welding Group Nordic AB can accept
no liability in respect thereof. Before using products supplied or manufactured by the company, customers should satisfy themselves of product suitability.
Figure 16: Thanks to their excellent properties, high-alloy fully austenitic steels are used for most applications where requirements are severe.
Use safety equipment for hands, eyes and body, e.g.:
gloves; helmet or face mask with flter glass; safety
boots; apron; and arm and shoulder guards.
Keep the workplace and equipment clean and dry.
Regularly check that safety clothing and equipment
are in good condition.
As far as possible, insulate all conducting elements

Further information on each product group is con-
tained in Avesta Weldings material safety data sheets.
These can be downloaded from Avesta Weldings
website, www.avestawelding.com , or ordered from
Avesta Weldings distributors and retailers.



Avesta Welding
P O Box 501, Modellvgen 2
SE-774 27 Avesta, Sweden
Tel: +46 (0)226 857 00
Fax: +46 (0)226 857 16
info@avestawelding.com
www.avestawelding.com

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