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DISSIMILAR METAL WELDING

- when two different metals/alloys are jointed together.
Autenitic, ferritic, or martensitic stainless steel can be readily fusion welded
to carbon or low alloy steel using a filler metal that can tolerate dilution by
both base metals without formation of flaws in the joint. An austenitic
stainless steel or nickel alloy filler metal is commonly used. The choice
depends on the application and the service conditions.

Selection of the filler metal is an important step for reasonable service life
when designing a fusion weld between a carbon or low alloy steel and
an austenitic stainless steel. Proper choice depend upon the expected
service conditions of the welded joint and the effect of dilution on the
composition of the weld metal.

A guide to select filler metal for dissimilar metal welding :
Anton L Schaeffler published in 1949 in the journal Metal Progress, what we
called Schaeffler Diagram :

Cromium equivalent = % Cr + % Mo + 1.5 % Si + 0.5 % Nb
Nickel equivalent = % Ni + 30 % C + 0.5 % Mn






















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Example :
Welding Mild Steel S235JRG to Stainless Steel Type 309. Choice a filler
metal is good and safe for this joint ?



Chemical Composition :

Content
Mild Steel
S235JRG
Stainless
Steel 309
% C 0.12 0.20
% SI 0.50 1.00
% Mn 1.60 2.00
% Cr 0.30 22.00
% Ni 0.30 12.00
% Mo 0.08 0.00

Welding process : E-hand/SMAW/111








Base 2 :
Stainless Steel
309
Base 1 :
Mild Steel
S235JRG
Filler Metal ???
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Answer :
Calculate Chrom equivalent and Nickel equivalent !

Content
Mild Steel
S235JRG
Stainless
Steel 309
% C 0.12 0.20
% SI 0.50 1.00
% Mn 1.60 2.00
% Cr 0.30 22.00
% Ni 0.30 12.00
% Mo 0.08 0.00

Cromium equivalent = % Cr + % Mo + 1.5 % Si + 0.5 % Nb
Nickel equivalent = % Ni + 30 % C + 0.5 % Mn

Base 1 (S235JRG)
Cr.eq = 0.30 + 0.08 + (1.5 x 0.50) = 1.13
Ni.eq = 0.30 + (30 x 0.12) + (0.5 x 1.60) = 4.70

Base 2 (309)
Cr.eq = 22 + (1.5 x 1) = 23.50
Ni.eq = 13 + (30 x 0.20) + (0.5 x 2) = 19.00

Trial 1 : using filler metal CN 13/4

Content S235JRG 309.00 CN 13/4
% C 0.12 0.20 0.04
% SI 0.50 1.00 0.30
% Mn 1.60 2.00 0.50
% Cr 0.30 22.00 12.20
% Ni 0.30 13.00 4.50
% Mo 0.08 0.00 0.50

Calculation of Chrom equivalent and Nickel equivalent for filler metal :
Filler Metal 1 (CN 13/4)
Cr.eq = 12.20 + 0.50 + (1.5 x 0.30) = 13.15
Ni.eq = 13 + (30 x 0.04) + (0.5 x0.5) = 5.95

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Summery calculations of Chrom equivalent and Nickel equivalent for
Base 1, Base 2 and Filler Metal 1 :

S235JRG 309.00 CN 13/4
Cr.Eq 1.13 23.50 13.15
Ni.Eq 4.70 19 5.95

Cr. Eq and Ni. Eq above are ploted to Schaeffler Diagram :



In the sample above, the welding point 1 is located in the Martensite and
Ferrite (M+F) area near the crack line. This means it is dangerous to weld
the two materials (S235JRG to SS type 309) together with filler metal
CN 13/4 (probably will produce hardness cracks).
It is recommended to change and look for another Filler Material which
has more Nickel in its composition.




Asep Suharto (9 December 2008)..

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to change and look for another Filler Material which has more Nickel in
its composition

Trial 2 : using filler metal FOX A7

Content S235JRG 309.00 CN 13/4 FOX A7
% C 0.12 0.20 0.04 0.11
% Si 0.50 1.00 0.30 1.20
% Mn 1.60 2.00 0.50 4.20
% Cr 0.30 22.00 12.20 19.20
% Ni 0.30 12.00 4.50 8.50
% Mo 0.08 0.00 0.50 0.70

Calculation of Chrom equivalent and Nickel equivalent for filler metal :
Filler Metal 2 (FOX A7) :
Cr.eq = 19.20 + 0.70 + (1.5 x 1.20) = 21.70
Ni.eq = 8.50 + (30 x 0.11) + (0.5 x 4.20) = 13.90

Summery calculations of Chrom equivalent and Nickel equivalent for
Base 1, Base 2 and Filler Metal 2 :

S235JRG 309.00 CN 13/4 Fox A7
Cr.Eq 1.13 23.50 13.15 21.70
Ni.Eq 4.70 20.00 5.80 13.90

Cr. Eq and Ni. Eq above are ploted to Schaeffler Diagram :















Asep Suharto (9 December 2008)..

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Cr. Eq and Ni. Eq below are ploted to Schaeffler Diagram :

S235JRG 309.00 CN 13/4 Fox A7
Cr.Eq 1.13 23.50 13.15 21.70
Ni.Eq 4.70 20.00 5.80 13.90




In the second sample above, the welding point 2 is located in the
austenite (A) area. This means it generated welding the two materials
(S235JRG to SS type 309) together with filler metal Fox A7 is possible
without problems and safe.