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Introduction
Stainless steel welds characteristically
consist of a two-phase austenite plus ferrite microstructure. Ferrite levels may
vary from a few percent in austenitic stainless steel welds to more than 50% in duplex stainless steel welds. The ability to
predict the ferrite content in these welds is
essential for many reasons. To a large extent, the final ferrite content determines a
weldments properties such as strength,
J. M. VITEK and S. A. DAVID are with Oak Ridge
National Laboratory, Oak Ridge, Tenn. C. R.
HINMAN, formerly an intern at Oak Ridge, is now
at Syracuse University, Syracuse, N.Y.
Paper presented at the AWS Annual Meeting,
March 47, 2002, Chicago, Ill.
10 -S JANUARY 2003
KEY WORDS
Ferrite Number
Neural Network
Duplex Stainless Steel
Austenitic Stainless Steel
Ferrite Content
Cooling Rate
Alloy Composition
Constitution Diagram
(1a)
WELDING RESEARCH
A
effect of manganese on the alloy composition has been noted before (Refs. 10,
11), but these composition-dependent effects have not been included in the most
recent diagrams. This limitation has been
removed in two new alternatives to traditional constitution diagrams. One recently developed model, the Function Fit
Model, considers the difference in free
energy between ferrite and austenite as a
function of composition (Ref. 12). In this
method, the difference in free energy between ferrite and austenite was calculated
as a function of composition and this was
related to the FN. A regression analysis
was used to determine the coefficients associating the FN with the free energy
change. It was found that this approach
was comparable in accuracy to that of the
WRC-1992 diagram.
The second approach is based on an artificial neural network analysis (Refs.
1315). Neural networks are ideally suited
to improve the flexibility, robustness, and
accuracy of ferrite predictions because they
make use of nonlinear regression methods.
The identification of complex trends due to
elemental interactions is straightforward
with the use of neural networks, whereas
they are extremely difficult or impossible to
identify by standard regression analyses.
The FNN-1999 model, developed with the
same data as the WRC-1992 constitution
diagram, was shown to reduce prediction
errors by as much as 40% (Refs. 13, 14).
Furthermore, composition-dependent effects of alloying elements were taken into
account and the consequences of this were
clearly demonstrated (Ref. 14). A more recent model, which is also based on neural
networks, also demonstrates significant improvements compared to the WRC-1992
constitution diagram (Ref. 15).
Another major shortcoming that is
present in the traditional constitutional diagrams as well as the newer models, including the recently developed neural network models, is the absence of any
consideration of welding conditions and
how they may influence the ferrite content
of welds. In particular, the weld cooling
WELDING JOURNAL
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WELDING RESEARCH
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Dataset Generation
FN Values
WELDING JOURNAL 13 -S
WELDING RESEARCH
(2)
Table 1 Composition and Cooling Rate Ranges in Datasets Used for Training Ferrite
Prediction Models
Model
Input Data
FNN-1999
ORFN
min.
max
min.
Concentration (wt-%)
They developed a vibrating sample magnetometer device for making measurements on small samples, but this method
was not available. Therefore, volumepercent (vol-%) ferrite was measured
metallographically in the DVH dataset
and a means for converting vol-% ferrite
to FN was needed. In the NEW dataset, a
mix of FN and vol-% ferrite measurements was made and, once again, conversion to FN was required for many data
points. In some cases, when generating the
new data, multiple side-by-side overlapping laser weld runs were made in order to
produce a wider weld zone that could be
used for direct FN measurements.
