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Influence of Weld Bead Area on Weld Metal Mechanical Properties

BY B. L. SHULTZ A N D C. E. J A C K S O N

The yield strength of weld metals in multipass welds varies inversely with the cross-sectional area of each weld bead

ABSTRACT. Variations in w e l d i n g conditions have been k n o w n to influence the properties of w e l d deposits by their effect o n the transformation and solidification processes for w e l d metal. These changes occur during the cooling portion of the w e l d thermal cycle; thus, it is important to know the cooling rates of w e l d metal in order to adequately describe its response to the welding process. In the past, the heat source for calculating w e l d metal cooling rates has been measured by the parameters of the welding arc; this heat input has been calculated in units of joules or watt-seconds per unit length of weld. Since various cooling rates can be obtained for a given welding energy i n put, the energy input concept cannot adequately predict mechanical properties. Recently it has been proposed that the calorific heat content of the weld metal is a more appropriate source for determining weld metal cooling rates. The calorific heat content is dependent upon the volume of molten

Metric C onversion 1 1 1 1 1 1 1 in. ipm lb/in. 2 ksi ft-lb kJ/in. in. 2 25.4 mm 0.423 mm/sec 6894.76 N/m 2 6.895 MN/m 2 1.35582 joules 0.03937 kJ/mm 645.16 mm 2

nugget areas for high strength steel. The effect of w e l d nugget area on weld metal cooling rates and the effects of variations in welding technique on resultant w e l d nugget areas are also presented. A unique cooling rate has been obtained for each combination of preheat and weld nugget area. Weld metal cooling rates and welding energy inputs are also investigated for possible relationships to mechanical properties. Introduction The properties of many w e l d deposits have been k n o w n to be significantly influenced by the arc welding technique used during the deposition of the weld metal. Variations in w e l d ing technique affect the dilution, solidification and transformation processes for w e l d metal. These processes are quite complex and are influenced by the rapid thermal changes associated w i t h welding. The area in the vicinity of a welding arc is subjected to a complex thermal cycle in w h i c h temperatures from the initial plate temperature to above the melting point of the alloy are involved. After the weld metal has been melted, not only does the rate of heat transfer to the surroundings determine the rate of solidification, but also the nature and pattern of heat flow during solidification have major effects in the microstructure and properties of the w e l d . The thermal cycle of the w e l d heat-affected zone

1 1 1 1 1 1

mm mm/sec MN/m2 joule kj/mm mm 2

0.03937 in. 2.362 ipm 0.145 ksi 0.737561 ft-lb 25.4 kJ/in. 0.00155 in. 2

B. L. SHULTZ is Welding Engineer, General American Transportation Corporation, Sharon, Pa., and C. E. JACKSON is Professor, Department of Welding Engineering, The Ohio State University, Columbus, Ohio. Based on paper presented at the A WS National Fall Meeting held in Baltimore, Md., during October 69, 1969. 26-s I J A N U A R Y 1 973

w e l d metal and is proportional to the w e l d metal area. In this investigation the calorific heat content of a unit volume of a single weld bead was the basis for measurement. For convenience, such unit volume has been termed " n u g g e t " volume, and its cross-sectional area " w e l d nugget area." These terms should not be confused w i t h the A W S definitions for nugget and nugget size w h i c h refer specifically to resistance welding. This paper attempts to present a working relationship between multipass shielded metal-arc w e l d metal mechanical properties and the w e l d

is determined by the heating and cooling rates of the w e l d metal. The effects of these rapid thermal cycles on the structure and subsequent mechanical properties are of primary concern in welding. The conduction of heat through the plate and the resulting w e l d m e n t properties are determined by the response of the metal to the heat introduced during welding. Thus, it is i m portant to know the effective t h e r m a l cycle produced by the welding technique, in order to adequately relate the response to the welding process. For years, investigators have studied the rapid thermal cycles associated w i t h welding, both mathematically and empirically. 1 - 6 The basic relationship w h i c h has been derived for the cooling portion of the thermal cycle in the vicinity of the w e l d has the following general form. The cooling rate in an arc w e l d on a very thick plate is given by: dT_ d0 (T - T0 )2
2TTK

Z = efficiency factor for heat transfer to the base metal. The heat source for calculating weld metal cooling rates has typically been considered to be the welding arc, and its energy, H, is usually calculated in energy units per linear inch of w e l d , as follows: H (joules per inch) = V (voltage) * A (current) * 60 S (travel, i n . / m i n ) or: H (joules per millimeter) V (voltage) * A (current) S (travel, m m / s ) (2)

Deposited Weld Metal

Base Metal I

Melted

Heat Affected Zone I /

Fig. 1 The cross-sectional area of a bead weld (shaded area) is the weld nugget area

ZH

(D

Not all of the energy generated by the welding arc enters the base plate, thus the efficiency factor, i.e., Z in eq (1), is used to account for the various heat losses. The value for the efficiency factor is typically assumed to remain constant for various welding techniques. Thus, it has been assumed that w e l d metal cooling rates (and subsequent mechanical properties) would be proportional to w e l d ing energy input, as follows: dT dO S (travel V (voltage) * A (current) (3)

dT where = cooling rate on the centerline of the w e l d ; K = thermal conductivity of the metal; T = temperature at w h i c h the cooling rate is to be determined; T0 = initial uniform temperature of the plate; H = arc energy input;

