Scripta

METALLURGICA

Vol. 23, pp. 995-1000, 1989 Printed in the U.S.A.

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FRACTURE M E C H A N I S M I N C O A R S E GRAINED HAZ OF H S L A S T E E L WELDS

S. Lee, B. C. Kim a n d D. Y. Lee D e p a r t m e n t of M a t e r i a l s S c i e n c e a n d E n g i n e e r i n g P o h a n g I n s t i t u t e of S c i e n c e a n d T e c h n o l o g y P o h a n g , K y u n g b u k , 790 Korea

(Received January ii, 1989) (Revised April 6, 1989)

Introduction R e c e n t l y , v e r y low t o u g h n e s s v a l u e s of h e a t - a f f e c t e d z o n e s (HAZ) h a v e b e e n n o t i c e d i n high strength low a l l o y (HSLA) s t e e l s w e l d e d w i t h m u l t i - p a s s s u b m e r g e d arc welding p r o c e d u r e s [1,2]. M e t a l l o g r a p h i c a n a l y s e s of HSLA s t e e l w e l d s r e v e a l s i g n i f i c a n t l y d i f f e r e n t r e g i o n s i n HAZ m i c r o s t r u c t u r e s . F o r example, i n s i n g l e p a s s w e l d s t h e r e a r e f o u r c h a r a c t e r i s t i c r e g i o n s i n t h e HAZ d e p e n d i n g o n t h e p e a k t e m p e r a t u r e t h a t t h e r e g i o n was e x p o s e d t o d u r i n g t h e weld t h e r m a l c y c l e ; a c o a r s e g r a i n e d r e g i o n , a f i n e g r a i n e d r e g i o n , a n intercritical region, and a subcritical region. In multi-pass welds these regions undergo multiple thermal cycles, resulting in an inhomogeneous and complicated distribution. I t is now g e n e r a l l y a c c e p t e d t h a t t h e c o a r s e g r a i n e d r e g i o n h a s t h e l o w e s t t o u g h n e s s b e c a u s e i t c o n s i s t s of t h e f o l l o w i n g u n f a v o r a b l e m i c r o s t r u c t u r a l f e a t u r e s , v~z., l a r g e p r i o r a u s t e n i t e g r a i n s i z e , u p p e r b a i n i t e , m a r t e n s i t e - a u s t e n i t e (M-A) c o n s t i t u e n t s , a n d m i c r o a l l o y p r e c i p i t a t e s [3-7]. T h e M-A c o n s t i t u e n t , w h i c h is a l s o c a l l e d a h i g h - c a r b o n m a t e n s i t e i s l a n d , is a d u a l p h a s e m i c r o s t r u c t u r e f o r m e d i n t h e c o a r s e g r a i n e d HAZ w h e n t h e t h e r m a l c y c l e of a s u b s e q u e n t weld p a s s h a s a p e a k t e m p e r a t u r e i n t h e i n t e r c r i t i c a i two p h a s e ( O t + ~ ) r e g i o n [3-5]. In the intercritical region, austenite nucleates and grows preferentially along the prior austenite g r a i n b o u n d a r i e s a n d b a i n i t i c l a t h b o u n d a r i e s , a n d t h e a u s t e n i t e is s t a b i l i z e