Weldability of steels

Carbon steels
Low alloy steels (Cr - Mo steels)
Quenched tempered steels
High alloy steel

Carbon steels
Low Carbon steels

<0.30 %C max.

Medium Carbon
Steel

0.30-0.65 %C

High Carbon steel

>1.8%C

Cr-Mo steels
Low alloy ferritic steel
- High temp application
- Pr vessels , Nuclear application
- Reactor vessel in refinery

Nominal chemical composition of Cr- Mo steels

Type

Cr

Mo

Mn

Cr-1/2 Mo

0.10-0.20

0.50-0.80

0.45-0.65

0.30-0.60

1Cr-1/2 Mo

0.15

0.80-1.25

0.45-0.65

0.30-0.60

1 Cr-1/2 Mo 0.15

1.00-1.50

0.45-0.65

0.30-0.60

2 Cr1/2 Mo

0.15

1.65-2.35

0.45-0.65

0.30-0.60

2 Cr-1 Mo

0.15

1.90-2.60

0.87-1.13

0.30-0.60

3 Cr1 Mo

0.15

2.65-3.65

0.80-1.06

5 Cr1/2 Mo

0.15

4.00-6.00

0.45-0.65

9 Cr 1Mo

0.15

8.00-10.00

0.90-1.10

8.00-9.50

0.85-1.05

9 Cr1 Mo Nb V 0.08-0.12

Cr- Mo steels
Type

Forging

pipe

Plate

Cr-1/2 Mo

A182-F2

A 335 P2

A387Gr 2

1Cr-1/2 Mo

A182 F12
A336 F12

A335 P12

A387 Gr 12

F182 F11

A335 P11

A387 Gr 11

A336 F11

A369 FP11

A 182 F22

A335 P22

A336 F22

A369 FP22

A369 FP12
A426 CP12
1 Cr-1/2 Mo

2 Cr-1 Mo

A387 Gr 22

Type

Forging

pipe

Plate

3 Cr 1Mo

A182 F21

A335 P21

A387 Gr 21

A336 F21

A369 FP21

A182 F5

A335 P5

A336 F5

A369 FP5

5 Cr-1/2 Mo

5 Cr MoSi

A335 P5b

5 Cr Mo Ti

A335 P5c

7 Cr-1/2 Mo

A182 F7

A335 P7

A387 Gr 5

A387 Gr 7

A369 FP7
9 Cr1Mo

9 Cr1 MovNbN

A 182 F9

A335P9

A336 F9

A369 FP9

A182 F91

A335 P91
A369 FP91

A387 Gr 9

A387 Gr 91

Weldability
Steel composition
Microstructure
Welding process

Weldability of steels
Carbon influences weldability
Alloy element influence weldability
C eq- C+Mn/6+(Cr+Mo+V)/5 + (Cu +Ni)/15

Metallurgical structures in steel

Ferrite
Austenite
Cementite (Iron carbide (Fe3C)
Pearlite

Martensite
Bainite

Ferrite

Pearlite

Bainite

Carbon steels
Low alloy steels
Stainless steels

Aluminimum

Dissimilar metals
Differing melting temp

SMAW, TIG, MIG

SAW

MIG

Soild phase welding

Problems
Hydrogen cracking
Solidification cracking
Lamellar tearing

Hydrogen crack
Cold crack
Delayed crack
Underbead crack

Crack can occur in

HAZ , Weld

Hydrogen cracking
Ductility

Hardness

Crack
sensitivity

Carbon equivalent C+Mn/4

70

60

50

40

30

50% martensite transformation

20

99.9 martensite transformation

10

0
0

0.1

0.2

0.3

0.4

0.5

0.6

%C

Hardness Vs carbon content

0.7

0.8

0.9

Diffusible hydrogen
Susceptible microstructure
Tensile stress

cracking

Cracking mechanism
Hydrogen dissociation ( H2

H+H)

Atomic Hydrogen dissolves in weld

metal
super saturation
localisation at defect sites
Recombination of atomic hydrogen
rupture

Cracking mechanism
Hydrogen solubility is high in liquid state
Upto the solubility limits present in interstial
solution
Beyond the solubility limit, retained in traps.
Localisation of hydrogen takes place
Adsorption of hydrogen reduces the surface
energy required for crack initiation

1.6

Log H in cm3 / 100g

of fe at STP

1.2

Liquid Fe

0.8

Gamma Fe

0.4
Alpha Fe

0.2
0.0
1600

1000

600

400

Temp C

Effect of temperature on solubility of hydrogen

Sources of hydrogen
Flux coating material in electrodes & SAW
welding Flux
Consumables exposed to atmosphere
Moisture in shielding gas
No/ improper baking of weld consumables
Hydrocarbons in base metal
Rusted consumable / base metal