In this expression the cooling rate is directly related to travel speed and inversely related to current and arc

Table 1Typical 5 N i - C r - M o - V Plate and W e l d Deposit Chemical Compositions, % and Mechanical Properties Plate 5Ni-Cr-Mo-V 012 4.91 0.56 0.48 0.32 0.84 0.070 W e l d deposit. 5 / 3 2 in. diam E-14018 0.09 2.74 0.59 0.44 0.47 1.77 0.020 0.031 0.006 0.010 0.01 0.02

Item C
Ni

Cr Mo Si Mn V Ti P S Al Cu Y.S., 0.2% offset: ksi MN/m2 T.S., ksi MN/m2 Elongation

0.003 0.005 0.021

141 972 151 1041

144 992 152 1048 15.8 58.0

,%

20.0 58.4

Reduction of area, % Charpy V-notch at 0 F(-17.8C): ft-lb joules

97 132

46 62

voltage. Various degrees of success have been reported by investigators using this equation for predicting cooling rates and subsequent mechanical properties in welding. One extensive investigation of cooling rates in weld metal recently published by Dorshu 3 showed that w e l d metal cooling rate is approximately linearly related to travel speed, inversely related to welding current, but practically unaffected by changes in the arc plasma length (arc voltage). Myers 4 reports that the overall results of using equations, such as eq (1), for predicting cooling rates in welding is that they are inadequate for fast travel speeds and only reasonably successful at moderate travel speeds. In reviewing the basic assumptions necessary for the derivation of cooling rate expressions, one of the major factors for error is precisely indicating the effective energy of the heat source. The energy of the heat source is typically considered to be the w e l d ing energy input modified by a constant efficiency factor. The exact relationship between welding technique and efficiency of energy utilization has not been determined. However, it has been pointed out that efficiency depends upon the specific welding technique used for depositing weld metal. This view has been established by a qualitative study bv Jackson et al.7 for the suomerged arc and shielded metal-arc welding process. The energy utilized in forming the weld metal was s h o w n to range from 2 0 to over 5 0 % of the total energy of the arc source. Thus, it w a s found that the total energy generated by the welding arc, modified by a constant efficiency factor, is not necessarily an accurate measure of the heat source for calculating cooling rates. This is because the efficiency of energy utilization is not constant over a wide range of welding conditions. One measure of the effective heat source for weld metal cooling rates, w h i c h has been proposed by Jackson, 8 is the calorific heat content of the molten w e l d metal. The heat con27-s

WELDING RESEARCH SUPPLEMENT!

Nugget Area ( m m 2 )
900

50

100

150

200

250

300

350

1
o

67

1,000

Input-Kilojoule Per Linear Millimeter 1 2 3 4 5

KEY:
A C 0 2 Solid Wire V Submerged Arc D Stick Electrode

<EY:
A V

1
y7

800

900

700

SL A
\ ->,
V

Tig
O C 0 2 C o r e d Wire A E l e c t r o n - Beam

60
*

800

C 0 2 Solid Wire Submerged Arc Stick Electrode Tig

60

Mig

700

600

o -+* * o

O C0 2 Cored Wire Electron-Beam

Mig

50
V

600
E 500

55 cj ty
CC

5 500 X E
Z5

.1 400
D
X

Mo

o o
AV O
A

E S 400 N -

4 0 rr

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< 300
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1
40

100

1
0.2

1
03

1
0.5 06

1 60

1 80

1 100

1 120

140

04

Nugget Area (in 2 )

I nput -Kilojoule Per Linear Inch Fig. 3 The relation of energy input to maximum hardness in the heat-affected zone for an AISI 1045 carbon steel9

Fig. 2 The relation of nugget area to maximum hardness in the heat-affected zone for an AISI 1045 carbon steel9

tent is proportional to the w e l d bead cross-sectional area (weld nugget area) per unit length. The w e l d nugget area represents the amount of metal (Fig. 1) w h i c h has been heated to the molten state; the thermal efficiency is inherent in the measurement. The w e l d nugget area increases w i t h welding current and decreases w i t h increasing travel speed. The area seems to be relatively unaffected by normal changes in arc voltage. A n empirical equation for the data (which are available) is as follows: na (in. 2 ) = 11 22 x IO" 7 A ' 5S_
o 0.903

(4)

where: na (in. 2 ) = nugget area in square inches, A = welding current, in amperes, and Sipm = speed of travel in inches per minute; or, in metric units: na(mm 2 ) = 3 3 , 3 1 2 x 1 0 - 6 A1
0903

where na(mm 2 ) = nuggetarea, in square millimeters; A = welding current in amperes and S mm/s = speed of travel in millimeters per second. This relationship has been s h o w n to be valid for the shielded metal-arc, gas metal-arc, and submerged arc welding processes. The cooling rate in the vicinity of the weiding arc has been s h o w n to be 28-s I J A N U A R Y 1 973

determined by the area of molten metal in the weld bead. A recent investigation 9 surveyed the effect of cooling rates in welding on a sample of AISI 1 045 steel. A variety of w e l d ing processes were used to produce surface beads on the steel. W e l d nugget areas were measured from photographs taken of polished and etched cross-sections of the weld deposits; they were then plotted against the maximum heat-affected zone hardness. The relationship of maximum hardness and weld nugget area is similar to the end quench hardenability plot for this steel and is s h o w n in Fig. 2. These data were also studied to determine the relation of the maximum hardness to the welding energy input as s h o w n in Fig. 3. A relationship between w e l d nugget area and maximum hardness in the heat-affected zone has been established. Therefore, since maximum hardness is a function of cooling rate, it should be possible to establish a meaningful relationship between weld nugget area and w e l d metal cooling rates.