d t o room temperature or transforms to martensite upon cooling from the intercritical temperature. Among t h e a b o v e m i c r o s t r u c t u r a l features in the coarse grained HAZ, t h e M-A c o n s t i t u e n t is t h e main f a c t o r c a u s i n g d e t e r i o r a t i o n of t o u g h n e s s b e c a u s e of i t s h i g h h a r d n e s s a n d c r a c k s u s c e p t i b i l i t y [6,7], a l t h o u g h t h e r e l a t i v e r a n k i n g of t h e m i c r o s t r u c t u r e s depends o n t h e c h e m i c a l c o m p o s i t i o n s a n d t h e local t h e r m a l c y c l e s i n c l u d i n g p o s t weld h e a t t r e a t m e n t s . I n t h i s p a p e r , t h e s p e c i f i c r o l e s of t h e M-A c o n s t i t u e n t in t h e p r o c e s s of v o i d a n d m i c r o c r a c k i n i t i a t i o n w e r e i n v e s t i g a t e d i n a 500 MPa c l a s s HSLA s t e e l . Specifically, by examining the i n i t i a t i o n of v o i d s a n d m i c r o c r a c k s i n s e c t i o n e d t e n s i l e s p e c i m e n s , we i d e n t i f i e d the m i c r o m e c h a n i s m of f r a c t u r e p r o c e s s e s a n d r e l a t e d i t to t h e o b s e r v e d C h a r p y i m p a c t e n e r g y . Experimental T h e e x p e r i m e n t w a s c a r r i e d o u t o n a 44 mm t h i c k p l a t e of a n o r m a l i z e d BS4360 Gr.50D s t e e l p r o v i d e d b y P o h a n g S t e e l Co. T h i s is a h i g h - s t r e n g t h grade steel with a tensile s t r e n g t h o f a b o u t 500 MPa, w h o s e c h e m i c a l c o m p o s i t i o n is 0 . 1 3 C - 0 . 4 S i - l . 4 3 M n - 0 . 0 1 9 P - 0 . 0 0 1 S 0.065AI-0.3Cu-0.22Ni-0.017Ti-0.021Nb. T h e s p e c i m e n s w e r e s u b j e c t e d t o a weld s i m u l a t i o n , l e a d i n g to c o a r s e g r a i n e d HAZ. T h e h e a t i n g r a t e w a s 10 C/s. After reaching the peak t e m p e r a t u r e of 1350 0C a n d a r e s t i n g time of a b o u t 5-10 sec, t h e s p e c i m e n s w e r e cooled d o w n w i t h a c o o l i n g time f r o m 800 C to 500 C (dts/s) of 42 s. T h i s c o r r e s p o n d s t o a s u b m e r g e d a r c w e l d i n g of a 44 mm t h i c k p l a t e w i t h a h e a t i n p u t of 50 k J / c m . T h e p e a k t e m p e r a t u r e of t h e s e c o n d t h e r m a l c y c l e (Tp 2) w a s v a r i e d b e t w e e n 600 0C a n d 1200 0C. T h e C h a r p y V - n o t c h s p e c i m e n s w i t h T-L o r i e n t a t i o n w e r e m a c h i n e d f r o m t h e o v e r s i z e d C h a r p y b l a n k s a f t e r t h e r m a l s i m u l a t i o n t r e a t m e n t s a n d w e r e t h e n t e s t e d a t - 1 0 C a n d - 8 0 C.