Cracking threshold
Stress Mpa)

2 ppm

4 ppm

8ppm
4

12
Time (h)

16

20

24

Fig. Effect of hydrogen on the critical stress and the time

needed for HIC

Threshold stress intensity for

delayed cracking of 2 Cr 1 Mo
steel

Safe hydrogen level to avoid

hydrogen crack growth below
300 F

Loss of ductility due to

hydrogen

Threshold stress intensity for

delayed cracking of 2 Cr 1 Mo
steel

Pre-heat
0.40

Carbon Content %

0.30
ZONE II

ZONE III

0.20

0.10
ZONE I
0.00
0.20

0.30

0.40

0.50

0.60

0.70

Carbon Equivalent CE

CE = C + (Mn+Si) / 6 + (Cr + Mo+ V) / 5 + ( Ni+ Cu) / 15

Microstructure
Composition of steel
Processing route
Composition of weld
metal
Welding conditions

Low carbon steel 20 mm thick 100 mm thick

Preheat

nil

80 deg

Low carbon steel 12 mm

Low alloy steel

Preheat

120

nil

12

Tensile stress
Restraint
Thickness
Improper fit up
Rapid cooling

To avoid hydrogen
cracking

Controlling diffusible hydrogen

content
Low hydrogen
welding process
basic coated Low
hydrogen welding
electrodes

Preheating

Post heating

Baking of electrodes
prior to welding
Rutile electrode 250 C
Basic electrode 350 C

Dont keep the

electrodes in open
atmosphere
keep the electrodes
in hand quivers

Preheat
Carbon equivalent
Thickness of the base metal
Diffusible hydrogen content
Restraint
Welding process, consumable &
conditions

Preheat

Reduces cooling rate of weld metal

Reduces hydrogen concentration
Reduces residual stresses

Preheat
No welding on the base metal covered with ice
No welding shall be done at or below - 18 deg C
Raise the base metal temperature to min. 16 C
when the ambient temp is 0 to - 18 deg c
Preheat temperature shall be measured at a
distance of 2t or 4 which is higher
Preheat temperature shall be maintained during
welding

F= 47 Si + 75 Mn + 30 Ni + 31 Cr

200

HEAVY RESTRAINT

LOW RESTRAINT

50

Preheat temp C

F= 115 CS; 116- 145 = C- Mn steel, 146-180 = K, 181- 225 = L,

%C

0.35

0.25

300

500
hardness

> 225 = M

Minimum preheat temperatures, with low hydrogen covered

electrodes
13mm
Steel

13 to 25 mm

25 mm

Temp In Deg C

Cr-1/2Mo

38

93

149

1Cr-1/2Mo

121

149

149

11/4Cr-1/2 Mo

121

149

149

2Cr -1/2Mo

121

149

149

21/4Cr-1Mo

121

149

149

3 Cr1 Mo

149

177

177

5Cr-1/2 Mo

149

177

177

7 Cr1/2 Mo

149

177

177

9Cr-1Mo
9C1Mo V NbN

149

177
177

177
204

204

Solidification
cracking

SOLIDIFICATION CRACKING
- Cracking occurs at high temperature close to
liqudus temp.
- Fully Austenitic weld metal are more susceptible
- Hot cracks may be macro cracks or micro cracks
Causes
- Segregation of impurities to the interdentritic regions
- Formation of low melting eutectic along the grain
boundary
- Shrinkage stresses

S, P, Si, O, form liquid films along GB

Below the solidus temperature of the alloy, the
metal has not developed strength
The contraction stresses cause tearing along
grain boundaries

Lamellar
Tearing
Lamellar Tearing
Tee Joint

Lamellar
Tear

Corner Joint

Fillet Weld

Lamellar Tear
Step like crack
in HAZ

Lamellar tearing
Causes
High tensile
stresses
parallel to
weld
Stringer type
inclusions in
base plate
Presence of
Diffusible
Hydrogen

Lamellar Tearing

Material
anisotropy
Poor Short Transverse
ductility
Inclusions

Restraint
stress
Joint thickness
Joint Design
Welding Procedure

Inclusion content in steel

Depends on
Type of steel
Deoxidation practice
Composition
Position of ingot

Inclusions
Type of inclusions

Sulphides
Oxides
Oxy sulphides
Silicates

Inclusion size & shape

Globular
Lamellar
Distribution of inclusion

Volume fraction
Mean spacing between inclusion

Oxidation limits for steel

Material

ASME spec.