oratory tests must be carried out; the objectives of the program that follows were: 1. To determine the relationship between weld nugget areas for multiple pass weldments and resultant weld metal mechanical properties. 2. To determine the effect of w e l d nugget areas on weld metal cooling rates. 3. To relate the effects of variations in welding technique to resultant weld nugget areas for the shielded metal-arc process. Experimental Work Plan of Investigation Test specimens w e r e prepared under controlled conditions with mechanized welding units and preselected welding procedures; the first series of specimens consisted of weld beads deposited on the surface of the plate followed by w e l d metal specimens prepared using multipass techniques. It is expected that, w i t h the results of these tests, it will be possible to establish relationships w h i c h w i l l aid in control of the process. Welding parameter limits also may be established. These w i l l provide manufacturing techniques for the production of desired mechanical properties and, thus, provide a basic quality-control method for the shielded metal-arc process.

Objective
As a result of the concepts w h i c h have been presented, it is expected that weld nugget area may influence weld metal mechanical properties. In order to determine whether definite trends can be detected, controlled lab-

Materials and Equipment A high strength, quenched and t e m pered steel w a s selected for this i n vestigation. It w a s chosen because minor variations in w e l d i n g techniques w e r e k n o w n to produce signif-

icant variations in mechanical properties of w e l d metal. This base metal used for experimental welds consisted of 1 and 2 i n . (25.4 and 50.8 mm) thick plates of 5Ni-Cr-Mo-V steel. The plates had

been water quenched from 1 5 0 0 F (814 C), and tempered at 1 1 8 0 F (638 C) to hardness values of 3 4 to 35 Rc. Shielded metal-arc w e l d deposits were made w i t h electrodes of the iron-powder (E-14018) low-hydrogen

Table 2 - - S u m m a r y of Data Obta ned from Bead-on-Plate Welds Plate thickness, in. 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1/2 1 1 2 2 1 1 1 1 1/2 1 1 2 1/2 1 1 1/2 1 2 1 1 1 1 1 1/2 1/2 1 2 1/2 1 1 1 1 2 1 1 1/2 1 1 2 2 1 1 1 Preheat temperature, F 225 225 225 225 225 225 225 225 225 225 225 225 200 200 500 80 200 500 200 200 200 200 80 200 200 200 200 80 200 200 200 500 80 500 200 200 80 500 200 200 80 200 200 200 200 200 500 200 500 80 200 80 500 200 200 200 200 200 Weld nugget area. in. 2 0.051 0.019 0.052 0.020 0.133 0.043 0.138 0.044 0.047 0.046 0.050 0.051 0.053 0.096 0.057 0.026 0.031 0.053 0.081 0.058 0.034 0.074 0.086 0.028 0.027 0.080 0.034 0.049 0.025 0.087 0.080 0.102 0.052 0.032 0.053 0.054 0.042 0.035 0.093 0.056 0.075 0.053 0.029 0.052 0.046 0.126 0.063 0.029 0.050 0.028 0.049 0.056 0.087 0.046 0.079 0.016 0.051 0.043 Heataffected zone, in. 2 0.081 0.024 0.103 0.032 0.194 0.052 0.266 0.058 0.073 0.069 0.075 0.072 0.079 0.170 0.110 0.033 0.043 0.140 0.111 0.078 0.052 0.127 0.131 0.074 0.040 0.099 0.046 0.071 0.035 0.134 0.136 0,258 0.071 0.043 0.078 0.084 0.053 0.077 0.226 0.097 0.086 0.077 0.040 0.076 0.049 0.202 0.136 0.036 0.104 0.075 0.074 0.161 0.059 0.059 0.119 0.026 0.074 0.065 Welding energy input, kJ/in. 34.6 9.24 44.6 11.9 69.3 18.5 89.1 23.8 29.0 29.0 29.0 29.0 29.0 63.2 29.0 16.6 16.9 29.0 40.8 29.0 23.0 49.2 56.2 20.4 17.9 35.8 20.4 29.0 13.1 46.0 40.8 56.2 29.0 16.6 29.0 39.6 25.4 20.4 56.2 32.2 40.8 32.6 16.6 29.0 20.1 79.3 32.6 16.6 25.4 20.4 25.4 32.6 40.8 25.4 56.2 10.6 29.0 29.0 Cooling rate at 1000 F, F/sec 54.4 169.4 45.1 154.6 26.6 92.7 21.0 86.9 70.8 64.0 64.6 68.3 ND(b| ND ND ND ND ND ND ND ND ND ND ND ND ND ND 48.8 150.7 41.9 15.2 10.7 732 50.7 61.5 54.9 97.7 131.8 12.9 38.8 40.8 57.3 109.9 59.9 101.4 23.5 27.5 115.7 38.2 119.9 45.8 75.3 23.1 65.9 31.4 193.4 73.2 62.8

Weld no.
1

Welding current, amp (a) 110 220 220 110 156 156 220 110 110 220 156 156 156 156 156 156 156 156 220 156 110 156 156 110 110 220 110 156 156 220 220 156 156 156 156 110 156 110 156 156 220 156 156 156 220 220 156 156 156 110 156 156 220 156 156 110 156 156