In order to investigate the micromechanism of fracture and determine the strain required for void initiation under high triaxial stress fields, tensile tests and subsequent

995 0036-9748/89 $3.00 + .00 Copyright (c) 1989 Pergamon Press

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metailographic analyses were conducted using circumferentially-notched specimens. The m a c r o s c o p i c s t r a i n a t a d i s t a n c e f r o m t h e p o i n t of minimum r a d i u s (~z) c a n b e o b t a i n e d f r o m t h e s t r a i n d i s t r i b u t i o n p r o f i l e of t h e t e n s i l e s p e c i m e n u s i n g t h e e v a p o r a t e d c a r b o n g r i d m e t h o d [8,9]. T h e t e n s i l e s p e c i m e n s p u l l e d a n d u n l o a d e d p r i o r to f r a c t u r e w e r e s e c t i o n e d p a r a l l e l t o t h e t e n s i l e axis, p o l i s h e d , e t c h e d a n d e x a m i n e d i n a SEM to i d e n t i f y t h e l o c a t i o n w h e r e a v o i d is f i r s t i n i t i a t e d . T h e f r a c t u r e d t e n s i l e s p e c i m e n s w e r e f i r s t n i c k e l - p l a t e d to a v o i d r o u n d i n g d u r i n g p o l i s h i n g a n d t h e n s u b j e c t e d t o t h e same m e t a l l o g r a p h i c p r o c e s s e s a s the unfractured specimens. Results and Discussion T h e c o a r s e g r a i n e d HAZ of t h e HSLA s t e e l w e l d s c a n b e r o u g h l y c a t e g o r i z e d i n t o f o u r r e g i o n s a c c o r d i n g to t h e r e h e a t i n g t e m p e r a t u r e a s follows: (a) s u b c r i t i c a l l y r e h e a t e d z o n e (SRCG HAZ), t h e z o n e r e h e a t e d below Acl, (b) i n t e r c r i t i c a l l y r e h e a t e d z o n e (ICRCG HAZ), t h e z o n e r e h e a t e d b e t w e e n Acl a n d Ace, (c) s u p e r c r i t i c a l l y r e h e a t e d z o n e (SCRCG HAZ), t h e z o n e r e h e a t e d a b o v e Ac~ a n d below a b o u t 1200 0C, a n d (d) u n a l t e r e d c o a r s e g r a i n e d z o n e (UACG HAZ), t h e z o n e t h a t is n o t r e h e a t e d o r r e h e a t e d a b o v e 1200 C. T h e r e s u l t s of C h a r p y t e s t s i n t h e s i m u l a t e d c o a r s e g r a i n e d HAZ a r e s h o w n i n F i g u r e 1. I t c a n b e s e e n f r o m F i g u r e 1 t h a t t h e c o a r s e g r a i n e d HAZ e x h i b i t s low C h a r p y i m p a c t e n e r g y i n two c a s e s . T h e f i r s t is t h e o n e s i m u l a t e d b y a s i n g l e t h e r m a l c y c l e w i t h a p e a k t e m p e r a t u r e of 1350 0C (UACG HAZ) a n d t h e s e c o n d is t h e o n e s i m u l a t e d b y d o u b l e t h e r m a l c y c l e s w i t h Tp t i n t h e r a n g e of 750 oC to 800 0C (ICRCG HAZ). M i c r o a t r u c t u r e s of t h e s e two z o n e s a r e m a i n l y c o m p o s e d of u p p e r b a i n i t e . When t h e s p e c i m e n s w e r e s p e c i a l l y e t c h e d b y u s i n g a 2 - s t a g e e l e c t r o l y t i c e t c h i n g t e c h n i q u e [7], M-A c o n s t i t u e n t s were revealed in the coarse grained bainitic microstructurea. F i g u r e 2 is a t y p i c a l SEM m i c r o g r a p h of M-A c o n s t i t u e n t s i n t h e s i m u l a t e d ICRCG HAZ. B e c a u s e t h e s e M-A c o n s t i t u e n t s a r e k n o w n to b e f o r m e d a l o n g t h e b a i n i t e l a t h e [3], t h e i r m a j o r c o n f i g u r a t i o n i s s t r i n g e r t y p e . A relatively small a m o u n t of b l o c k y t y p e M-A c o n s t i t u e n t s o c c u r s a s well. T h e v o l u m e f r a c t i o n of M-A c o n s t i t u e n t s w a s e v a l u a t e d b y t h e image p r o c e s s i n g m e t h o d , a n d t h e v a l u e s a r e s h o w n i n F i g u r e 1. By c o m p a r i n g t h e a m o u n t of M-A c o n s t i t u e n t s a n d C h a r p y e n e r g y , o n e f i n d s t h a t t h e t o u g h n e s s v a l u e s of t h e c o a r s e g r