Temp Limit
( C)

Carbon steel

SA 178 , SA 210 ,
SA 192

454

Carbon + 1/ 2 Mo

SA 209 T1

480

1 Cr Mo

SA 213 T 11

550

2 Cr 1 Mo steel

SA 213 T22

580

25 Cr 20 Ni

1050

Welding of Cr- Mo steels

Choice of Filler
Base metal / base metal combinations
Service conditions
Deposited filler metal shall match
base metal as close as possible
Filler metals standards
Low alloy steel SMAW A 5.5,
GTAW GMAW 5.18

FCAW 5.20

Welding consumables for Cr-Mo steel welding

Type

SMAW

GMAW

Cr-1/2 Mo

E 80xx-B1

FCAW

E7XT5 A1

SAW

F8XX EXXX B1

E8XT1-A1
1Cr-1/2 Mo

E 801XB2

ER 80X B2 E8XTX B2

F8XX EXXX B2

1 Cr-1/2 Mo

E 701XB2L

ER 70XB2L E8xTXB2L

F8XX EXXX B2H

E8XTXB2H
2 Cr-1 Mo

E901X B3

ER 90XB3 E 9XTXB3

E 801X B3L

ER 80X B3LE9XTXB3L

F9XX EXXX B3

E9XTxB3H
3 Cr1 Mo

No matching

>>>

5 Cr1/2 Mo

E502 1X

ER502

E801X B6

ER 80X B6 E6XT5B6

E502T

E801X B6L
7 Cr1/2mO

E801XB7

No matching >>>

F9XX EXXX B6
F9XX EXXX B6H

9 Cr 1Mo

E5051X

ER505

E505 T1,2 F9xx ExxxB8

E 8018 B8

ER 80X B8

EX15B8

E8018 B8L
9 Cr1 Mo Nb V

E 901X B9

E6XT5B8L
ER 90X B9

FXX EXXX B9

Preheat reqd for thermal cutting operation, tack

welding
In some cases preheat is to be maintained until
PWHT
Heating should be uniform

Root welding Back purging

Under 4% Cr

Not required

4- 6% Cr - Preferable
> 6 % Cr - Essential
Partially welded pipes Care during handling to
avoid bending stress

PWHT temp
Steel

Temp ( C)

Cr-1/2Mo

620-704

1Cr-1/2Mo

620-720

11/4Cr-1/2 Mo

2Cr -1/2Mo
21/4Cr-1Mo
3 Cr1 Mo

680-760

5Cr-1/2 Mo
7 Cr1/2 Mo

700-760

9Cr-1Mo
9C1Mo V NbN

730-760

WELDING of 12 Cr steels
THICKENSS RANGE: 15 TO 75 mm
PREHEAT (ROOT) 250C
SUBSEQUENT PASS PREHEAT: 350C
ROOT RUN: TIG WELDING
FILLER PASS : MMAW
ELECTRODE BAKING: 300TO 350C
ELECTRODE HOLDING : 100 TO 150C( KEEP AT PORTABLE
OVEN)
Hold at 100C until taken for PWHT
HT 760 +- 10C 3min/mm
Slow cool after 300C

Temper embrittlement
Brittleness that results near ambient temp when
certain alloy steels are held in temp range 700 1100
F or cooled slowly in the range
Increase in ductile brittle transition temp
No change in tensile properties
Embrittlement is reversible
By heating above above 1100 F, can be de-embrittled
Occurs only in the presence of specific impurity
elements P, Sb,Sn As
Impurity build up by segregation at Grain boundary
Grain boundary decohesion takes place

No embrittlement below 85 Ksi for N&T

Increase in transition temp up to 300 F
Cr- Mo steel 40 Ft Lb at 50 F is essential to avoid
brittle fracture
J factor 300 transition temp increase by 150 F
J factor 150 transition temp increase by 30 F
Minimum stress required to cause brittle
fracture is 5000 to 15000 PSI
Reduce pressure during shut down to avoid
massive brittle fracture

Step cool heat treatment

1h

15h
1

24h
1

1- cooling rate 10 F / h
2 cooling rate 20 F / h
Transition temp for 40 ft lb(

60h
1

100h
1

AC

Typical gas contents of fusion

welds in steels (PPM)
H

SMAW basic

3-9

120

250

SMAW Rutile

30-45

Cellulose

50-65

SAW

3-13

60

200-700

Self shielded

3-9

50 / 170 *

130

* Combined nitrogen

Code relevant for process plant

Pressure vessels

ASME Sec VIII

Heat Exchangers

TEMA

Structures

AWS D1.1

Tankage

API 650, API 620

Materials for specific service