Arc voltage,
V

Travel speed ipm 15 15 4 4 7.75 7.75 15 15 4 4 7.75 7.75 7.75 4 7.75 15 15 7.75 7.75 7.75 7.75 4 4 7.75 7.75 7.75 7.75 7.75 15 7.75 7.75 4 7.75 15 7.75 4 7.75 7.75 4 7.75 7.75 7.75 15 7.75 15 4 7.75 15 7.75 7.75 7.75 7.75 775 7.75 4 15 7.75 7.75

2 3 4 5 6 7 3 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

27 21 27 21 24 24 27 21 27 21 24 24 24 27 24 24 27 24 24 24 27 21 24 24 21 21 24 24 21 27 24 24 24 24 24 24 21 24 24 27 24 27 24 24 24 24 27 24 21 24 21 27 24 21 24 24 24 24

(a) Electrode positive

not determined

WELDING

RESEARCH

SUPPLEMENT!

29-s

ing rates were determined from cooling curves for each of the bead-onplate welds. Cooling curves w e r e obtained by plunging a high temperature Pt-Rh 18 thermocouple in the molten w e l d metal. The thermocouple millivoltage was fed into an X-Y recorder w i t h a time base. The thermocouple consisted of a 2 4 in. (610 mm) long pair of 0.020 in. (0.05 mm) diam w i r e s of Pt-6%Rh vs. Pt-30%Rh calibrated by comparison w i t h a National Bureau of Standards platinumplatinum 10% rhodium thermocouple. The base metal was preheated by a 3 0 0 0 w a t t strip heater. The electrodes were conditioned in an electric furnace and stored in a stabilizing oven. Electrodes w e r e conditioned immediately after removal from the hermetically sealed shipping containers for one hour at 775 25 F (413 + 14 C) and immediately transferred to the stabilizing oven at 2 5 0 F (121 C). Bead-On-Plate Tests The bead welds for testing during this part of the program consisted of bead-on-plate tests to obtain information on the effects of weld current, arc voltage, and travel speed on the weld nugget area and cooling rate for the shielded metal-arc process. Plate sizes of 1/2 in. (12.7 mm), 1 in. (25.4 mm) and 2 in. (50.8 mm) thick by 8 in. (203 mm) w i d e by 12 in. (305 mm) long w i t h a preheat temperature of 225 F (107 C) were used. The plates were ground to bright metal to remove all mill scale before depositing the bead welds on each side. The PtRh18 thermocouple was manually i m mersed in the molten w e l d metal at the plate centerline slightly behind the arc column. Weld metal cooling rates at 1000 F (538 C) w e r e graphically determined. Weld nugget areas w e r e measured from macrophotographs of the bead weld cross-sections cut from the center of each w e l d bead. The side of the

cross-section facing the w e l d start was polished and etched for metallographic examination. W e l d nugget areas and heat-affected zone areas were measured from the macrophotographs by a compensating polar planimeter. The welding energy input w a s calculated for each of the weld beads by equation (2). The levels of the three variables in this series of tests w e r e picked by setting the m i n i m u m and maximum level for each variable and then calculating the center point on a logarithmic scale (base*). Such a calculation w a s necessary in order for the data obtained herein to be used in a computerized program. The series of beadon-plate w e l d s w e r e used to obtain i n formation on the effects of welding current, arc voltage, and travel speed on w e l d nugget areas and cooling rates. The welding conditions and the results obtained for these welds are shown in Table 2. Mechanical Property Weldments For mechanical property measurements 10 weldments were prepared w i t h the automatic welding equipment. A l l 10 weldments w e r e f a b r i cated w i t h a double-vee groove joint in 2 in. (50.8 mm) thick plate as shown in Fig. 4. A constant preheat and interpass temperature between 2 2 5 - 2 5 0 F ( 1 0 7 - 1 2 1 C ) w a s used during welding. Table 3 shows a summary of the welding conditions for the 10 weldments. The root beads of the first 4 weldments were deposited automatically; however, good penetration w a s not obtained and very deep arc gouging of the second side was required to get to sound w e l d metal. The root beads for the last 6 weldments were deposited manually; the remaining beads for these w e l d ments were deposited automatically. Every weld bead in each w e l d m e n t was run at the same welding current, arc voltage, and travel speed w i t h the

Fig. 4 Location of mechanical property test specimens in weldments: A, tensile specimens; B, Charpy V-notch; C, macrosection

type. Typical chemical composition and mechanical properties are indicated in Table 1 for plate and w e l d metal. Mechanized shielded metal-arc welds were made using an arc-welding system consisting of a control motor-generator set, a control panel, an operator's panel, and a welding head equipped w i t h a covered-electrode feed attachment. The control motor-generator set is used to supply power to operate the control panel and the motor in the welding head. The head is used to feed the welding electrode and to maintain a constant arc voltage. The feed attachment is designed to feed straight lengths of covered electrode of the type ordinarily used for manual shielded metalarc welding. The welding head w a s mounted on a machine carriage, w i t h an electronic governor. Welding power was supplied by a 3 0 0 amp static d-c power supply. Welding current and voltage w e r e continuously recorded on 50 mv and 130v Esterline-Angus recorders. A n electric clock, w h i c h was interlocked to the welding current by an internal relay in the welding system, w a s used to measure arc time. Weld metal temperatures and cool30-s I J A N U A R Y 1 973