a i n e d HAZ a r e s t r o n g l y a f f e c t e d b y t h e a m o u n t of M-A c o n s t i t u e n t s a n d t h a t M-A c o n s t i t u e n t s p l a y a n i m p o r t a n t r o l e i n r e d u c i n g t h e t o u g h n e s s of t h e c o a r s e g r a i n e d HAZ. T h e f r a c t u r e s u r f a c e s of C h a r p y i m p a c t s p e c i m e n s a n d c i r c u m f e r e n t l a l l y n o t c h e d t e n s i l e s p e c i m e n s w e r e e x a m i n e d to d e f i n e t h e n a t u r e of t h e f r a c t u r e s u r f a c e s . All t h e f r a c t u r e s u r f a c e s of b o t h s p e c i m e n s , p r e s e n t e d i n d e t a i l e l s e w h e r e [2], w e r e r o u g h a n d f i b r o u s i n appearance. Q u a n a t i t a t i v e m e a s u r e m e n t s of t h e dimple s i z e s o n m a n y f r a c t u r e surfaces revealed that the features on the fracture s u r f a c e s w e r e t h e same f o r b o t h s p e c i m e n geometries. T h u s , i t is s u g g e s t e d t h a t t h e m i c r o s t r u c t u r a l p r o c e s s e s w h i c h l e a d t o f r a c t u r e a r e t h e same f o r b o t h t e s t s i n t h i s s i m u l a t e d s t e e l HAZ e v e n t h o u g h t h e l e v e l of t h e s t r a i n r a t e is q u i t e d i f f e r e n t . To i d e n t i f y a n d q u a n t i f y t h e m i c r o m e c h a n i c a i f r a c t u r e p r o c e s s e s i n v o l v e d i n v o i d a n d cleavage microcrack initiation, the results of tensile testa and subsequent metallographic s t u d i e s of t h e c i r c u m f e r e n t i a l l y - n o t c h e d s p e c i m e n s s u b j e c t e d to t h e d o u b l e c y c l e s w i t h Tp z of 800 oC w h e r e t h e ICRCG HAZ w a s o b t a i n e d w e r e a n a l y z e d . F i g u r e 3(a) s h o w s t h e m i c r o s t r u c t u r e b e n e a t h t h e f r a c t u r e s u r f a c e s of t h e t e n s i l e s p e c i m e n s f r a c t u r e d a t - 1 0 C. Voids a r e o b s e r v e d to i n i t i a t e b y t h e c r a c k i n g a n d d e c o h e s i o n of t h e M-A c o n s t i t u e n t s f r o m the matrix. Once n u c l e a t e d , v o i d s g r o w m a i n l y i n t h e d i r e c t i o n of t e n s i l e axis; t r a n s v e r s e growth occurs only in the late stages of necking. When t h e t e s t t e m p e r a t u r e was l o w e r e d to - 8 0 oC, a n u m b e r of m i c r o c r a c k s a l o n g a z i g - z a g p a t h w e r e o b s e r v e d i n s t e a d of c o n n e c t e d v o i d s (see F i g u r e 3 ( b ) ) . As t h e M-A c o n s t i t u e n t is c o n s i d e r e d t o b e b r i t t l e p h a s e , t h e M-A constituent itself breaks and the crack formed acts as a Griffith crack when external stresses are applied. I t is i n t e r e s t i n g t o n o t e t h a t t h e s e m i c r o c r a c k s w e r e e a s i l y f o r m e d f r o m t h e s t r i n g e r - t y p e M-A c o n s t i t u e n t s a t t h e o r i e n t a t i o n of 4 0 - 5 0 d e g r e e t o t h e t e n s i l e axis w h e n t h e M-A c o n s t i t u e n t s t r i n g e r s w e r e a p p r o x i m a t e l y p a r a l l e l to t h e t e n s i l e a x i s a s s h o w n i n F i g u r e 3(c). Conversely, only few microcracks were observed when the stringer-type M-A c o n s t i t u e n t s w e r e a l i g n e d n o r m a l t o t h e t e n s i l e axis. T h i s t y p e of i n i t i a l c r a c k i n g o f M-A constituents can be explained by the "shear cracking process" described for pearlite colonies b y Miller a n d S m i t h [10]. F i g u r e 4 s h o w s a i d e a l i z e d s k e t c h of s h e a r c r a c k i n g m e c h a n i s m i n M-A c o n s t i t u e n t s . When t h e s p e c i m e n i s u n d e r t e n s i l e s t r e s s e s , small v o i d s w h i c h a r e n u c l e a t e d i n i t i a l l y a t M-A c o n s t i t u e n t s p r o m o t e s h e a r i n g o f t h e b a i n i t i c m a t r i x o n t h e s l i p