The approach that was adapted for
converting vol-% ferrite to FN relied on
the concept of an extended ferrite number
(Ref. 29). It was shown that the maximum
FN for a 100% ferritic material is a function of the Fe content of the material. Several different expressions for maximum
FN as a function of Fe content were proposed (Ref. 29) and the following equation was used:
Fe
Cr
Ni
C
N
Mo
Mn
Si
Cu
Ti
Nb
V
Co
45.60
14.74
4.61
0.008
0.01
0.01
0.35
0.03
0.0
0.0
0.0
0.0
0.0
72.51
32
33.5
0.2
0.3
6.85
12.67
1.3
3.04
0.54
0.88
0.23
0.32
45.60
14.74
4.61
0.008
0.01
0.01
0.35
0.03
0.0
0.0
0.0
0.0
0.0
1.00
max
72.52
32
33.5
0.2
0.33
6.85
12.67
1.3
3.04
0.54
0.88
0.23
0.45
6.54
Table 2 Parameters Used in the Calculation of Cooling Rates, According to Equations 4(a)
and 4(b)
Parameter
K (thermal conductivity)
Cp (density x specific heat)
T (temperature at which
cooling rate is calculated)
T0 (initial plate temperature,
ambient temperature)
Value
Reference
0.28 watt/cm-C
4.6 J/cm3-C
1450C
32
32, 33
25C
achieve an accurate prediction model. Instead, what is necessary is that the cooling
rates for different conditions must be
ranked properly with respect to one another, and the cooling rates must be consistent with the data with which the network was trained. For example, although
the absolute value for the cooling rate in a
laser welded sample is not required, the
assigned cooling rate must be properly
ranked with respect to another weld, made
on a different sample thickness, or with a
different welding speed, power, or
process. This consideration requires that
all cooling rates be calculated in the same,
consistent manner. Thus, actual cooling
rate measurements are not appropriate as
inputs; instead calculated cooling rates
must be used throughout.
The analytical expressions for the cooling rate that were used are those derived
by Adams (Ref. 30), based on the solutions
of Rosenthal (Ref. 31) for heat conduction
as applied to welding. These same expressions were used by David et al. (Ref. 18)
for their extensive series of laser welds on
stainless steels. However, David et al. only
considered 3-D cooling conditions. This
was reasonable in their work since most,
but not all, of their laser welds resulted in
only partial penetration welds. In contrast,
in the present work, a broader perspective
that includes 2-D cooling was needed. The
relevant expressions for 2-D and 3-D cool-
WELDING RESEARCH
Table 3 Alloys Used to Generate the New Dataset and Their Compositions (wt-%)
Alloy
304A
304B(a)
308A(a)
308B(a)
309A(a)
309B(a)
310A(a)
310B(a)
312A(a)
312B(a)
316A(a)
316B(a)
347A(a)
347B(a)
S20910
S21904
308LT1
309LT1
316LT1
2209
2209Wa
2209Wb
2209Wc
2507
2507W
2553Wa
2553Wb
2553Wc
4462
4462W
Z100
Z100Wa
Z100Wb
Z100Wc
(a)
Fe
Cr
Ni
69.058
70.258
67.744
65.87
60.398
59.632
49.797
53.682
60.688
59.09
66.488
62.486
67.502
70.271
57.197
62.74
68.232
59.509
64.872
63.226
61.5952
59.7412
59.5253
64.386
60.506
63.639
63.436
63.585
66.895
63.599
64.385
58.035
57.995
58.081
18.84
18.29
20.04
20.15
23.8
23.36
26.73
25.62
28.92
29.72
17.01
19.07
19.5
19.38
21.25
19.54
19.01
23.96
17.62
23.166
24.6
24.6
24.8
23.061
24.833
22.4
22.46
22.4
21.988
22.67
22.857
25.4
25.4
25.3
9.58
8.7
9.9
10.68
12.86
14.05
21.15
19.18
8.44
8.78
11.44
12.85
10
8.66
13.26
7.18
9.83
13.03
12.06