Table 3 S u m m a r y of Welding Conditions Used to Fabricate Mechanical Property Weldments'in 2 in. ( 5 0 . 8 m m ) Thick H Y - 8 0 w i t h 2 2 5 F ( 1 0 7 C) Preheat Weld ment no. 1 2 3 4 5 6 7 8 9 10 Welding Current dcrp, amp 115 160 210 260 160 111 270 230 180 110 Arc voltage,
V

Travel speed, ipm 4.7 6.6 8.6 9.4 4.9 4.0 8.1 5.0 16.0 3.0

Nugget area in. 2 0.045 0.050 0.059 0.085 0.068 0.048 0.086 0.098 0.034 0.061

24 24 24 21 23 27 30 22 27 27

Fig. 5 Weld nugget area shown outlined on etched macrosection of a weld

' x.i.y'%.

exception of 4 root beads w h i c h were run at 1 1 0 amp., 2 4 v, and 6 ipm (2.54 m m / s ) . The 10 weldments w e r e radiographed at least 2 days after fabrication. From each of the 10 w e l d m e n t s , t w o 0.357 in. (9.068 mm) diam all w e l d metal tension and eight Charpy V-notch test specimens w e r e machined as s h o w n in Fig. 4. The nugget area was determined from the last pass on etched macrosection of the w e l d as s h o w n in Fig. 5. A l l tensile specimens w e r e mechanically tested by an independent testing laboratory. Room temperature

tensile strength, yield strength (0.2% offset), elongation and reduction of area values w e r e obtained for each test bar. Charpy V-notch test specimens were tested at 30, 0, -30 and -60 F ( - 1 , -18, - 3 4 and -51 C). Specimens were stabilized at test temperature in an acetone and dry ice bath for at least 2 0 min, and tested w i t h i n 3 sec after removal from the bath. The bath temperature w a s measured w i t h a +60 to - 1 0 0 F (16 to - 7 3 C) t h e r m o m eter, w h i l e specimen temperature was measured w i t h a copper constantan thermocouple inserted in a spe-

cial aluminum " d u m m y " specimen w h i c h had been drilled to locate the thermocouple at the specimen center. Energy absorption values in ft-lb were obtained for each test specimen. Results Bead-On-Plate Test Metallographic examination of the bead-on-plate weld cross-sections included measurements of the w e l d nugget area and the heat-affectedzone area. Table 3 includes the data obtained for the nugget area measurements.

2800

WELDING CONDITIONS
2400 I in plate Nugget area 2 0 0 F preheat HAZ I 10 amp Cooling rate 2 4 volts Dilution I 5.0 ipm 0 0l6in 0 0 2 6 in 2 193 F/s 47 %
2

1400

200

1000I 600

800 a >

E
I1200

CL

800 Fig. 6 Cooling portion of weld thermal cycle weld 56, Table 2

400

J
6

L
8 10 12 14 16 16

Time (sec) WELDING RESEARCH SUPPLEMENT! 31-s

2800

WELDING
2400

CONDITIONS
0 0 1 9 in 2 0.0 29 in 2 1 6 9 F/s 53 %

400

2000

2 in plate Nugget area 2 2 5 F preheat HAZ 1 1 0 amp Cooling rate 2 1 volts Dilution 1 5 0 ipm

1200 O 1000

1600
8 0 0 cu

E I- 1200
600

800
Fig. 7 Cooling cycle portion of weld 2 thermal weld 2, Table

400
8 Time 10 (sec) 12

2800

WELDING
2 in plate 2 0 0 F preheat 156 amp 2 4 volts I50ipm

CONDITIONS
0029m2 0 0 3 6 in 2 1 16 F/s 57 %

r-

2000

Nugget area HAZ Cooling rate Dilution

1200

800 $
CL

800 Fig. 8 Cooling thermal cycle 8 Time 10 (sec) portion of weld weld 48, Table 2

2800

WELDING
2400 I in plate 2 0 0 F preheat 2 2 0 amp 2 4 volts 1.50 ipm

CONDITIONS
0 0 4 6 in 0 0 4 9 in 2 I 01 F/s 62 %
2

1400

r- 2000

Nugget area HAZ Cooling rate Dilution

1200

1600 8 0 0 n>
Q.

<u I - 1200 600

Q.

800

400 Fig. 9 Cooling portion of weld thermal cycle weld 45, Table 2 8 Time 10 (sec)

32-s

j J A N U A R Y

1 9 7 3

2800

WELDING
2400
I in plate 2 0 0 F preheat

CONDITIONS
0 0 5 3 in 0 0 7 8 in 2 6 I F/s 50 %

56 amp 2000
2 4 volts 7 7 5 ipm

Nugget area HAZ Cooling rote Dilution

200 o 1000

1600
8 0 0 cu
Q-

1200
600

800
Fig. 10 weld thermal Table 2 Cooling cycle portion weld of 35,

400

400
8 Time 10 (sec)

2800

WELDING
2400
I in plate 2 0 0 F preheat 1 10 amp 2 4 volts 4 0 ipm

CONDITIONS

400

2000

Nugget area 0.054 i n 2 HAZ 0 0 8 4 in 2 Cooling rate 55 F/s Dilution 4 I % O IOOO

B
Q.