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plane. These initial voids then link up enough. In the case where crack growth capable of propagating catastropically as constituents whose size is considerably colonies is to initiate the microcracks by lamaliae.

to form a microcrack if the shear becomes large occurs by cleavage, the first microcrack formed is a cleavage crack. Thus, the primary role of M - A larger than that of cementite lamsllae in pearlite the the same cracking mechanism as the cementite

Figure 5 shows the relationship between the percentage of M - A constituent associated with voids (%VM) and the macroscopic strain (z) in a notched tensile specimen subjected to the ICRCG HAZ simulation. Elongated M n S inclusion particles generally decohered even at macroscopic strains well below the strains at which voids initiated at M - A constituents. Examination of the fracture surfaces in the S E M using EDS indicated that less than 5 pct of the voids contributing to fracture originated at M n S particles, showing that void initiation at M - A constituent is the dominant initiation mechanism. As shown in Figure 5, % V M increases slowly at first, approximately linearly with strain, and then increases more sharply with increasing strain. The s m o o t h i n c r e a s e o f %VM a p p e a r s to b e t h e r e s u l t o f r e l a t i v e l y e x t e n s i v e a n d u n i f o r m d i s t r i b u t i o n of v o i d s e v i d e n c e d b y t h e h o m o g e n e o u s d e f o r m a t i o n a l o n g t h e c e n t e r line o f f r a c t u r e d t e n s i l e s p e c i m e n s . The minimum s t r a i n s a t w h i c h v o i d s a p p e a r (E,~) a r e v e r y low, i.e., in t h e r a n g e 0.13 ~ 0.15 a s i n d i c a t e d b y a r r o w s in F i g u r e 5, and n e a r l y i n d e p e n d e n t of t h e t e s t i n g t e m p e r a t u r e s in c o n t r a s t to t h e t r u e f r a c t u r e s t r a i n s w h i c h w e r e f o u n d to d e p e n d p r e d o m i n a n t l y o n t h e t e s t t e m p e r a t u r e s . C o n s e q u e n t l y , t h e lack o f t o u g h n e s s in t h e s i m u l a t e d ICRCG HAZ is mainly a t t r i b u t e d t o low v a l u e s of Cv~ r e s u l t i n g f r o m p r e m a t u r e v o i d n u c l e a t i o n a t M-A c o n s t i t u e n t o r b r i t t l e f r a c t u r e of M-A c o n s t i t u e n t .
B a s e d o n t h e a b o v e c o n s i d e r a t i o n s , it a p p e a r s t h a t low C h a r p y e n e r g y in local b r i t t l e z o n e r e s u l t s f r o m t h e f o r m a t i o n o f M-A c o n s t i t u e n t s , w h i c h a r e e a s i l y c r a c k e d in t h e c a s e o f applying external stresses. I t c a n b e t h u s c o n c l u d e d t h a t t h e a m o u n t of M-A c o n s t i t u e n t s s h o u l d b e l o w e r e d t o i m p r o v e t h e t o u g h n e s s o f t h e HAZ.

Sum ,m~r7
1. The e f f e c t s o f M-A c o n s t i t u e n t o n t h e m i c r o m e c h a n i s m of f r a c t u r e p r o c e s s e s in t h e c o a r s e g r a i n e d HAZ of HSLA s t e e l w e l d s w e r e i n v e s t i g a t e d b y e x a m i n i n g t h e i n i t i a t i o n o f v o i d s a n d m i c r o c r a c k s in s e c t i o n e d t e n s i l e s p e c i m e n s . 2. The c o a r s e g r a i n e d HAZ i n c l u d e s two locally b r i t t l e m i c r o s t r u c t u r e s , w h o s e t o u g h n e s s v a l u e s a r e s t r o n g l y a f f e c t e d b y t h e a m o u n t of M-A c o n s t i t u e n t s . 3. Voids a n d m i c r o c r a c k s a r e o b s e r v e d to i n i t i a t e a t t h e M-A c o n s t i t u e n t s b y t h e s h e a r c r a c k i n g p r o c e s s , i.e., c r a c k i n g o r d e c o h e s i o n o f t h e M-A c o n s t i t u e n t s a t t h e o r i e n t a t i o n of 4050 d e g r e e to t h e t e n s i l e axis w h e n t h e M-A c o n s t i t u e n t s a r e a p p r o x i m a t e l y p a r a l l e l to t h e t e n s i l e axis. 4. The v o i d i n i t i a t i o n s t r a i n in t h e c o a r s e g r a i n e d HAZ a r e v e r y low b e c a u s e of p r e m a t u r e v o i d n u c l e a t i o n o r b r i t t l e f r a c t u r e a t M-A c o n s t i t u e n t s , c o n f i r m i n g t h a t t h e M-A c o n s t i t u e n t is t h e main m e t a l l u r g i c a l f a c t o r w h i c h g o v e r n s t h e t o u g h n e s s o f t h e c o a r s e g r a i n e d HAZ.