9.195
8.94
8.97
8.96
6.945
9.477
9.06
9.12
9.09
5.881
8.178
7.261
10.05
9.97
9.98
C
0.058
0.066
0.052
0.059
0.052
0.018
0.11
0.03
0.13
0.11
0.04
0.042
0.06
0.04
0.027
0.017
0.036
0.027
0.03
0.028
0.0248
0.0248
0.0237
0.023
0.026
0.029
0.029
0.03
0.022
0.024
0.034
0.03
0.028
0.033
Mo
0.028
0.018
0.013
0.026
0.052
0.03
0.01(b)
0.01(b)
0.01(b)
0.01(b)
0.022
0.019
0.01(b)
0.01(b)
0.33
0.29
0.12
0.19
0.049
0.128
0.177
0.171
0.178
0.28(b)
0.215
0.164
0.166
0.166
0.168
0.167
0.227
0.248
0.251
0.251
0.11
0.15
0.02
0.01(b)
0.23
0.03
0.05
0.15
0.15
0.2
2.3
2.3
0.1
0.05
2.14
0.4
0.32
0.42
2.49
2.86
3.23
3.19
3.22
3.819
3.821
3.11
3.22
3.16
2.968
3.165
3.571
3.56
3.67
3.61
Mn
1.45
1.31
1.65
1.92
1.87
2.21
1.64
0.9
1.24
1.68
1.95
2.21
1.5
1.21
4.97
9.4
1.23
1.34
1.48
0.886
0.74
0.77
0.76
0.747
0.511
0.89
0.87
0.88
1.42
1.625
0.757
0.67
0.64
0.67
Si
0.52
0.74
0.38
0.78
0.41
0.39
0.5
0.42
0.43
0.39
0.3
0.51
0.6
0.35
0.29
0.34
0.59
0.78
0.49
0.405
0.4
0.41
0.42
0.229
0.443
0.39
0.39
0.39
0.455
0.437
0.193
0.42
0.42
0.43
Cu
Ti
Nb
0.14
0.15
0.06
0.01
0.12
0.01
0(b)
0(b)
0(b)
0(b)
0.19
0.04
0(b)
0(b)
0.14
0.07
0.36
0.38
0.34
0.047
0.13
1.96
1.95
0.338
0.126
0.22
0.21
0.2
0.169
0.104
0.672
0.7
0.72
0.022
0.01
0(b)
0(b)
0.38
0(b)
0.11
0(b)
0(b)
0(b)
0(b)
0(b)
0.31
0(b)
0(b)
0(b)
0(b)
0.03
0.033
0.017
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0
0.01
0(b)
0(b)
0.01
0.01
0(b)
0(b)
0(b)
0(b)
0.01
0.01
0.7
0(b)
0.19
0(b)
0.01
0.02
0.01
0.012
0(b)
0(b)
0(b)
0.015
0(b)
0.03
0.03
0.03
0(b)
0(b)
0(b)
0.04
0.04
0.04
(b)
V
0.04
0.05
0.05
0.04
0.03
0.08
0(b)
0(b)
0(b)
0(b)
0.04
0.02
0(b)
0(b)
0.18
0(b)
0.081
0.08
0.051
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0(b)
0.1
0.1
0.1
Co
0.12
0.22
0.06
0.02
0.12
0.04
0(b)
0(b)
0(b)
0(b)
0.17
0.03
0(b)
0(b)
0(b)
0(b)
0.12
0.17
0.45
0(b)
0.13
0.13
0.13
0.118
0(b)
0.04
0.04
0.04
0(b)
0(b)
0(b)
0.07
0.07
0.07
4(a)
4(b)
where T = cooling rate (C/s), K = thermal conductivity (watts/cm-C), = density (gm/cm3), Cp = specific heat (J/gmC), V = weld velocity (cm/s), t = thickness
(cm), q = heat source power (watts), T =
temperature at which the cooling rate is
calculated (C), and To = initial plate temperature (C). The values of the variables
used in the calculations are given in Table
2. It should be noted constant values for
the thermophysical properties were used
in spite of the fact the values will depend
upon alloy composition and the relative
amounts of ferrite and austenite. Furthermore, cooling rates were calculated at a
constant temperature (T) of 1450C that
corresponds roughly to the liquidus temperature. The ambient, initial plate temperature, To, was taken as 25C. While calculating the cooling rate at the liquidus
temperature may be appropriate for describing behavior related to solidification
conditions, the cooling rate at a lower temperature may be more appropriate for describing behavior related to the solid-state
ferrite-to-austenite transformation. However, given a 2-D or 3-D condition, the
ranking of cooling rates for different conditions will be the same regardless of the
temperature at which the cooling rate is
evaluated, and so one temperature for assessing cooling rates (1450C) was used to
quantify cooling rate effects due to both
solidification and solid-state transformation behavior.