1600 800 cu
CL

E I 200
600

Fig. 11 weld thermal Table 2

Cooling cycle

portion weld

of 36, 8 Time IO (sec)

Time IO

(sec) 12

iwA

'

'

WELDING i m plate
. ^ v ^ ^

CONDITIONS
0 0 9 3 in 2 0 2 2 6 in 2 3 F/s
39%

Nugget area 200 F preheat HAZ I 56 amp Cooling rate 24 /olts Dilution 4 0 pm

-5 o
CO

I600

a.
E *1200

8 0 0 co a
E

"I

I-

CD

600

Fig. 12 Cooling portion of weld thermal cycle weld 39, Table 2

I 26

I 28

30 Time (sec)

32

34

36

38

40

W E L D I N G

R E S E A R C H

S U P P L E M E N T !

33-s

W e l d metal cooling curves w e r e obtained for the bead-on-plate tests to determine the effects of weld nugget areas on w e l d metal cooling rates. Cooling curves for some of the beadon-plate welds are s h o w n in Figs. 6 to 12. Cooling rates were graphically determined at 1000 F (538 C) from the temperature vs. time plots. The cooling rates w e r e determined at 1000 F (538 C); this temperature is above the transformation range for this weld metal composition, thus eliminating any sudden changes in slope introduced by transformations on cooling. Subsequent examination of the cooling curves revealed that there w e r e no abrupt changes in slope. Hence, the weld metal was

Mechanical Property Weldments The first four weldments radiographed exhibited areas of porosity w h i c h were correlated to w e l d starts. Since a backwash starting technique w a s not feasible w i t h the automatic equipment, all additional w e l d starts were ground before depositing subsequent weld beads. After this technique was adopted, no porosity was visible on subsequent radiographs. No transverse delayed weld metal cracks w e r e observed in any of the 10 weldments: however, 4 of the 8 t e n sile specimens from the first 4 w e l d ments exhibited poor tensile ductility and two exhibited fish-eyes on the fracture surfaces. Fish-eyes on the tensile specimen fracture surfaces

set of 4 mechanical property w e l d ments (1 to 4) was made at a welding energy input of 35.2 kilojoules per linear inch (1385 j / m m ) , but w i t h various welding currents and travel speeds. W e l d metal yield strength ranged from 1 53.0 to 135.5 ksi (1056 to 934 M N / m 2 ) at the same level of welding energy input. A second set of 3 mechanical property weldments (7, 8, and 10) w a s made at a welding energy input of 60.0 kilojoules per linear inch (2362 j / m m ) , but w i t h various welding currents and travel speeds. W e l d metal yield strength ranged from 148.8 to 131.8 ksi (1026 to 1009 M N / m 2 ) at this level of welding energy input. Three other mechanical property

Table 4 -- A l l Weld Metal Tension and Charpy V-Notch Impact Test Results Weldment
no.

Beads
58 49 43 35 38 47 34 28 96 37

Layers
18 19 19 16 16 18 18 15 29 17

Weld energy input, kJ/in. 35.2 35 2 35.2


352

Weld cooling rate, F/sec 77.0 62.0 45.5 32.0 41.0 66.0 31.5 27.2 108.0 47.0

Nugget area in2 0.045 0.050 0.059 0.085 0.068 0.048 0.086 0.098 0.034 0.061

Yield strength Tensile Elon(0.2%) strength, gation, ksi ksi % 151.6 153.0 150.4 150.1 144.1 142.1 140.3 135.6 139.4 144.1 148.3 149.3 138.8 140.3 131.8 135.2 152.5 153.0 148.8 148.0 153.3 158.4 154.8 153.5 148.6 146.7 144.8 145.7 153.1 152 7 154.4 156.0 146.9 148.0 145.0 148.4 152.8 145.4 151.2 154.8
4.3

Reduction in area, % 12.9 49.0 39.0 64.0 36.0 28.0 64.0 65.0 59.4 62.4
260

Charpy V-notch energy absorpti on; 'tt-lb +30 F OF -30 F -60 F 35.0 39.0 41.0 42.0 36.0 42.0 33.0 48.5 44.5 49.5 30.0 38.5 29.0 40.0 45.0 48.5 32.0 44.0 34.0 36.5 32.5 37.5 33.0 43.5 32.5 43.5 35.0 42.0 40.0 45.0 33.0 43.0 32.0 41.5 41.5 43.0 33.5 35.0 29.0 42.0 24.0 32.5 23.0 20.0 37.0 34.5 29.5 40.0 42.0 34.5 27.5 31.5 25.0 30.5 33.0 36.0 24.0 34.5 31.0 36.5 16.0 22.0 23.0 29.0 19.0 25.0 25.0 29.0 27.0 34.5 25.0 23.0 23.0 32.5 29.0 33.0 21.0 28.0 21.5 33.5

1 2 3 4 5 6 7 8 9

16.4 14.3 20.0


86

12.1 18.6
207

45.1 45.0 60.0 60.8 18.2 59.4

15.7 20.0
9.3

17.9 20.0 20.0 20.7 20.0 13.6 12.9


9.3 93

10

60.0 61.0 60.0 33.0 61.0 40.0 28.0 25.0


250

(a) Surface specimens reported first; center specimens are reported second.