AcknowledKments
This work was s u p p o r t e d b y t h e R e s e a r c h I n s t i t u t e of I n d u s t r i a l S c i e n c e a n d T e c h n o l o g y (RIST) u n d e r c o n t r a c t n u m b e r 8-118-A. U s e of t h e RIST T e c h n i c a l S e r v i c e C e n t e r F a c i l i t y is a l s o g r a t e f u l l y a c k n o w l e d g e d . References 1. J. G. Youn a n d H. J. Kim: Proc. o f t h e 2 n d Conf. on M e c h a n i c a l B e h a v i o r s o f Materials, Seoul, Korea, p p . 35-43, (1988) (Korean). 2. B. C. Kim, J. H. Eom, C. S. Lee, S. Lee a n d D. Y. Lee: "Local B r i t t l e Zone of O f f s h o r e S t r u c t u r a l S t e e l Welds", s u b m i t t e d to J. o f t h e K o r e a n W e l d i n g S o c i e t y , (1989). 3. J. Y. Koo a n d A. Ozekcin: " W e l d i n g M e t a l l u r g y o f S t r u c t u r a l S t e e l s " , Ed. J. Y. Koo, P u b . , A/ME, p p . 119-135, (1987). 4. D. P. F a i r c h i l d : i b i d , p p . 303-318. 5. R. D e n y s a n d H. I. McHsnry: P r o c . o f t h e 7th I n t . Conf. on O f f s h o r e M e c h a n i c s a n d A r c t i c E n g i n e e r i n g , H o u s t o n , Texas, p p . 379-385, (1988).

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6. T. Haze a n d S. A i h a r a : ibid, pp. 515-523. 7. K. U c h i n o a n d Y. Ohno: ibid, p p . 159-165. 8. S. Lee: Scr. Mete11., 22, pp. 59-64, (1988). 9. It. C o u q u e , R. J. A s a r o t J. Duffy, a n d S. Lee: Met.all. Trans. A, 19A, p p . 2179-2206, (1988). 10. L. E. Miller a n d G. C. Smith: J. Iron SLeel Inst., 208, p p . 998-1005, (1970).

150

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(o.~ or Ira)

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FIG. 1. C h a r p y i m p a c t e n e r g y vs. p e a k t e m p e r a t u r e of t h e s e c o n d t h e r m a l c y c l e (Tp=), s h o w i n g two local b r i t t l e z o n e s , UACG HAZ a n d ICRCG HAZ. P a r e n t h e s e s i n d i c a t e t h e v o l u m e f r a c t i o n of M-A c o n s t i t u e n t s .

FIG. 2. S c a n n i n g e l e c t r o n m i c r o g r a p h o f t h e s i m u l a t e d ICRCG HAZ p r e p a r e d b y t h e 2 - s t a g e e l e c t r o l y t i c e t c h i n g t e c h n i q u e t o o b s e r v e M-A c o n s t i t u e n t s .

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999

FIG. 3. S c a n n i n g e l e c t r o n m i c r o g r a p h s of n o t c h e d r o u n d t e n s i l e s p e c i m e n s s e c t i o n e d p a r a l l e l to t h e t e n s i l e axis showing the m i c r o s t r u c t u r e b e n e a t h the f r a c t u r e s u r f a c e s of t h e s i m u l a t e d ICRCG HAZ f r a c t u r e d a t (a) -10 C a n d ( b ) - ( c ) -80 C. The t e n s i l e axis is v e r t i c a l f o r t h e m i c r o g r a p h s .

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01i I b
c d FZG. 4. Schematic d e s c r i p t i o n of s h e a r c r a c k i n g p r o c e s s of M-A c o n s t i t u e n t s , a f t e r Miller and Smith [10].

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FIG. 5. The p e r o e n t a g e of M-A c o n s t i t u e n t s associated with v o i d s vs. t h e macroscopic s t r a i n (~,) in t h e notched tensile specimen s u b j e c t e d to ICRCG HAZ simulation. Arrow shows v o i d initiation s t r a i n ( E ~ ) a t which v o i d s were f i r s t detected.