A procedure was needed to allow for a
continuous transition in calculated cooling rate from a 2-D to a 3-D condition as
the thickness or weld conditions changed.
The recommended procedure described
in the Welding Handbook (Ref. 32) uses a
factor , called the relative plate thickness. is derived from the condition
where the 2-D and 3-D cooling rates are
equal and is defined as =
t(CpV(TTo)/q. According to Ref. 32,
if < 0.6, then the 2-D equation is appropriate, while if > 0.9, then 3-D cooling
prevails. Between these two limits, the
cooling rate is between the 2-D and 3-D
bounds. After examining many weld cross-
WELDING JOURNAL 15 -S
WELDING RESEARCH
crucial. The transition from 2-D to 3-D
cooling rates shown in Fig. 4 depends on
the thickness that is used; as the thickness
increases, the transition shifts to higher
heat inputs.
Perhaps the most serious assumption
that was made was related to the cooling
rates that were used for the WRC dataset.
This dataset made up 80% of the total
dataset and, therefore, it was essential to
include these data when training the
neural network in order to achieve a robust predictive model that was valid and
accurate over a large composition range.
However, there were no details regarding
the welding conditions (such as power,
speed, thickness) that were used to generate this dataset, and so it was impossible to
calculate a cooling rate for this critical and
dominant component of the entire
dataset. In order to utilize this extensive
dataset, a default cooling rate of 10C/s
was assigned to all the data in the WRC
dataset. This value is reasonable since the
WRC dataset consisted of data from arc
welds only and was generated under conventional conditions, so it is unlikely that
high weld speeds were used, or that high
cooling rate conditions prevailed.
There are significant sources of error
in generating the cooling rate as an input
variable. When the cooling rate was calculated, errors may arise from any or all of
the following sources:
1) The same thermal property parameters were used regardless of alloy composition or the relative amounts of ferrite
and austenite.
2) The transition from 2-D to 3-D cooling yielded a nonmonotonic variation in
cooling rate with increasing heat input.
3) The effect of weld composition on
weld penetration, such as that due to variations in the magnitude and direction of
the Marangoni-induced fluid flow, were
ignored.
4) A default cooling rate was assigned to a large portion of the data.
However, in order to produce a model
that can be readily used, many of these
simplifications and assumptions were unavoidable. The use of LOG(cooling rate)
as a variable reduces the sensitivity of the
model to cooling rate to some degree. In
addition, as will be shown later, the
changes in FN as a function of cooling rate
occur over several orders of magnitude in
cooling rate and, therefore, the accuracy
in the cooling rate calculation is not quite
so critical; an order of magnitude accuracy may be acceptable.
Procedures for Generating New Data
New welds were made from several alloys and welding conditions to supplement
the high cooling rate data available in the
16 -S JANUARY 2003
Network Development
In the present analysis, a feed-forward
network with a back-propagation optimization scheme was utilized (Ref. 26). A
commercial software package (NeuralWorks Professional II/PLUS) was used for
WELDING RESEARCH
of the networks in the committee was used.
However, the committee predictions were
only marginally better than the predictions
from the single best network and so the
simpler, single network model was used.
The prediction accuracy of the network,
evaluated by several means, as well as sample results and comparisons with other
models, are detailed in Part 2 (Ref. 24).
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