probably transforming to martensite at a lower temperature. The M s temperature of this weld metal is probably in the range 7 0 0 - 8 0 0 F ( 3 7 1 427 C) based on the M s temperature of the base plate. Slopes of the cooling curves were not taken at the lower temperature range. This was not done because the millivoltage response of the thermocouple per degree in temperature is much smaller in the temperature range 7 0 0 - 8 0 0 F ( 3 7 1 - 4 2 7 C ) t h a n at 1000 F (538 C) and would result in decreased accuracy for the measurement of weld metal cooling rates. Welding conditions for the graphical determination of weld metal cooling rates are also given in Table 3. 34-s I J A N U A R Y 1973

were attributed to the presence of excessive hydrogen in the w e l d metal. All electrodes w e r e removed from the holding oven and reconditioned at 775 2 5 F (413 + 14 C). None of the remaining six weldments exhibited fish-eyes on the fracture surfaces, and all but t w o specimens exhibited cup and cone fractures. Results of the all-weld-metal t e n sion and impact tests are given in Table4. Discussion Effect of Welding Energy Input The effect of welding energy input on E-14018 weld deposit yield strength is s h o w n in Fig. 13. The first

weldments were made, one at 18.2 kilojoules per linear inch (716 j / m m ) and t w o at 4 5 . 0 kilojoules per linear inch (1771 j / m m ) . In general, yield strength decreased w i t h increasing welding energy input. The effect of cooling rate on Charpy V-notch energy absorption at - 6 0 F (-51 C) is s h o w n in Fig. 14. Energy absorption tended to increase slightly w i t h increasing w e l d nugget area and lower cooling rate. The relationships between welding energy input and w e l d metal properties show that a calculation of the arc energy is not a positive means of controlling w e l d deposit mechanical properties. The scatter in the results suggests that calculated welding e n -

Welding 160

Energy 1000

Input

(j/mm) 2000

Cooling Rate ( C / s ) L
M

50

10 I I

50
I I

o S: 40 a. L,
O
CO

- 6 0 F Test Temperature

o 50 "3

<

30

>,
CJl

CD

l5 20
JZ

<
3s

o o Z

10

> >,
0 15 Welding Fig. 13 Relation input 30 Energy 45 Input 60 (kj/in) and welding energy

I I

~ 10
20 40 60 80 IOO I20

9- r.

Cooling Rate ( F / s )
Fig. 14 Relationship between measured Charpy V-notch energy absorption at -60 F cooling rates and

between

yield strength

ergy input may not be the best indicator of weld metal mechanical properties.

Effect of Weld Nugget Area A review of the data for Fig. 13 showed that, for a given welding e n ergy input, the w e l d m e n t w i t h the most passes always had the highest yield strength and the w e l d m e n t w i t h the least passes always had the lowest yield strength. This suggested that the area of the weld bead may be a contributing factor in controlling yield strength. The relationship between w e l d nugget area and E-14018 w e l d deposit yield strength is s h o w n in Fig. 15. W e l d deposit yield strength is inversely related to weld nugget area.

Practical Application of the Nugget Area Concept The data presented in the preceding sections were confined to automatic shielded metal-arc welds. Automatic equipment w a s used to e n sure uniformity and reproducibility of the basic relationships derived from the data. The w e l d nugget area concept was also used to analyze data from manual 5Ni-Cr-Mo-V steel w e l d ments. W e l d i n g energy input for each weldment was calculated from equation (2). W e l d nugget areas w e r e calculated from the nomograph shown in Fig. 17, w h i c h gives the solution to equation (4). Analysis of the data indicated that even calculated w e l d nugget area appears to be directly related to w e l d metal deposit yield strength Fig. 16.

W e l d nugget area has been s h o w n to be more directly related to w e l d metal mechanical properties than welding energy input. Nonetheless, there still remains the problem of controlling w e l d nugget areas under production conditions. Once a usable range of yield strengths is determined and related to w e l d nugget areas, the chart s h o w n in Fig. 17 can be used to help personnel maintain the range of nugget areas desired. It is to be remembered that voltage is a minor factor and is not used in this calculation. Since measurement and control of travel speed for the manual process is quite difficult, an additional solution to the problem would be to specify the minimum number of passes to be deposited for a given joint as a means

Nugget A r e a (mm 2 ) I60 IO 20


1

Nugget 60

Area ( m m 2 \ 50 I 100

30

40

50

1 -

100

150

t

1000

I40 -a 130

900

n
0

,
0 02 0.04 Nugget

,
006 008 A r e a (in 2 ) 0 1 0.04 0.06 Weld Nugget 0.08 0.I0 Area ( i n . 2 ) strength

Fig. 15 Relationship between measured weld nugget area and yield strength for E14018 high strength multipass weld metal

Fig. 16 Effect of calculated for E14018 weld deposits

weld nugget area on yield

WELDING RESEARCH SUPPLEMENT!

35-s

Chart for Determining Nugget Area for a given Welding Technique

TRAVEL (S) too


.200

CURRENT (A)
100-

NUGGET AREA (no)


ZOO

50^-100
90 80

5 - O.Ol
IO

70 60

300
C M

0.02
= 50 40 |

400
m
cu cu

6 E

0.03 0.04
0 05 vh .C;

A e
"CJ

500
600

% 100 - CD

0.08 -g
Is

o o

<=

30

cu

-O.IO cj

W k,
Q_

700 800 900

/O-

CU

CJ

0.20 0.30 0.40


0.50 0.60

Crto

CX

v.

=>
C3CO

20 t$
.C;

/OOO

500

080 1.00
10

9
2000

8 7 6 5

Fig. 17 Nomograph for determining nugget area for a given welding technique. Welding voltage is not a controlling factor. A straight line drawn to connect the current (A) and travel (S) intersects the nugget area (na) at the calculated value 36-s ! J A N U A R Y 1973

of maintaining production quality. The recognition of the influence of nugget area and its accompanying cooling rate on the mechanical properties of weld metal is significant. This approach w i l l provide a guide for establishing welding techniques w h i c h result in more uniform mechanical properties. Conclusions The experimental tests and equipment used in this program were d i rected toward obtaining a working relationship between multipass w e l d metal mechanical properties and weld nugget areas for a high strength steel. W e l d metal cooling rates and welding energy inputs w e r e also investigated for possible relationships to mechanical properties. W e l d nugget areas (the cross-sectional area of a single w e l d bead) were measured from the last pass of the multiple pass weldments. Welding energy inputs were calculated in units of joules per unit length of w e l d . Weld metal cooling rates w e r e measured at 1000 F (538 C) from cooling curves obtained w i t h a high temperature Pt-Rh 18 thermocouple. Each of the factors selected for investigation were related

to w e l d metal mechanical properties; however, some were more significant than others. Based on the results the following conclusions have been d r a w n : 1. The result of these tests is a good indication of a clear relationship bet w e e n w e l d nugget area and w e l d metal cooling rates. The w e l d nugget area becomes a useful indicator of weld metal mechanical properties w h i c h are influenced by cooling rate. A n inverse relationship between weld nugget area and yield strength in multipass w e l d metal of high yield strength is indicated. 2. The w e l d metal cooling rate associated w i t h a given nugget area was a good indicator of the mechanical properties and a linear relationship existed in these tests between yield strength and the inverse of the cooling rate. 3. W e l d nugget areas and cooling rates appear to be determined by welding current and travel speed. The results of bead-on-plate tests suggest that arc voltage has no significant effect on w e l d nugget area or w e l d metal cooling rate.

References 1. Rosenthal, D., " M a t h e m a t i c a l Theory of Heat Distribution During Cutting and Welding," Welding Journal, 2 0 (5), Research Suppl., 2 2 0 - s to 2 3 4 - s (1941). 2. Rykalin, N. N., "Effectiveness of T h e Metal-Fusion Process During Arc W e l d i n g , " Doklady Akademii Nauk SSR, 63 (11), 131 to 1 3 4 ( 1 9 4 8 ) . 3. Dorschu, K. E., " C o n t r o l of Cooling Rates in Steel Weld M e t a l , " Welding Journal, 4 7 (2), Research Suppl., 49-s to 6 2 - s (1968). 4. Myers, P. S., "Fundamentals of Heat Flow in W e l d i n g , " Welding Research Council Bulletin 123, July 1967. 5. Christenson, N., "Distribution of Temperatures in Arc W e l d i n g , British Welding Journal, 12 (2), 5 4 - 7 5 (1965). 6. Barry, J . M., " H e a t Conduction f r o m Moving Arcs in W e l d i n g , " Welding Journal, 4 2 (3), Research Suppl., 97-s to 104-s (1963). 7. Jackson, C. E., and Shrubsall, A. E., "Energy Distribution in Electric W e l d i n g , " Welding Journal, 29 (5), Research Suppl., 231-s to 241-s (1950). 8. Jackson, C. E., "The Science of A r c W e l d i n g , " Part I, Welding Journal, 39 (4), (5), (6), 1 29-s to 140-s; Part II, 39 (5), 1 77-s to 190-s; and Part III, 3 9 (6), 2 2 5 - s to 230-s (1960) 9. Jackson, C. E., " W e l d i n g Engineeri n g , " Welding Journal, 4 7 (1 1), 8 8 4 to 855 (1968).

( 1 ) S e n s i t i v i t y of t h e D e l t a T e s t t o S t e e l Compositions and Variables by L. J . McGeady

WRC Bulletin No. 172 May 1972

The introduction and use of higher strength heat-treated steels have demonstrated the need for awareness of weldability and fracture problems in the total composite of weld metal, heat-affected zone and plate material. Hence there has developed need for an appropriate test specimen and procedure applicable to the total composite weldment providing the opportunity for failure in any area. This report describes a specimen applicable to this need and to present data to determine whether the proposed specimen, the Delta, allows failures to follow leastresistant paths because of specimen geometry and loading system. It is not the purpose to recommend materials, welding procedures or processes, though it has been necessary to study many of these in a wide variety of combinations to determine their influences on behavior of the specimen. The work reported in this paper was sponsored by the Pressure Vessel Research Committee of the Welding Research Council.

(2) E x p e r i m e n t a l S t r e s s A n a l y s i s a n d F r a c t u r e B e h a v i o r of D e l t a S p e c i m e n s by J . M. Barsom

This investigation was undertaken to analyze the stress distribution in the Delta specimen and to investigate the possible effect of the stress distribution on the flow and fracture behavior of the Delta specimen. The price of WRC Bulletin should be sent to the American 33125. Orders for bulk lots, 10 Research Council, 345 East 47th 172 is $3.00 per copy. Orders for single copies Welding Society, 2501 N.W. 7th St., Miami, Fla. or more copies, should be sent to the Welding Street, New York, N.Y. 10017.
WELDING RESEARCH SUPPLEMENT! 37-s

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